CN102009445A - Full-automatic vacuum molding control system and method - Google Patents
Full-automatic vacuum molding control system and method Download PDFInfo
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- CN102009445A CN102009445A CN2010102907797A CN201010290779A CN102009445A CN 102009445 A CN102009445 A CN 102009445A CN 2010102907797 A CN2010102907797 A CN 2010102907797A CN 201010290779 A CN201010290779 A CN 201010290779A CN 102009445 A CN102009445 A CN 102009445A
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Abstract
The invention relates to a full-automatic vacuum molding control system and a method. The system comprises a detection module, a control module and an execution module, wherein the control module comprises a computer as a main controller and a programmable logic controller as a secondary controller, the detection module comprises a CCD (Charge-Coupled Device) high-speed digital camera, a digital pressure sensor and a limit switch, the execution module comprises a vacuum pump connected with a vacuumizing motor, a stirring rod connected with a stirring motor, and a firming agent material cup and a mixed material cup connected with a tilted motor as well as an electromagnetic valve for air intake. The control method realizes visual, automatic and intelligent control of the vacuum molding process. The invention can greatly save the labor resource cost and improve the molding working efficiency and the product quality.
Description
Technical field
What the present invention relates to is a kind of new automatic vacuum casting control system and method, this system adopts the two-stage distributed structure of being made up of computer and programmable logic controller (PLC), be specially adapted to automatic detection, supervision and the control of vacuum and mould material bubble, provide different technological parameters at different mould materials and customer demand, finish the Automatic Control of vacuum injection molding technique process.
Background technology
Rapid shaping and fast mould technology make enterprise shorten Products Development and manufacturing cycle, thereby have realized the quick-reaction capability of enterprise's reply turn of the market, have improved the competitiveness of product in market.Can be as the type vacuum injecting and forming technology of typical one of fast mould technology indirectly at the vacuum state downward flowing type, thus air bubble problem in the material solved preferably, and percent defective is lower, so development is rapidly.
The type vacuum injecting and forming technology at first utilizes master mold to make silica gel mould under vacuum condition, mould material is vacuumized, mix after the operations such as stirring, air inlet froth breaking then, be injected into the silica gel mould die cavity, finish liquid by chemical reactions such as crosslinked, curing at last and change, thereby obtain required part to the form of solid.The type vacuum injecting and forming technology has unique advantage aspect thin-wall part and the Transparent Parts making, have broad application prospects in industries such as automobile, household electrical appliances, light industry, handicraft and toys for children, so both at home and abroad some enterprises and research institution all at development type vacuum injecting and forming equipment.
The product quality of type vacuum injecting and forming device fabrication mainly relies on the following aspects: the degree that mixes of mould material, casting process parameters (as the setting time of die entrance pressure, poring rate, composite material in the casting process etc.), the mould material bubble detects and the regulation and control accuracy of elimination degree and vacuum.Therefore, how according to different requirements of customers optimization ground control casting process parameters, the bubble of farthest eliminating in the mould material is the key issue that solves the type vacuum injecting and forming product quality.
Existing type vacuum injecting and forming equipment mainly adopts manual, electronic and the automatic three kinds of control modes of memory pattern.Type vacuum injecting and forming equipment for manual and electronic control, the detection of its vacuum and the judgement of defoaming effect, all be by artificial range estimation subjective judgement, cause problems such as the low and maloperation of production efficiency easily, the human factor influence is unfavorable for the stable control of quality of item greatly.And there is defectives such as producing flexibility is poor, antijamming capability deficiency in the automatic control of memory pattern, promptly one group of parameter of She Dinging can only adapt to a kind of working condition, can't realize according to different mould materials, profiled member geometric properties and quality standard adjusting process parameter automatically.In a word, existing vacuum casting control system is strong to operator's experience and qualification dependence, and production efficiency is low, it is flexible poor to produce, thereby causes the difficult quality guarantee of product.
Summary of the invention
The objective of the invention is to defective at existing vacuum casting control system and method, a kind of open fully automatic vacuum notes type control system and method with the software and hardware organic integration is provided, to realize control automatically in real time, improve its automaticity and processing flexibility, the rate of reducing the number of rejects and seconds to key process parameter.This control system adopts the two-stage distributed structure of being made up of computer and programmable logic controller (PLC), and integrated technology such as sensor, Based Intelligent Control, database, microcomputer interface and image processing realize the automation and the intellectuality of whole type vacuum injecting and forming process.Be mainly reflected in the bubble that can detect, judge, eliminate automatically mould material in real time, can recommend moulding material and corresponding optimum working process parameter is provided according to customer demand and profiled member geometric properties, significantly reduced the dependence of equipment, therefore improved the stability of flexibility, production efficiency and the product quality of type vacuum injecting and forming equipment operating personnel's experience.
Design of the present invention is:
Fully automatic vacuum notes type control system of the present invention is: replace the artificial visually examine with vision sensor and realize detecting in real time automatically of bubble, again by the designed image Processing Algorithm and program and realize objective analysis and judgement, thereby replace the subjective judgement defoaming effect to the bubble diagram picture that collects; Realize the real-time detection of vacuum pressure with digital pressure sensor, and realize obtaining and handling of data signal by real-time communication, carry out and bleed or the air inlet action thereby replace traditional manual observation Pressure gauge subjective judgement with computer; Write the control program of whole technical process with the programming software of Mitsubishi's Programmable Logic Controller, and realize that with host computer real-time communication is to receive command signal and control execution object; Utilize database software to set up type vacuum injecting and forming material depot and technology library, configuration software conducts interviews to it by the open type data interface and the technological parameter of intelligent optimization is provided according to user's request.
This fully automatic vacuum notes type control system adopts the two-stage distributed structure of being made up of computer and programmable logic controller (PLC), can realize visual, the automation of type vacuum injecting and forming process, intelligent control.For the ease of maintenance and expansion, its hardware using modular construction mainly comprises controller module, detection module and Executive Module.Wherein controller module comprises master controller (computer PC) and slave controller (programmable logic controller (PLC) PLC); Detection module is used for signals collecting, comprises that material cup position probing, drive motors speed detect, the composite material bubble detects and vacuum chamber pressure detects; Executive Module vacuumizes, stirs, topples over and action such as air inlet according to controller instruction, comprises and stirring and cast drive motors, magnetic valve and vavuum pump.
According to the foregoing invention design, the present invention adopts following technical proposals:
A kind of fully automatic vacuum notes type control system, form by a controller module, a detection module and an Executive Module, described controller module connects described detection module and Executive Module, it is characterized in that: described controller module connects a slave controller by a master controller and constitutes; Described detection module is made of a CCD high-speed figure camera, a digital pressure sensor and four limit switches; Described Executive Module is to vacuumize motor by one to connect a vavuum pump, stirring motor and connect a stirring rod, two and topple over motor and connect a curing agent material cup and compound cup and a magnetic valve respectively and constitute;
In the described controller module, master controller is a computer, and slave controller is a programmable logic controller (PLC), and programmable logic controller (PLC) is connected by SC-09 programming cable with computer;
Limit switch in the described detection module connects through described slave controller topples over motor, thereby controls the limit travel position of compound cup and curing agent material cup respectively; Pressure sensor is realized the real-time collection and the monitoring of vacuum chamber pressure by serial line interface and computer communication; CCD high-speed figure camera is by the real-time detection of USB interface and computer communication realization batch mixing cup liquid level bubble, and supporting light source is used to adjust brightness to improve collection effect;
The control line of in the described Executive Module, vacuumize motor, stirring motor, toppling over motor and magnetic valve is connected in the output of programmable logic controller (PLC), and each drive motors connects by mechanical connection and corresponding driven object respectively.
The concrete function of the related module of above-mentioned full-automatic control system is described below:
1. controller module
(1) master controller (computer PC)
Mainly finish man-machine interface design, with the functions such as real-time monitoring of the visit of the real-time processing of the data communication of slave controller and detecting element, bubble diagram picture, external data base and maintenance, executive component running status.
(a) man-machine interface
By the design of configuration software realization man-machine interface, this interface comprises following components: technological parameter setting, bubble video monitoring, the emulation of notes type, communication setting, database access, real-time tendency curve, history report.
(b) data communication
Programmable logic controller (PLC) is connected by SC-09 programming cable with computer realizes data communication, uses the specific PLC programming software to work out control program according to technological requirement in the computer, it is downloaded to the driving instruction of PLC as executive component again; In addition, can in man-machine interface, carry out the technological parameter setting, by the related online modification of realizing the control parameter of variable;
CCD high-speed industrial digital camera is connected by standard USB interface with computer realizes data communication, the bubble diagram that collects is looked like to be real-time transmitted to computer, and show in real time in the bubble video monitoring window in man-machine interface;
Digital pressure sensor and computer are realized data communication by the RS485 serial ports, the detected vacuum tank force value of sensor are fed back in computer and the real-time tendency curve window in man-machine interface in real time show.Simultaneously, be control variables with detected design of pressure, be associated with in the PLC control program as the instruction of controlling vavuum pump and magnetic valve.
(c) image is handled
Analyze and handle by the view data that VC++ establishment image processing program collects the CCD camera, concrete steps are: image preliminary treatment → graphical analysis → judgement decision-making, finally obtain result to the objective analysis and the processing of defoaming effect, and the result that will handle passes to Programmable Logic Controller as instruction, as the foundation of control air inlet froth breaking;
(d) database access and maintenance
Utilize ACCESS or SQL exclusive data library software to set up type vacuum injecting and forming material and technological data bank, configuration software can be realized outside access of database and maintenance by the open type data interfacing.The relevant information (title, physical characteristic, chemical characteristic and the applicable situation etc. that comprise material) of main storage type vacuum injecting and forming material commonly used in the material database, technological data bank is mainly stored the related process parameter (comprise pumpdown time, mixing speed and time, topple over speed and time etc.) of notes type process.The user only need just can search for and safeguard corresponding data information easily by man-machine interface, recommends optimal processing parameter automatically.Variable in key process parameter in the database and the control program is associated, to realize the controlling vacuum injection molding technique process automatically.
(e) monitoring in real time
The emulation interface can show the technical process of type vacuum injecting and forming and the running status of each executive component in real time, represent by the corresponding indicator light colors at emulation interface as the start-stop of motor and the break-make of magnetic valve, by to motor-driven pulse count make that the angle that the material cup is toppled in the emulation interface is consistent with actual angle, stirring speed and stirring motor rotating speed unanimity.In addition, warning function can be realized the warning of maloperation and equipment fault.
(2) slave controller (programmable logic controller (PLC) PLC)
PLC according to the characteristics of controlled object and the selected FX2n-48MR of the Mitsubishi model of quantity.Major function comprises: the control of notes type process automatically (comprise and vacuumize, air inlet, stir, topple over etc.), with computer communication received signal (comprising associated variable value, processing result image, force value result etc.), electric machine speed regulation (generation pulse-width signal).
2. detection module
Material cup position probing: in order to make curing agent and mould material topple over as far as possible thoroughly, then need to limit the dump angle of corresponding material cup, respectively place a small-sized limit switch at the initial position and the dump position of curing agent material cup and batch mixing cup respectively, finish material cup travel position control in the vacuum casting control process.
Vacuum chamber pressure detects: artificially to observe the Pressure gauge subjective judgement inaccurate and cause the problem of maloperation in order to overcome traditional vacuum notes type equipment, adopt digital pressure sensor that the pressure in the casing is detected in real time, send detected pressure signal to computer by data communication, and compare with the given pressure of technological requirement, judged result opens and closes and the control of vavuum pump start-stop magnetic valve by related realization of correlated variables.
The IMAQ of bubble: present type vacuum injecting and forming equipment generally is the bubble state of artificially estimating composite material, by the subjective judgement defoaming effect, cause erroneous judgement disconnected and cause waste product easily, so adopt vision sensor to carry out detecting in real time automatically of bubble, again by the designed image Processing Algorithm and program and realize objective analysis and judgement to the bubble diagram picture that collects.Hardware comprises high-speed industrial CCD camera, supporting support and light source.In order to obtain better to detect effect best camera parameter need be set, simultaneously the image information that collects be passed to computer and demonstration in real time in man-machine interface.
3. Executive Module
Executive component receives the control signal of controller module, realizes vacuumizing, air inlet, stirs, topples over action such as cast, mainly comprises:
Vavuum pump---vacuumize, the size of pressure sensor feedback vacuum is by the start-stop of PLC control vavuum pump;
Magnetic valve---the signal according to PLC keeps opening or disconnecting, to realize air inlet froth breaking or the action that vacuumizes;
Stirring motor---the notes section bar material in the stir mixing cup is selected stepper motor or servomotor, and the driving pulse that generates by the PLC software programming carries out speed governing;
The cast motor---the curing agent in the cup of will preparing burden is poured in the batch mixing cup and is mixed with notes section bar material, when froth breaking finishes batch mixing cup material is poured onto funnel and realizes cast, topple over speed by the driving pulse FREQUENCY CONTROL, dump angle is controlled by limit switch, and dumping time is set by the time parameter at configuration interface according to the character of material.
The specific implementation flow process of this control system is as follows:
1. system component is installed to connect and reach relevant parameter and is set:
Hardware method of attachment in conjunction with visible this control system of vacuum casting control system structured flowchart (see figure 1) is as follows:
(1) connection of controller
When programmable logic controller (PLC) being carried out program when writing or revising, programmable logic controller (PLC) need be connected by SC-09 programming cable with computer; When equipment is in running status, need not cable between the two and connect.
(2) installation of detecting element
(a) CCD digital camera and light source
The annular light source level is installed on batch mixing cup support top, and light is vertical with batch mixing cup liquid level, and the light source control line is connected to the special light source controller; The camera support inversion is fixed on the casing top by screw attachment; CCD high-speed industrial digital camera is connected with computer by the usb data line; Relevant parameter according to actual processing environment setting camera comprises light-source brightness and camera parameter (focal length, the depth of field, shooting angle, shooting distance, time for exposure etc.), makes the image of gathering reach optimum efficiency by adjusting relevant parameter;
(b) digital pressure sensor
Digital pressure sensor is connected with casing by M20 * 1.5 external screw threads, link to each other with computer by the RS485/RS232 interface convertor, adopt the MODBUS communications protocol to realize the collection and the transmission of pressure data, be electrically connected and adopt the Huo Siman joint, the 24VDC power supply;
(c) limit switch
Limit switch is adjusted a correct position according to material cup dump angle, and the input that is connected to programmable logic controller (PLC) be used to control topple over motor displacement to realize the spacing of dump angle.
(3) connection of executive component
Vacuumizing motor, stirring motor, toppling over motor and magnetic valve all is program behavior according to Programmable Logic Controller as executive component, so its control line is connected in the output of programmable logic controller (PLC), and each drive motors connects by mechanical connection and corresponding driven object respectively, wherein vacuumize motor connects with vavuum pump by key realize bleeding, stirring motor drives stirring rod by belt transmission and rotates, topples over motor by gear drive drive curing agent material cup and compound cup inclination batch turning.
2. write the control program-vacuum casting control method of fully automatic vacuum forming machine:
According to the technology characteristics of type vacuum injecting and forming, determine the switch condition between the different conditions, utilize the programming software GX-Developer of Mitsubishi to write the control ladder diagram again according to state of a control flow chart (see figure 2).Adopt said system to carry out type vacuum injecting and forming, its vacuum casting control step is as follows:
(1) when pressing vacuum pump switch X0, startup vacuumizes the running of motor (Y0) drive vavuum pump and begins to bleed;
(2) digital pressure sensor detects vacuum chamber pressure in real time and passes to pressure variations in the configuration by serial communication, when force value reaches setting value, the vacuumize stop condition related with pressure variations satisfies (being the X1 closure), start stirring motor (Y1) this moment and drive stirring rod, stir simultaneously and curing agent dumping time intervalometer (T0) startup timing the material mixing stirring in the batch mixing cup (B cup);
(3) then start curing agent when timing reaches setting value at interval with the curing agent dumping time and topple over motor and just change (Y2) and drive curing agent material cup (A cup) and topple over curing agent is imported batch mixing cup (B cup) when stirring;
(4) topple over when the A cup and bump against when toppling over limit switch (X2), the A cup is toppled over motor and is stopped just to change, and A cup batch turning timer (T1) is opened and carried out batch turning regularly simultaneously;
(5) the A cup is toppled over motor counter-rotating (Y3) drive A cup return when A cup batch turning timing reaches setting value;
(6) when A cup return bumps against return limit switch (X3), the A cup is toppled over motor and is stopped counter-rotating, and A cup return and air inlet foam time intervalometer (T2) start simultaneously;
(7) when A cup return and air inlet foam time intervalometer reach setting value, start magnetic valve (Y4) and carry out the air inlet froth breaking, topple over motor and just change (Y5) and pour into a mould if start the B cup when bubble is up to standard when (X6 closure),
If actions such as bubble (be X6 disconnect) not up to standard then re-execute is bled, air inlet froth breaking just can be poured into a mould until up to standard;
(8) topple over when the B cup and bump against when toppling over limit switch (X4), the B cup is toppled over motor and is stopped just to change, and the B cup is toppled over timer (T3) and started simultaneously;
(9) when B cup batch turning timing reaches setting value, the B cup is toppled over motor counter-rotating (Y6) and is driven B cup return;
(10) when B cup return bumps against return limit switch (X5), the B cup is toppled over motor and is stopped counter-rotating;
(11) original state is got back to by system.
Wherein difficult point is: the pressure variations that stops condition of vacuumizing and digital pressure gauge in the technological process is associated, when reaching setup pressure value, stop to vacuumize; For circulation froth breaking part, associate whether pouring into a mould the result who handles with the bubble diagram picture, according to the instruction that result is sent, pour into a mould if bubble is up to standard, on the contrary air inlet froth breaking once more.
3. communication setting and data association: the communications protocol that CCD, digital pressure sensor, PLC and computer are set respectively.Pouring condition variable related whether in the variable of finishing processing result image simultaneously and the control program, whether stop the related of froth breaking conditional-variable in the variable of finishing the pressure sensor value and the control program, related with in the control parametric variable in the database and the control program to dependent variable.
4. processing parameter setting: in vacuum injection molding technique, according to the feature (color, classification, transparency, material etc.), performance requirement of the rapid shaping spare of processing (precision, insulating properties, intensity, high temperature resistant etc.), goods characteristics (Transparent Parts, thin-wall part, large piece, small articles etc.), choose corresponding notes section bar material, obtain the corresponding informance of material simultaneously.In technology library, search for corresponding technological parameters by fuzzy matching, and automatically generate and recommend technology (comprising proportioning, weight and framed size, the gate location of selected materials etc.).
5. image processing process: bubble standard up to standard is set in man-machine interface, realizes collection, processing, analysis, the decision-making of bubble diagram picture finished the judgement of defoaming effect again by image processing algorithm.
The collection of image: utilize high-speed industrial CCD digital camera to take batch mixing cup liquid level in real time, by data line image is transferred in the computer and shows in real time.The video that CCD is taken carries out regularly grasping the instantaneous bitmap images that obtains as handling object.
Image preliminary treatment: comprise zone selection → image smoothing filtering (filtering interfering noise) → contrast enhancing/sharpening (tonal range of original image is extended to whole tonal range make clear picture) → binary conversion treatment (is binary image with greyscale image transitions).
Graphical analysis: the binary image that obtains at the preliminary treatment through image carries out rim detection and feature extraction, utilize the edge that is extracted to discern bubble to be detected, again its feature (as area, girth and number etc.) is added up, obtain the result and can be used as the index of judging decision-making.
Judge decision-making: judge according to graphical analysis combined process requirement as a result whether number of bubbles satisfies the Part Quality Control standard, whether decision circulation froth breaking process needs to proceed.Judged result sends the condition of PLC as the froth breaking of whether proceeding to circulate to.
6. beginning type vacuum injecting and forming operation: by configuration emulation interface, select mode of operation, under automatic mode, click start button, then carry out full automatic notes type operation according to the vacuum injection molding technique flow process.In the running, the user can observe the bubble situation of actual mould material by the video monitoring window, monitor the ruuning situation of each executive component by real-time tendency curve observation vacuum chamber pressure situation, by the emulation interface.
The present invention has following conspicuous outstanding substantial characteristics and remarkable advantage compared with prior art:
(1) this control system has adopted the two-stage distributed structure that is made of computer and programmable logic controller, and function is distributed clear and definite, and integrated management is convenient, hardware using modularization, be convenient to safeguard and expand that it is convenient, easy to operate that each intermodule connects;
(2) adopt checkout gears such as vision sensor, pressure sensor and limit switch, can in time feed back detection information, realized the closed-loop control of system, thereby improved the precision and the automaticity of control system greatly;
(3) use of vision sensor has realized the automatic detection and the elimination of bubble, overcome the shortcoming of manual froth breaking and memory froth breaking flexible difference strong to the human factor dependence, improved notes type efficient, improved defoaming effect, reduced because the goods percent defective that bubble causes, improved the quality of shaped article, especially the production for thin-walled class, transparent class, grid series products has great significance;
(4) use of database has realized automatically providing different technological parameters according to the user to the particular requirement of product, has improved the flexibility of producing greatly, has improved working (machining) efficiency, has optimized technological parameter, has improved notes type effect.
(5) this control system has changed the manual and automatic control mode of memory type of traditional vacuum notes type, and all control functions are integrated in the configuration interface, is convenient to centralized management and control, and simple to operate, the interface is clear.Only need the input product information can generate recommendation technology automatically, press start button, just can full automatic realization whole process flow.
In a word, the fully automatic vacuum notes type control system of this invention design can be saved cost of human resources greatly, improves the operating efficiency and the quality of item of forming machine equipment, thereby has good economic worth and market prospects.
Description of drawings
Fig. 1 is a fully automatic vacuum notes type control system structured flowchart of the present invention.
Fig. 2 is the state flow chart of PLC control.
Fig. 3 is that database access and technological parameter are provided with surface chart.
Fig. 4 is bubble image processing effect figure.
Fig. 5 is a type vacuum injecting and forming emulation surface chart.
The specific embodiment
The preferred embodiments of the present invention accompanying drawings is as follows:
Embodiment one:
Participate in Fig. 1, this fully automatic vacuum notes type control system, form by a controller module, a detection module and an Executive Module, described controller module connects described detection module and Executive Module, it is characterized in that: described controller module connects a slave controller by a master controller and constitutes; Described detection module is made of a CCD high-speed figure camera, a digital pressure sensor and four limit switches; Described Executive Module is to vacuumize motor by one to connect a vavuum pump, stirring motor and connect a stirring rod, two and topple over motor and connect a curing agent material cup and compound cup and a magnetic valve respectively and constitute; In the described controller module, master controller is a computer, and slave controller is a programmable logic controller (PLC), and programmable logic controller (PLC) is connected by SC-09 programming cable with computer; Limit switch in the described detection module connects through described slave controller topples over motor, thereby controls the limit travel position of compound cup and curing agent material cup respectively; Pressure sensor is realized the real-time collection and the monitoring of vacuum chamber pressure by serial line interface and computer communication; CCD high-speed figure camera is by the real-time detection of USB interface and computer communication realization batch mixing cup liquid level bubble, and supporting light source is used to adjust brightness to improve collection effect; The control line of in the described Executive Module, vacuumize motor, stirring motor, toppling over motor and magnetic valve is connected in the output of programmable logic controller (PLC), and each drive motors connects by mechanical connection and corresponding driven object respectively.
Embodiment two:
Present embodiment and embodiment one are basic identical, and special feature is as follows:
Present embodiment is an example to prepare a complex-shaped surface mould thin-walled transparent plastic article (20g), introduces the specific implementation process of fully automatic vacuum notes type control system in conjunction with the accompanying drawings in detail.
1. camera is linked to each other with computer by the usb data line, open the special light source controller.Adjust the camera shooting angle makes batch mixing cup liquid level be presented at the monitoring window comprehensively, adjusting lens focus according to batch mixing cup liquid level makes the liquid level image the most clear, consider that liquid level is kept in motion, maximum line velocity reaches 0.18m/s, and it is 0.0001s that the camera maximum exposure time is set.Because vacuum chamber light is darker, needing the illuminance of adjusting light source is about 500lux.
2. the writing and downloading of the control program of fully automatic vacuum forming machine:
Utilize the control function weaving Automatic Control program of programming software GX-Developer according to Fig. 2, wherein the vacuum of X1 correspondence is set to-0.95Mpa, and other technological parameters generate by technology library automatically as stirring with curing agent dumping time interval T 0, A cup dumping time T1, cup return and air inlet foam time interval T 2, B cup dumping time T3.By SC09 programming cable the Automatic Control program that writes is downloaded among the PLC at last, close programming port simultaneously, discharge serial ports of computers.
3. communication and correlated variables association are set:
CCD realizes its control by OPenCV programming, and digital pressure sensor realizes that by the MODBUS agreement computer uses the programming port communications protocol to realize interconnected with computer to the reading in real time of pressure on the number signal, PLC.Pouring condition variable related whether in the variable of finishing processing result image simultaneously and the control program, whether stop the related of froth breaking conditional-variable in the variable of finishing the pressure sensor value and the control program, related with in the control parametric variable in the database and the control program to dependent variable.
4. processing parameter setting:
Require (transparent plastic article) according to part performance to be processed, design feature (complex-shaped surface mould, thin-walled) is opened notes section bar material database by man-machine interface, chooses and annotates section bar material PX521HT, obtains the relevant information of this material simultaneously.Import the volume or weight of product etc. again, in technology library, search for corresponding technological parameters, and generate recommendation technology automatically by fuzzy matching.Database access and technological parameter are provided with the interface as shown in Figure 3.
5. get the raw materials ready according to the technique information of recommending:
The proportion relation of curing agent and PX521HT is 100/55, by balance proportionally weighing well pour batching cup and batch mixing cup respectively into, and will expect that cup is fixed on the cell therefor frame, mould is placed on the die frame of casting room, and with conduit sprue gate and funnel is coupled together.
6. the bubble diagram picture is handled:
By man-machine interface (as shown in Figure 5) bubble standard up to standard is set, passes to the image processing program of VC establishment as Rule of judgment by dynamic data exchange (DDE).The image of whole bubble is handled and is comprised processes (treatment effect as shown in Figure 4) such as collection, preliminary treatment, analysis, decision-making, final analysis result is given configuration by the DDE back transfer equally, configuration passes to PLC by the whether froth breaking instruction that the data association will finally obtain, if judged result is qualified then enters cast, otherwise continue circulation froth breaking process, until reaching standard or reaching hardening time of material.
7. beginning fully automatic vacuum notes type operation:
Opening control emulation interface, opening power is selected " automatic mode ", clicks " ON ", enters fully automatic vacuum notes type operating process.The operator by bubble video monitoring window observe actual mould material the bubble situation, observe the vacuum chamber pressure situation, monitor the ruuning situation of each executive component by the emulation interface, as shown in Figure 5 by the real-time tendency curve.
Embodiment three:
This fully automatic vacuum notes type control method adopts embodiment one described control system to carry out type vacuum injecting and forming, and it is as follows that it specifically controls step:
(1) when pressing vacuum pump switch X0, startup vacuumizes the running of motor (Y0) drive vavuum pump and begins to bleed;
(2) digital pressure sensor detects vacuum chamber pressure in real time and passes to pressure variations in the configuration by serial communication, when force value reaches setting value, the vacuumize stop condition related with pressure variations satisfies (being the X1 closure), start stirring motor (Y1) this moment and drive stirring rod, stir simultaneously and curing agent dumping time intervalometer (T0) startup timing the material mixing stirring in the batch mixing cup (B cup);
(3) then start curing agent when timing reaches setting value at interval with the curing agent dumping time and topple over motor and just change (Y2) and drive curing agent material cup (A cup) and topple over curing agent is imported batch mixing cup (B cup) when stirring;
(4) topple over when the A cup and bump against when toppling over limit switch (X2), the A cup is toppled over motor and is stopped just to change, and A cup batch turning timer (T1) is opened and carried out batch turning regularly simultaneously;
(5) the A cup is toppled over motor counter-rotating (Y3) drive A cup return when A cup batch turning timing reaches setting value;
(6) when A cup return bumps against return limit switch (X3), the A cup is toppled over motor and is stopped counter-rotating, and A cup return and air inlet foam time intervalometer (T2) start simultaneously;
(7) when A cup return and air inlet foam time intervalometer reach setting value, start magnetic valve (Y4) and carry out the air inlet froth breaking, topple over motor and just change (Y5) and pour into a mould if start the B cup when bubble is up to standard when (X6 closure), if actions such as bubble (being that X6 disconnects) not up to standard then re-execute is bled, air inlet froth breaking just can be poured into a mould until up to standard;
(8) topple over when the B cup and bump against when toppling over limit switch (X4), the B cup is toppled over motor and is stopped just to change, and the B cup is toppled over timer (T3) and started simultaneously;
(9) when B cup batch turning timing reaches setting value, the B cup is toppled over motor counter-rotating (Y6) and is driven B cup return;
(10) when B cup return bumps against return limit switch (X5), the B cup is toppled over motor and is stopped counter-rotating;
(11) original state is got back to by system.
Claims (8)
1. fully automatic vacuum notes type control system, form by a controller module (1), a detection module (2) and an Executive Module (3), described controller module (1) connects described detection module (2) and Executive Module (3), it is characterized in that: described controller module (1) connects a slave controller (11) by a master controller (9) and constitutes; Described detection module (2) is made of a CCD high-speed figure camera (4), a digital pressure sensor (5) and four limit switches (6); Described Executive Module (3) is to vacuumize motor (12) by one to connect a vavuum pump (13), stirring motor (14) and connect a stirring rod (15), two and topple over motor (16) and connect a curing agent material cup (17) and compound cup (18) and a magnetic valve (19) formation respectively;
In the described controller module (1), master controller (9) is a computer, and slave controller (11) is a programmable logic controller (PLC), and programmable logic controller (PLC) is connected by SC-09 programming cable with computer;
Limit switch (6) in the described detection module (2) connects through described slave controller (11) topples over motor (16), thereby controls the limit travel position of compound cup (18) and curing agent material cup (17) respectively; Pressure sensor (5) is realized the real-time collection and the monitoring of vacuum chamber pressure by serial line interface (8) and computer (9) communication; CCD high-speed figure camera (4) is by the real-time detection of USB interface (7) with computer (9) communication realization batch mixing cup liquid level bubble, and supporting light source is used to adjust brightness to improve collection effect;
In the described Executive Module (3), the control line of vacuumize motor (12), stirring motor (14), toppling over motor (16) and magnetic valve (19) is connected in the output of programmable logic controller (PLC) (11), and each drive motors connects by mechanical connection and corresponding driven object respectively.
2. fully automatic vacuum notes type control system according to claim 1, it is characterized in that the master controller in the described controller module is the collection signal that computer (9) receives CCD high-speed figure camera (4), utilize the image processing software coding that the bubble diagram that collects is looked like to handle, the instruction of the result that the obtains froth breaking as whether is passed to programmable controller (11) by the data association, realization replaces the artificial visually examine with vision sensor and carries out detecting in real time automatically of bubble, handles with the bubble diagram picture to replace the subjective judgement defoaming effect.
3. fully automatic vacuum notes type control system according to claim 1, it is characterized in that the instruction that whether stopped to vacuumize after pressure signal that described computer (9) collects pressure sensor (5) is handled, send the start-stop of programmable controller (11) to by serial ports (8) again, avoid the maloperation that causes by the manual observation vacuum meter with the control vavuum pump.
4. fully automatic vacuum notes type control system according to claim 1, the database access and the processing parameter setting part that it is characterized in that described computer (9), with manual input or by selecting the data in the corresponding material match query database to obtain the control parameter of type vacuum injecting and forming, and utilize the data association that it is passed to the control instruction of programmable controller (11) as relevant executive component by serial ports (8).
5. fully automatic vacuum notes type control system according to claim 1, it is characterized in that the man-machine simulation interface of described computer (9) by design of Configuration Software, the emulation interface can show the technical process of type vacuum injecting and forming and the running status of each executive component in real time, is convenient to realize on-line monitoring.
6. fully automatic vacuum notes type control system according to claim 1, it is characterized in that described computer (9) writes automatic control program by the specific PLC programming software and download in the programmable controller (11) by programming cable (10), control executing agency vacuumizes motor (12), stirring motor (14), topple over motor (16) and magnetic valve (19) moves.
7. fully automatic vacuum notes type control system according to claim 1, it is characterized in that in the described Executive Module (3), vavuum pump (13) drives to finish and vacuumizes action by vacuumizing motor (12), stirring rod (15) is driven by stirring motor (14) and finishes composite material stirring action, curing agent material cup (17) and compound cup (18) drive to finish and topple over action by toppling over motor (16), and magnetic valve (19) is finished the air inlet action and realized froth breaking.
8. a fully automatic vacuum notes type control method adopts fully automatic vacuum notes type control system according to claim 1 to control, and it is as follows to it is characterized in that specifically controlling step:
(1) when pressing vacuum pump switch X0, startup vacuumizes the running of motor (Y0) drive vavuum pump and begins to bleed;
(2) digital pressure sensor detects vacuum chamber pressure in real time and passes to pressure variations in the configuration by serial communication, when force value reaches setting value, the vacuumize stop condition related with pressure variations satisfies (being the X1 closure), start stirring motor (Y1) this moment and drive stirring rod, stir simultaneously and curing agent dumping time intervalometer (T0) startup timing the material mixing stirring in the batch mixing cup (B cup);
(3) then start curing agent when timing reaches setting value at interval with the curing agent dumping time and topple over motor and just change (Y2) and drive curing agent material cup (A cup) and topple over curing agent is imported batch mixing cup (B cup) when stirring;
(4) topple over when the A cup and bump against when toppling over limit switch (X2), the A cup is toppled over motor and is stopped just to change, and A cup batch turning timer (T1) is opened and carried out batch turning regularly simultaneously;
(5) the A cup is toppled over motor counter-rotating (Y3) drive A cup return when A cup batch turning timing reaches setting value;
(6) when A cup return bumps against return limit switch (X3), the A cup is toppled over motor and is stopped counter-rotating, and A cup return and air inlet foam time intervalometer (T2) start simultaneously;
(7) when A cup return and air inlet foam time intervalometer reach setting value, start magnetic valve (Y4) and carry out the air inlet froth breaking, topple over motor and just change (Y5) and pour into a mould if start the B cup when bubble is up to standard when (X6 closure), if actions such as bubble (being that X6 disconnects) not up to standard then re-execute is bled, air inlet froth breaking just can be poured into a mould until up to standard;
(8) topple over when the B cup and bump against when toppling over limit switch (X4), the B cup is toppled over motor and is stopped just to change, and the B cup is toppled over timer (T3) and started simultaneously;
(9) when B cup batch turning timing reaches setting value, the B cup is toppled over motor counter-rotating (Y6) and is driven B cup return;
(10) when B cup return bumps against return limit switch (X5), the B cup is toppled over motor and is stopped counter-rotating;
(11) original state is got back to by system.
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| CN102527272A (en) * | 2011-11-10 | 2012-07-04 | 江苏耀华机电科技有限公司 | Intelligent stirring equipment used for producing lithium battery |
| CN102564402A (en) * | 2011-12-31 | 2012-07-11 | 大连理工大学 | Universal real-time observation device with adjustable scale for high-molecular casting formation process |
| CN104085067A (en) * | 2014-04-28 | 2014-10-08 | 上海大学 | Fully-automatic vacuum casting control system and method thereof |
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| CN104416705B (en) * | 2013-08-28 | 2017-05-03 | 中国石油化工股份有限公司 | Automatic pouring system for seismic physical model and operation method of automatic pouring system |
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| CN108479543A (en) * | 2018-03-20 | 2018-09-04 | 谢蔓蓉 | A kind of asphalt production solvent mixing arrangement |
| CN108881245A (en) * | 2018-06-27 | 2018-11-23 | 江苏科技大学 | It is a kind of that Transmission system and control transmission method are controlled based on the unmanned boat of dual master control and power management |
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Application publication date: 20110413 |