CN112497126B - Electric impact wrench controlled by current PID - Google Patents
Electric impact wrench controlled by current PID Download PDFInfo
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- CN112497126B CN112497126B CN202011345938.9A CN202011345938A CN112497126B CN 112497126 B CN112497126 B CN 112497126B CN 202011345938 A CN202011345938 A CN 202011345938A CN 112497126 B CN112497126 B CN 112497126B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING OR HOLDING
- B25B21/00—Portable power-driven screw or nut setting or loosening tools; Attachments for drilling apparatus serving the same purpose
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING OR HOLDING
- B25B23/00—Details of, or accessories for, spanners, wrenches, screwdrivers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING OR HOLDING
- B25B23/00—Details of, or accessories for, spanners, wrenches, screwdrivers
- B25B23/14—Arrangement of torque limiters or torque indicators in wrenches or screwdrivers
- B25B23/147—Arrangement of torque limiters or torque indicators in wrenches or screwdrivers specially adapted for electrically operated wrenches or screwdrivers
- B25B23/1475—Arrangement of torque limiters or torque indicators in wrenches or screwdrivers specially adapted for electrically operated wrenches or screwdrivers for impact wrenches or screwdrivers
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- Details Of Spanners, Wrenches, And Screw Drivers And Accessories (AREA)
Abstract
The invention discloses an electric impact wrench controlled by current PID, which comprises a power supply, a driving motor, a planetary gear reducer, an impact mechanism and a control system. The wrench is connected with the planetary gear reducer through the driving motor to drive the impact mechanism to carry out bolt fastening; the control system comprises a single chip microcomputer, a motor driving module, a sensor detection module and a key control module; the method comprises the steps that a relation model of motor current and output torque is driven by a wrench in a single chip microcomputer, corresponding current values of different torque values are prestored in a database by using the relation model and a relation curve, after a preset torque value is given, an actual measurement value of the motor current is detected by a control current sensor and is enabled to reach the prestored value, and bolt fastening operation is stopped after the preset torque value is reached. The invention realizes the constant torque output of the electric impact wrench by monitoring the current of the motor in real time and combining the double closed loop PID control of the rotating speed and the current, thereby obtaining higher assembly precision.
Description
Technical Field
The invention belongs to the technical field of electric torque wrenches, and particularly relates to an electric impact wrench controlled by current PID.
Background
The impact type electric torque wrench is a wrench with a rotary tangential impact mechanism, and plays an important role in the aspect of thread assembly due to the advantages of high work efficiency, small counter torque, low energy consumption and the like. However, the assembling torque is usually determined by the hand feeling of the operator holding the wrench and the observation of the rotation of the sleeve to determine whether the required torque is achieved, and in this case, the assembling torque has a large precision error. Because the working principle of the electric impact wrench is complex, and a large number of parts are involved in the work, the principle analysis and the accurate modeling of the electric impact wrench are difficult. How to realize the constant torque control of the electric impact wrench is a key problem to be solved at present. When the electric impact wrench is used for fastening bolts of different types, the problem that the bolts are deformed and damaged due to the fact that the torque is too large and the bolts are excessively tightened or the bolts are loosened and fall off due to the fact that the torque is too small and the bolts are insufficiently tightened is avoided. This requires the electric impact wrench to be able to perform constant torque control in order to prevent the above-described situation from occurring.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a current PID controlled electric impact wrench, which drives a relation model of motor current and output torque through a wrench built in a single motor control system, prestores corresponding current values of different torque values into a database by using the relation model, detects an actual measured value of the motor current through a control current sensor after a preset torque value is given so as to enable the actual measured value to reach the prestored value, and combines double closed-loop PID control of rotating speed and current after the preset torque value is reached, so that higher assembly requirements can be realized, and better control precision can be achieved.
In order to achieve the purpose, the invention adopts the following technical scheme: a current PID controlled electric impact wrench comprises a brushless direct current motor 1, a planetary gear reducer 2, a main shaft 3, a main pressure spring 4, a driving block 5, a driven block 6, a shell 7, a power supply 8, a display device 9 and a control system 10;
the kinetic energy generated by the brushless direct current motor 1 arranged in the wrench is partially converted into the kinetic energy for driving the driving block 5 to rotate through the planetary gear reducer 2, and partially converted into the potential energy compressed and stored by the main pressure spring 4, and part of the energy disappears in the forms of heat energy and mechanical loss. The potential energy compressed and stored by the main pressure spring 4 acts on the driving block 5, a part of the potential energy is converted into the translational kinetic energy of the driving block 5, a part of the potential energy is converted into the rotational kinetic energy of the driving block 5, and a part of the energy disappears in the process. The shoulder of the driving block 5 drives the driven block 6, so that impact torque is generated;
the output torque of the wrench is transmitted to the bolt or the nut through the sleeve, so that the bolt or the nut rotates for a certain angle, and the impact cycle is continued until the bolt assembling and disassembling work is completed;
the power supply 8 of the wrench is a rechargeable storage battery, provides electric energy for the driving motor and the display device, and is detachably mounted;
the control system 10 circuit board includes the following modules:
the single chip microcomputer microprocessor module is internally provided with a relation model for controlling the current-output torque of the driving motor, the corresponding current values of different torque values are prestored in a single chip microcomputer database according to the relation model, after a set torque value is input, the actual measured value of the motor current detected by the control current sensor is enabled to reach the prestored value, and the bolt fastening operation is stopped after the preset torque value is reached;
the communication module stores the wrench working data in the EEPROM, and when the communication module is connected with an upper computer, the upper computer can read the stored data and record and monitor the use condition of the electric impact wrench in real time;
the motor driving module adopts a driving chip and an inverter circuit to drive the motor, the singlechip microprocessor outputs 6 paths of PWM signals to be transmitted to an input pin of the driving chip, and then the PWM signals are output to the MOSFET through an output pin of the driving chip, so that the on-off of the MOSFET is controlled;
the detection module is divided into a current detection module and a position detection module, wherein the current detection module collects the current of the driving motor through a current sensor, the collected signal is input into the single-chip microprocessor module, and data processing is carried out to obtain a real-time torque value, so that the torque is accurately controlled. The position detection module detects the position of the rotor through the 3 Hall sensors, the single-chip microcomputer microprocessor sends out corresponding trigger signals to control the on-off of the MOSFET according to position signals collected by the Hall sensors, and finally the rotating speed of the motor is calculated through high and low level signals of the 3 Hall sensors.
Furthermore, the relation model is obtained according to a polynomial fitting experiment data sample, a signal acquisition system is set up to acquire an output torque signal and a current signal of the driving motor of the electric impact wrench in real time, the signals are subjected to noise reduction treatment through an SG filter, and the data obtained after the treatment are used as the data sample of the polynomial fitting, so that the relation model and the relation curve of the output torque of the electric impact wrench and the current of the driving motor are obtained.
Furthermore, the relation curve of the output torque of the electric impact wrench and the current of the driving motor can realize the prediction and control of the output torque of the electric impact wrench, and the purpose of controlling the fixed torque of the wrench is achieved.
Furthermore, the sensor of the detection module comprises a current sensor and a Hall sensor, the current sensor is used for collecting current signals when the wrench motor works, the Hall sensor is used for detecting the position of the rotor, and the rotating speed of the motor is calculated through the obtained position signals.
Further, the control system controls output torque by monitoring motor current, after the system is powered on, a port register of the single chip microcomputer microcontroller is initialized, a sensor starts to acquire data, a display device starts to display, an output torque expected value is set, the single chip microcomputer calculates to obtain a motor current pre-stored value, a PWM signal in the control system is output to drive the motor to rotate, a current detection module starts to detect an actual motor current value, the actual current value reaches the current pre-stored value, the drive motor stops rotating, and the system enters a standby state.
Furthermore, the double closed-loop PID control of the control system is used for improving the response speed and stability of the control system, the current feedback of the driving motor is used as an inner loop, the speed feedback provided by the rotor position is used as an outer loop, the inner loop is used for improving the stability of the system, the outer loop is used for reducing the external interference, and the control precision of the system is improved by combining a PID algorithm.
The technical effects of this application lie in: when the electric impact wrench is used for fastening a bolt, a relation model of motor current and output torque is driven through a built-in wrench of a single chip microcomputer, corresponding current values of different torque values are prestored in a database by using the relation model and a relation curve, after a preset torque value is given, an actual measurement value of the motor current detected by a control current sensor is enabled to reach the prestored value, and after the preset torque value is reached, the constant torque output of the electric impact wrench is reached by combining double closed loop PID control of rotating speed and current, so that higher assembly precision is obtained.
Drawings
FIG. 1 is a cross-sectional view of an electric impact wrench, wherein 1-brushless DC motor, 2-planetary gear reducer, 3-spindle, 4-main compression spring, 5-driving mass, 6-driven mass, 7-housing, 8-power supply, 9-display device, 10-control system;
fig. 2 is a front view and a side view of an impact block of the electric impact wrench, wherein fig. 2(a) is a front view and a side view of the impact block, and fig. 2(b) is a simplified front view and a simplified side view of the impact block;
FIG. 3 is a graph showing the relationship between the output torque and the motor current during the process of tightening the bolt with the electric impact wrench;
FIG. 4 is a block diagram of an electric impact wrench according to an embodiment of the present invention;
FIG. 5 is a control flow chart of the present invention.
Detailed Description
In order to better explain the technical scheme and the innovative features of the present invention, the present invention is further explained with reference to the embodiments in the following figures.
As shown in fig. 1, an electric impact wrench controlled by current PID comprises a brushless dc motor 1, a planetary gear reducer 2, a main shaft 3, a main compression spring 4, a driving block 5, a driven block 6, a housing 7, a power supply 8, a display device 9 and a control system 10. The kinetic energy generated by the brushless direct current motor 1 arranged in the wrench is partially converted into the kinetic energy for driving the driving block 5 to rotate through the planetary gear reducer 2, partially converted into the potential energy compressed and stored by the main pressure spring 4, and partially disappeared in the forms of heat energy and mechanical loss. The potential energy compressed and stored by the main pressure spring 4 acts on the driving block 5, a part of the potential energy is converted into the translational kinetic energy of the driving block 5, a part of the potential energy is converted into the rotational kinetic energy of the driving block 5, and a part of the energy disappears in the process. The shoulder of the driving block 5 drives the driven block 6, so that impact torque is generated; the output torque of the wrench is transmitted to the bolt or the nut through the sleeve, so that the bolt or the nut rotates for a certain angle, and the impact cycle is continued until the bolt assembling and disassembling work is completed;
the planetary gear reducer 2 of the electric impact wrench is composed of a sun gear, a ring and three planetary gears. The sun gear is a driving gear, the three planet gears are driven gears, and the circular ring is formed by fixing the driven gears on the shell. After the desired planetary gear ratio is determined, the appropriate sun gear, ring and planetary gear tooth counts for the power impact wrench can be selected according to the expression for the ratio.
And (3) calculating the reduction ratio of the planet gear:
wherein i is the planetary reduction gear ratio, n1Is the sun gear speed, nHIs the ring rotation speed, z1Is the number of sun gear teeth, z3The number of the ring gear teeth.
Calculating the average load of the main pressure spring:
wherein, FaIs the mean load of the main compression spring, F1Is the minimum load of the spring, F2Is the maximum load of the spring, k is the spring constant, s1Is the minimum amount of elastic deformation, s2Is the minimum amount of elastic deformation.
As shown in fig. 2, the impact block of the wrench has an irregular shape, and in order to calculate the mass m of the impact block, the impact block is dynamically calculated by using a simplified impact block.
The mass of the impact block is as follows:
wherein rho is the density of the material of the impact block, alpha and D0、d1、d2、l1、l2、l3、lsRespectively correspond to the impact blocks in FIG. 2(b)
Part (A)
Fractional size parameter, /)3＝ls-l1-l2。
Absolute angular velocity of impact block before impact: omega0＝ωa+ωt
Wherein, w0Is the absolute angular velocity, w, of the impact mass before impactaAdding angular velocity, w, to the impact blocktIs the mean angular velocity of the main shaft.
The principle of the electric impact wrench is to periodically store and release rotational kinetic energy generated by a motor, thereby continuously generating impact of large torque. The residual torque developed by the final fastener is a cumulative torque since the output torque is large at the instant of impact, but decays very quickly.
When bolts of different types are fastened, the spanner is to avoid the damage of the bolts due to the deformation of the bolts caused by the 'overtightening' caused by overlarge torque or the loosening and falling of the bolts caused by the 'undertightening' caused by the undersightness of the torque. This requires the electric impact wrench to be able to perform constant torque control in order to prevent the above-described situation from occurring.
Because the working principle of the electric impact wrench is complex, and a large number of parts are involved in the work, the principle analysis and the accurate modeling of the electric impact wrench are difficult. How to realize the constant torque control of the electric impact wrench is a key problem to be solved at present.
For the current electric impact wrench, the cost and the manufacturing difficulty of the wrench can be increased by adding the sensor in the wrench, and larger impact vibration and noise can be generated in the using process of the wrench, so that a relation model of the wrench output torque and the motor current is difficult to directly establish.
However, it is not accurate enough to obtain a model of the relationship between the current of the driving motor and the electromagnetic torque by analyzing the driving motor of the electric impact wrench, because the transmission mechanism of the electric impact wrench is complex and the working process includes uncertain factors such as vibration and noise, which will directly affect the precision of the final torque output by the wrench, therefore, in the implementation process of the invention, the current signal of the driving motor and the torque output by the wrench are directly collected in real time by the signal collection system.
Because the spanner has interference factors such as vibration and noise in the process of collecting signals, the torque signal that leads to gathering appears the spike form, if directly can directly influence the accuracy of model as the model building data sample of spanner output torque and motor current relation after with signal datamation. In order to obtain accurate modeling data samples, noise reduction processing needs to be performed on the noise signal in the output torque signal through an SG filter.
And after an effective data sample is obtained, modeling the relation between the output torque T of the electric impact wrench and the current I of the motor through polynomial fitting. And carrying out one-to-one correspondence on the output torque data subjected to noise reduction processing and the original data of the motor current in a time domain range, selecting the output torque value at a certain moment and the motor current value at the corresponding moment as an effective data point, and carrying out curve fitting on the selected data point in the MATLAB.
Fitting a curve expression:
wherein the content of the first and second substances,
for the predicted output torque after fitting, n is the order of polynomial fitting, akThe coefficient is determined for a polynomial, wherein k is 0, 1, …, n.
And according to the fitting effect and precision of polynomials of different orders, selecting a third-order polynomial fitting expression as a polynomial mathematical model reflecting the relation between the wrench output torque and the motor current.
Mathematical model of relationship between wrench output torque and motor current:
as shown in fig. 3, the present application further provides a relationship curve between the output torque and the motor current of the electric impact wrench when fastening the bolt, which can be divided into three stages, wherein the motor current is 126mA to 263mA, the wrench drives the socket to operate at a constant rotation speed, and an output torque value of about 0.5N · m is generated, and the bolt is not fastened by the wrench at this stage; and in the 263 mA-794 mA stage, the current of the motor is continuously increased, the output torque of the wrench is slowly increased, and the wrench performs pre-tightening action on the bolt. The current of the motor continuously inclines after 794mA, the wrench performs bolt fastening action, and the output torque is continuously increased until bolt fastening is completed.
Through the established mathematical relation model and relation curve of the spanner output torque and the motor current, data under the fastening of bolts with different specifications are sorted and stored in a single chip microcomputer control system, and the output torque of the electric impact spanner is predicted and controlled by using a current detection module in the control system, so that the aim of controlling the fixed torque of the spanner is fulfilled.
As shown in fig. 4, the present embodiment discloses an electric impact wrench controlled by current PID. A single chip microprocessor of a control system generates 6 paths of PWM signals, the signals are transmitted to a driving circuit, and a driving chip controls the on-off of 6 MOSFETs according to the PWM signals to realize the switching energization of a three-phase winding of a driving motor. The current sensor sampling circuit detects a motor current signal and feeds the motor current signal back to the single chip microcomputer microprocessor, and the current is adjusted in real time. The Hall position sensor detects the position of the rotor, the singlechip microprocessor acquires a feedback pulse signal, judges the correct position of the rotor, outputs corresponding PWM signal phase-change control, and calculates the rotating speed as the speed feedback adjusting rotating speed. The keyboard circuit sets the rotating speed and the torque through key control. The display circuit can display the given rotating speed and torque and the actual rotating speed and torque through an LCD display screen.
The power module of the electric impact wrench supplies power to the wrench driving motor and the single chip microcomputer, and the wrench motor drives the wrench impact mechanism to rotate the fastening bolt through the planetary gear reducer. The mechanical switch of the wrench is connected with the wrench driving motor and used for controlling the on-off of the power supply of the wrench motor, and meanwhile, the mechanical switch of the wrench can also be controlled by the control system.
In the use process of the utility model,
and step S1, setting the rotating speed and the torque value through the key control of the keyboard circuit, outputting a torque-motor current relation model through a wrench built in the singlechip, and converting a corresponding motor current calculation value.
And step S2, the switch is turned on manually or controlled by a single chip microcomputer through a built-in control program, so that a power supply supplies power to a driving motor of the wrench, and an impact mechanism of the wrench is driven to rotate to output torque to fasten the bolt.
And step S3, the current sensor detects the current signal of the wrench driving motor and transmits the current signal to the single chip microcomputer microprocessor, and the current value is calculated by the control program built in the single chip microcomputer to adjust the current in real time. The Hall position sensor detects the position of the rotor and is used for calculating the rotating speed as a speed feedback adjusting rotating speed.
Step S4, when the current of the driving motor reaches the calculated current value, the current reaches a preset torque value, and the fastening action is stopped; and the switch is controlled to be switched off by a control program arranged in the singlechip or the switch is manually closed to stop the power supply.
As shown in fig. 5, when the electric impact wrench of the present embodiment is used, after the control system is powered on, the port register of the microcontroller of the single chip microcomputer performs initialization operation, the sensor data acquisition circuit works, the liquid crystal display is powered on, and the wrench output torque signal and the driving motor current signal acquired in real time are displayed on the liquid crystal display. After the torque value is set, the corresponding drive motor current pre-stored value is calculated in the microcontroller through the polynomial mathematical model between the output torque of the wrench and the drive motor current. After the current pre-stored value of the driving motor is obtained, a PWM output module in the microcontroller starts to output PWM signals, and the driving motor drives the spindle to rotate. And the current sensor detects the actual value of the motor current in the rotating process of the driving motor and compares the actual value of the driving motor current with a driving motor current prestored value corresponding to the wrench output torque set value. If the actual current value is smaller than the current prestored value, the PWM output circulation is continuously executed; if the actual current value reaches the current pre-stored value, the driving motor stops rotating, the wrench stops fastening operation and acts for locking, meanwhile, the liquid crystal display screen is locked, the wrench output torque real-time value when jumping out of the cycle is displayed, and the system enters a standby state.
Through the technical scheme of the embodiment, the current monitoring method has good stability and high anti-interference performance compared with a single speed control method, the torque output precision can be controlled to be less than or equal to +/-10%, and meanwhile, the wrench adopts a rotating speed and current double closed-loop PID control mode, so that the control precision and robustness of a control system are improved.
The foregoing is directed to the preferred embodiment of the present invention, and not to all embodiments. Any simple modification or change of the above embodiments according to the technical spirit of the present invention falls within the scope of the technical solution of the present invention.
Claims (3)
1. The utility model provides an electric impact wrench of electric current PID control which characterized in that: the device comprises a brushless direct current motor (1), a planetary gear reducer (2), a spindle (3), a main pressure spring (4), a driving block (5), a driven block (6), a machine shell (7), a power supply (8), a display device (9) and a control system (10);
the kinetic energy generated by the brushless direct current motor (1) arranged in the wrench is partially converted into the kinetic energy for driving the driving block (5) to rotate through the planetary gear reducer (2)，One part of the energy is converted into potential energy compressed and stored by the main pressure spring (4), and the other part of the energy disappears in the form of heat energy and mechanical loss; potential energy compressed and stored by the main pressure spring (4) acts on the driving block (5), one part of the potential energy is converted into translational kinetic energy of the driving block (5), one part of the potential energy is converted into rotational kinetic energy of the driving block (5), and a part of the energy disappears in the process; the shoulder of the driving block (5) drives the driven block (6) so as to generate impact torque;
the output torque of the wrench is transmitted to the bolt or the nut through the sleeve, so that the bolt or the nut rotates for a certain angle, and the impact cycle is continued until the bolt assembling and disassembling work is completed;
the power supply (8) of the wrench is a rechargeable storage battery, provides electric energy for the driving motor and the display device (9), and is detachably mounted;
the control system (10) circuit board comprises the following modules:
the single chip microcomputer microprocessor module is internally provided with a relation model for controlling the current-output torque of the driving motor, the corresponding current values of different torque values are prestored in a single chip microcomputer database according to the relation model, after a set torque value is input, the actual measured value of the motor current detected by the control current sensor is enabled to reach the prestored value, and the bolt fastening operation is stopped after the preset torque value is reached;
the communication module stores the wrench working data in the EEPROM, and when the communication module is connected with an upper computer, the upper computer can read the stored data and record and monitor the use condition of the electric impact wrench in real time;
the motor driving module adopts a driving chip and an inverter circuit to drive the motor, the singlechip microprocessor outputs 6 paths of PWM signals to be transmitted to an input pin of the driving chip, and then the PWM signals are output to the MOSFET through an output pin of the driving chip, so that the on-off of the MOSFET is controlled;
the detection module is divided into a current detection module and a position detection module, wherein the current detection module collects the current of the driving motor through a current sensor, the collected signals are input into a single-chip microprocessor module, data processing is carried out to obtain a real-time torque value, so that accurate control of torque is carried out, the position detection module detects the position of a rotor through 3 Hall sensors, the single-chip microprocessor sends out corresponding trigger signals according to the position signals collected by the Hall sensors to control the on-off of the MOSFET, and finally the rotating speed of the motor is calculated through high and low level signals of the 3 Hall sensors;
the double-closed-loop PID control of the rotating speed and the current is used for driving feedback of a motor current signal and a rotor position signal, improving the control precision of a system and reducing the motor rotation overshoot, the control system controls output torque by monitoring the motor current, after the system is powered on, a port register of a microcontroller of a single chip microcomputer is initialized, a sensor starts to collect data, a display device displays a collected torque value and a collected current value, an output torque expected value is set, a motor current pre-stored value is obtained by calculation inside the single chip microcomputer, PWM signals are output in the control system, the motor is driven to rotate, a current detection module starts to detect the motor current actual value, the motor is driven to stop rotating after the current actual value reaches the current pre-stored value, and the system enters a standby state.
2. The electric impact wrench controlled by the current PID as claimed in claim 1, wherein the relation model is obtained by fitting an experimental data sample according to a polynomial, a signal acquisition system is set up to acquire an output torque signal and a drive motor current signal of the electric impact wrench in real time, the signals are subjected to noise reduction processing by an SG (Savitzky-Golay) filter, and the processed data are used as a data sample of polynomial fitting, so that a relation model and a relation curve of the output torque and the drive motor current of the electric impact wrench are obtained;
the relation curve of the output torque of the electric impact wrench and the current of the driving motor can realize the prediction and control of the output torque of the electric impact wrench, and the purpose of controlling the fixed torque of the wrench is achieved.
3. The electric impact wrench controlled by the current PID as claimed in claim 1, wherein the double closed loop PID control of the control system is used to improve the response speed and stability of the control system, the current feedback of the driving motor is used as an inner loop, the rotor position provides the speed feedback as an outer loop, the inner loop is used to improve the system stability, the outer loop is used to reduce the external interference, and the control accuracy of the system is improved by combining with the PID algorithm.
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