Summary of the invention
Deficiency at above-mentioned prior art exists the invention provides a kind of new type of metal shape material rolling and process equipment and network control system thereof.
According to an aspect of the present invention, provide a kind of metal bar section roll milling and process equipment, comprising:
Servo feed mechanism is in order to carry work metal shape material;
Laser Processing mechanism carries out Laser Processing to the complicated shape of work metal shape material;
Punch mechanism carries out punching processing to the fixedly hole shape of work metal shape material;
Cutting-off mechanism blocks processing to the work metal shape material after punching processing;
Roll forming mechanism, the cross sectional shape that work metal shape material rolling that will be after blocking processing becomes to need;
Punching mechanism carries out punch process to the work metal shape material behind roll forming, makes it be retracted to specific cross-sectional width, and
Control system comprises motion-control module, in order to the startup of control electric system, stop the operation with movement locus and described each mechanism.
Above-mentioned metal bar section roll milling and process equipment also comprise reshaping device, in order to the work metal shape material after punching and punch process is carried out shaping processing, to proofread and correct the cross section deformation that causes in described punching and the punch process.
Above-mentioned metal bar section roll milling and process equipment also comprise coding mechanism, in order to spray corresponding character on work metal shape material.
Above-mentioned metal bar section roll milling and process equipment, Laser Processing mechanism wherein comprises laser instrument, focusing barrel or galvanometer assembly to laser instrument emitted laser Shu Jinhang focuses on reflex to the speculum of focusing barrel or galvanometer assembly and the screw mandrel guide rail planker that is driven focusing barrel or the motion of galvanometer assembly by driven by servomotor with laser beam from laser instrument.
Above-mentioned metal bar section roll milling and process equipment, Laser Processing mechanism wherein also comprises arriving the aluminum pipe sleeve of the overcoat bellows that the light path of focusing barrel or galvanometer assembly seals by laser instrument through speculum, passes to Purge gas in the described aluminum pipe sleeve.
Above-mentioned metal bar section roll milling and process equipment, servo feed mechanism wherein comprises the unreeling structure that discharges described work metal shape material, in order to detect and to control the position detecting mechanism of unreeling structure feeding state, in order to the measurement mechanism of the feed distance of measuring described work metal shape material, labelling apparatus that on the appropriate location of work metal shape material, makes marks according to the measured value and the control strategy of measurement mechanism and the checkout gear that detects the convey error of described work metal shape material according to described mark.
Above-mentioned metal bar section roll milling and process equipment, control system wherein comprises human-computer interaction module, be provided for the gui interface of man-machine interaction, collect user's operational order and generate corresponding data and send into motion-control module, or read data and show corresponding information to the user from motion-control module.。
Above-mentioned metal bar section roll milling and process equipment, control system wherein also comprises remote communication module, is used for the transmitting-receiving of communication data and the maintenance of communication link.
Above-mentioned metal bar section roll milling and process equipment, control system wherein also comprise the exchanges data that is used between motion-control module, human-computer interaction module and the remote communication module and the data buffering module of information sharing.
According to a further aspect in the invention, provide the network control system of a kind of metal bar section roll milling and process equipment, comprise being connected to the central server produced on the network switching equipment and many above-mentioned metal bar section roll millings and process equipment.
Adopt metal bar section roll milling of the present invention and process equipment, servo feed mechanism adopts closed loop servo control, and pushing precision is much better than frequency conversion feed mechanism commonly used.After equipment is introduced Laser Processing mechanism, make process flexibility and flexible similar devices much larger than common simple employing hydraulic pressure punching mechanism.Simultaneously, integrated real-time online corrective system in the control system, real-time online is adjusted equipment because the convey error that weares and teares, skids etc. and cause automatically.Adopt network control system of the present invention, equipment can be communicated by letter with distance host in real time, feedback device information and reception control instruction.Therefore, metal bar section roll milling provided by the invention and process equipment have good processing flexibility and machining accuracy, both can use by unit, also can the multimachine networking use.
The specific embodiment
Referring to Fig. 1, metal bar section roll milling of the present invention and process equipment for example are made up of servo feed mechanism 101, Laser Processing mechanism 103, punch mechanism 104, cutting-off mechanism 105, roll forming mechanism 106, punching mechanism 107 and control system 109.Preferably, metal bar section roll milling and process equipment can also comprise reshaping device 108 and coding mechanism 110.After processed metal bar section 102 was sent from feed mechanism 101, Laser Processing mechanism 103 realized different processing tasks under the control of control system 109, as processed needed various hole shape or the hemisect of dotted line formula.Simultaneously, some are processed a fairly large number of fixedly hole shape and then finish processing by hydro piercing mechanism 104.Guaranteed that so promptly processing flexibility and processing has guaranteed certain speed of production again.By the cross sectional shape of roll forming mechanism 106 rollings for needing, for example, C shape or Z-shaped enters punching mechanism 107 to the shape material that processes then after cutting-off mechanism 105 blocks.Punching mechanism 107 carries out punching press to shape material privileged site under the control of control system 109, make it be retracted to specific cross-sectional width.The shape material enters reshaping device 108 and carries out shaping then, proofreaies and correct the cross section deformation that may cause in aforementioned punching, the punching operation.When material process coding mechanism 110, coding mechanism 110 can spray corresponding character in the appropriate location of shape material under the control of control system 109.
Fig. 2 A is depicted as the structural representation of servo feed mechanism, and it comprises unreeling structure 201, position detecting mechanism 202, feeding roll 203, measurement mechanism (for example using the increment rotary encoder) 204, labelling apparatus 205, checkout gear 206, reductor 208 and servomotor 209.
Wherein, position detecting mechanism 202 relies on the gravity effect to be close to and is transmitted on the material (shape material), when feeding begins, servomotor 209 starts and unreeling structure 201 is motionless, the material position raises gradually, drives detecting mechanism 202 and also raises, and triggers the feeding enabling signal after detecting mechanism 202 arrives certain position, unreeling structure 201 starts, and finishes the feeding start-up course.If detecting mechanism 202 is crossed the continuation rising of feeding starting position then triggered the feeding fault-signal, force feeding to stop.After feeding was finished, servomotor 209 cut out and unreeling structure 201 does not stop, and the material position descends, detecting mechanism 202 positions also descend thereupon, trigger the feeding stop signal after it drops to certain position, unreeling structure 201 stops feeding, finishes the feeding stopped process.If the detecting mechanism position is crossed feeding stop position continuation decline then triggered the material spacing wave, send the prompting of reloading.During feeding, servomotor 209 drives roll 203 by reductor 208 and produces the feeding driving force.At this, also can there be other power transmission form, for example, chain transmission and gear drive.
In whole feeding process, measurement mechanism 204 relies on the effect of hold-down mechanism to be pressed on and is sent on the material 200, detects feed distance by frictional drive, and the feed distance data are sent to control system 109.Control system 109 makes marks being sent on the appropriate location of material 200 according to the measured value of measurement mechanism 204 and control strategy control mark device 205.Checkout gear 206 includes known sensor 206a and the 206b of a pair of distance each other.When the same mark of making when labelling apparatus arrived the position of sensor 206a and 206b respectively, checkout gear 206 sent detection signals to control system 109.Control system 109 reads the measured value of measurement mechanism 204 according to the detection signal of receiving, reads the difference of measured value and the known distance between sensor 206a, 206b according to twice, can draw the convey error of material.Because measurement mechanism 204 also is the feed length that relies on frictional drive to detect to be sent material 200, thereby can well react actual feeding situation.
Fig. 2 B is depicted as labelling apparatus 205 and carries out the FB(flow block) that mark is handled.Step S21, control system 109 reads the measured value of measurement mechanism 204; Step S22, control system compares judgement with the measured value that reads and the mark spacing of setting; Step S23, when measured value reached the mark distance values of setting, control system sent marking signal, and did a series of mark at step S24 control mark device 205 on the material being sent.The mark spacing can be definite value, also can change.By the mark spacing that changes, system promptly can detect and the irrelevant error of feed length, also can detect the error relevant with feed length.
Fig. 2 C is depicted as mark detection procedure block diagram, and this flow process is waken up when mark is by the first sensor 206a in the checkout gear 206.Step S25, whether system's judge mark is by first sensor 206a.In this way, enter step S26, system is according to the feeding position of this moment under the value record of measurement mechanism 204.Step S27, same marking whether by the second sensor S206b judged by system.In this way, step S28, system notes feeding position once more.Then, step S29, control system can draw feed distance by the position of noting for twice, can draw the error of feeding after known distance between itself and the first sensor and second sensor is compared.Then, step S30, system judges that the error obtain is whether in the feeding error range.If error in allowed limits, then system does not do any action and enters idle condition; If error exceeds the error range of permission, then enter step S31, enter idle condition after the corresponding feeding control of the system's correction parameter, wait for being waken up once more.For example, if power set are stepper motor, then when detecting the error relevant, can be compensated by the conversion coefficient of change feed distance to pulse equivalency with feed length; When detecting the error that has nothing to do with feed length, can be by adding that on feed distance a constant is compensated.
By rational arrangement mark spacing and sensor between distance, system can obtain the better controlled performance and can not get muddled.
Fig. 3 A and 3B are respectively the side view of Laser Processing mechanism and vertical view, and (Fig. 3 A and Fig. 3 B provide by the flight light path typical structure, only need change following assembly 301 when adopting the galvanometer assembly and get final product.)。Laser Processing mechanism mainly comprises focusing barrel/galvanometer assembly 301, two lead screw guide rails plankers 302 and 304, servomotor 303 and 305, speculum 306 and 307, laser instrument 308.Lead screw guide rails planker 302 and 304 is driven by servomotor 303 and 305 respectively.Lead screw guide rails planker 302 is fixedly installed on the nut of lead screw guide rails planker 304, realizes that X and Y to two axially motions, are separately installed with left and right sides limit switch and initial point signaling switch (not shown) on it.Focusing barrel 301 and speculum 306 are fixedly installed on the planker 302, and speculum 307 is fixedly installed on the planker 304, and laser instrument 308 is fixedly installed on the support.The whole flight light paths that arrive focusing barrels 301 through speculum 306 and 307 by laser instrument 308 light-emitting windows are for example by the aluminum pipe sleeve seal of overcoat bellows, for example pass to therebetween to purify air.By the various moving interpolations of planker 302 and 304, focusing barrel can be finished various machining locus.When adopting the galvanometer optical system; arrive galvanometer assembly 301 by laser instrument 308 emitted laser bundles through speculum 306 and 307; motion by control galvanometer internal mirror makes the laser beam that is focused finish various machining locus, and the light channel structure part still needs sealing and passes to Purge gas protection optics.
Fig. 4 is the punch mechanism structure chart, has mainly comprised up and down oil cylinder 401 and 406, installing rack 402 and 405, punching die 403 and 404 up and down up and down.Travel switch (not shown) monitors oil cylinder position is installed on the oil cylinder 401 and 406.Upper cylinder 401 is fixedly mounted on the installing rack 402, and following oil cylinder 406 is fixedly mounted on down on the installing rack 405, and last punching die 403 is installed on upper cylinder 401 push rods, and following punching die 404 is installed in down on oil cylinder 406 push rods.During punching, keep after following oil cylinder 406 push rods are up to the precalculated position, upper cylinder 401 push rods are descending then, and last punching die 403 on it and the following punching die 404 on following oil cylinder 406 push rods fit tightly.While rollback original position behind the oil cylinder maintenance certain hour is finished the one-off hole-piercing process then.In whole punch process, feed system is in halted state.Can arrange a plurality of punch mechanisms as required in process equipment, its mold can have nothing in common with each other with the different hole shape of punching press.
Fig. 5 is the cutting-off mechanism structure chart, has mainly comprised oil cylinder 501, upper bracket 502, last cutting die 503, following cutting die 504, guide rod 505 and undersetting 506.Oil cylinder 501 is installed on the upper bracket 502.The shape material is when blocking, and oil cylinder 501 is descending, and cutting die 503 is descending in the drive.Block material by last cutting die 503 and following cutting die 504 effects that are installed on the undersetting.Cutting die all is installed on the guide rod 505 up and down, is guaranteeing that cutting die tool setting has up and down guaranteed the stationarity of cutting die 503 motions accurately simultaneously.
Fig. 6 is a roll forming mechanism structure chart, mainly comprise roller spacing adjusting nut 601, profile roll to 602 and 606, axle 603 and 609, edge forming roll 605 and clamp nut 608.Adjusting nut 601 is used to regulate the distance between pair of rollers 602 and 606, makes it be suitable for the moulding material of different-thickness.On the relevant position of pair of rollers 602 and 606, have concavo-convex mould, go out reinforcement with rolling when being shaped.Roller 602 is connected mechanically with axle 603, roller 606 and axle 609.Side roller 605 links to each other with axle 609 by bearing 607, compresses by clamp nut 608 simultaneously.The hole shape that stamps out in the punch mechanism in front has groove on the side roller 605, so that can not be destroyed by rolling mechanism safely.Generally in system of processing, arrange to have many group roll formings mechanisms, go out final cross sectional shape with the mode rolling of gradual change.
The structure of reshaping device 108 is with roll forming mechanism, and just the material cross sectional shape that pair of rollers and side roller are formed about it is final cross sectional shape.
Fig. 7 is the punching mechanism structure chart, mainly comprises upper cylinder 701, upper bracket 702, patrix 703, right oil cylinder 704, counterdie 705, undersetting 706, following oil cylinder 707, left oil cylinder 708, left support abutment 709 and right support abutment 710.Upper cylinder 701 is fixedly installed on the upper bracket 702, and following oil cylinder is fixedly installed on the undersetting 706, and left and right sides oil cylinder 708,704 is fixedly installed in respectively on the left and right sides bearing 709,710.Patrix 703 is installed on upper cylinder 701 push rods, and counterdie 705 is installed on down on oil cylinder 707 push rods.During punching press, following oil cylinder 707 push rods are up, and arrival keeps behind the precalculated position; Upper cylinder 701 push rods come downwards to patrix 703 and counterdie 705 fits tightly then, keep then; Left then oil cylinder 708 push rod right laterals, right oil cylinder 704 push rod left lateral, to and patrix fit, make the contraction of material cross-sectional width; Each oil cylinder rollback is finished punching course one time to original position then.
Figure 8 shows that the control system structure chart.Control system mainly comprises a motion-control module 801, it is responsible for and the communicating by letter of bottom hardware system, control, comprise that mainly collecting various sensor informations carries out analysis-by-synthesis and make the control corresponding decision-making, control electric system start and stop and movement locus, the behavior of control Laser Processing mechanism etc.In a preferred embodiment, control system also comprises a human-computer interaction module 802, it is provided for the gui interface of man-machine interaction, collect user's operational order and generate corresponding data and send into motion-control module 801, or read data and show corresponding information to the user from motion-control module 801.In another preferred embodiment, control system also comprises a remote communication module 803, and metal bar section roll milling and process equipment can be connected to the distance host or the central server of appointment by this module, form a network control system.This remote communication module is responsible for the transmitting-receiving of communication data and the maintenance of communication link.In preferred embodiment, control system also comprises data buffering module 804.Data buffering module 804 occupy the center of system, is used for the exchanges data and the information sharing of all the other each intermodules.The data buffering module provides event interface, triggers variety of event when each module read-write buffer module.For example, the user's operational order that human-computer interaction module 802 is collected and the corresponding data of generation also can be sent into the ad-hoc location of data buffering module 804, or human-computer interaction module 802 reads the data in the data buffering module 804 and shows corresponding information to the user.
Figure 9 shows that the operating process block diagram of a personal-machine interactive module 802.After described module starts and finishes initialization, start two threads 901 and 902.Wherein thread 901 main supervision and processing are arranged in the information of the human-machine interactive information buffering area of data buffering module 804.When in the human-machine interactive information buffering area during no information, thread 901 is in blocked state; When information arrived, this thread was waken up so that information is handled.For example, when information arrived, program entered step 903, judged whether system is demonstration information.In this way, program enters step 904 demonstration information.As not, program enters step 905 and further judges whether to be interactive information.As judged result is interactive information, and system carries out that interbehavior is concurrent delivers mutual result.As judged result is not interactive information, and system abandons this information and sends error reporting.The operation of thread 902 main monitoring users, and user's operating result is converted to corresponding information requirements send to motion-control module 801 or send it on the distance host by remote communication module 803.For example, step 906, when judging that the user is operating as motor performance, system sends information into motion buffering area in the data buffering module 804, and puts the movable information arriving signal.Step 908, when judging that the user is operating as traffic operation, system sends to information on the distance host by remote communication module 803.
Figure 10 shows that the operating process block diagram of motion-control module 801.Described module starts in the background thread mode, finish corresponding systematic parameter initialization after, this thread block arrives buffering area up to motion control information.This module can be handled the legal control instruction of two classes, and a class is a motion control instruction, and control appliance is finished roll forming and machining functions; One class is the information exchange instruction, is used for the user and reads/be provided with corresponding apparatus information/state.For example, after system finished corresponding systematic parameter initialization, program entered step 1001, and the information that judged whether arrives.In this way, program enters step 1002, judges further whether the information that arrives is legal movement instruction.In this way, program enters step 1003, judges further whether this legal movement instruction is legal exercise data.In this way, program enters step 1004, and whether successful execution is moved further to judge system; As not, program enters step 1009, and system abandons error message.Judge system's successful execution motion as program in step 1004, then relevant information is sent into mutual buffering area, put the interactive information arriving signal and send successful information in step 1005.Judge not successful execution motion of system as program in step 1004,, information is sent into mutual buffering area and put the interactive information arriving signal then in step 1006 fetch equipment status information.Judge that in step 1002 information that arrives is not legal movement instruction as program, then judge further in step 1007 whether the information that arrives is the legal information instruction.In this way, system's fetch equipment status information is sent into information mutual buffering area and is put the interactive information arriving signal; As not, step 1009, system abandon error message and send error reporting.
Figure 11 shows that the FB(flow block) of remote communication module 803.When equipment network, described module will attempt connecting the distance host or the central server of appointment; Register after the successful connection, current working ability from this equipment to distance host that report with become information such as tee section.The sending function of described module is a method of calling, is called by transmit leg and finishes; Receiving function is the background thread mode.When the communication information arrives, the receiving thread execution that is triggered.Described communication module can receive the legal communication information of two classes, is respectively to be used for human-computer interaction module 802 and motion-control module 801 manageable information.For example, after remote communication module successfully was connected to distance host or central server, program had judged whether that in step 1101 data arrive.In this way, program enters step 1102, judges further whether the data that arrive are legal data.In this way, program enters step 1103, judges further whether these legal data are human-machine interactive information.In this way, program enters step 1104, and this information is sent into mutual buffering area and put the interactive information arriving signal.Judge that in step 1103 these legal data are not human-machine interactive informations as program, then enter step 1105 and judge further whether these legal data are motion control information.In this way, system sends into information the motion buffering area and puts the movable information arriving signal; As not, system sends error reporting in step 1106.
Figure 12 shows that networking structure figure according to the network control system of metal bar section roll milling of the present invention and process equipment.In the described network system, each process equipment 120 and central server 122 all are connected to be produced on the network of network switching equipment.When each process equipment is produced network on connecting,, report its production capacity to central server from the registration of trend central server.During production, central server can be according to the load of the production on each process equipment of production task autobalance, to maximally utilise the production capacity of each process equipment.Production task sends to each process equipment that each is networked by central server, and the information state of each process equipment feeds back to central server automatically by network.The physical arrangement of described network can be an EPA, also can be other various fieldbus networks.
Below in conjunction with the accompanying drawings and embodiments metal bar section roll milling of the present invention and process equipment and network control system thereof have been made detailed description.Those skilled in the art can also make various conversion and modification to embodiment wherein by foregoing description of the present invention, but these conversion and modification all belong to scope of the present invention.