CN103737771B - For PLC control system and the control method thereof of plastic floor vulcanizer - Google Patents

For PLC control system and the control method thereof of plastic floor vulcanizer Download PDF

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CN103737771B
CN103737771B CN201310696888.2A CN201310696888A CN103737771B CN 103737771 B CN103737771 B CN 103737771B CN 201310696888 A CN201310696888 A CN 201310696888A CN 103737771 B CN103737771 B CN 103737771B
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冯美英
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Liuzhou Vocational and Technical College
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Abstract

The invention discloses a kind of PLC control system for plastic floor vulcanizer and control method thereof, for the PLC control system of plastic floor vulcanizer, comprise fuse, touch-screen, PLC, pressure sensor, A/D modular converter, control relay, A.C. contactor, thermal overload relay, temperature controller, transistor driving plate and Switching Power Supply.By replacing former Control with PLC, and disclosing a kind of control method, reaching control system and stablizing and the object avoiding contactor melting welding.

Description

用于塑胶地板硫化机的PLC控制系统及其控制方法PLC control system and control method for plastic floor vulcanizing machine

技术领域 technical field

本发明涉及塑胶地板生成设备领域,具体地,涉及一种用于塑胶地板硫化机的PLC控制系统及其控制方法。 The invention relates to the field of plastic floor production equipment, in particular to a PLC control system for a plastic floor vulcanizing machine and a control method thereof.

背景技术 Background technique

目前,现有塑胶地板主要制作工艺为将塑料块粉碎成细末→将塑料末与石粉按一定的比例混合并均匀搅拌→将混合好的粉末放上模具进行第一次压制→压制成块状的塑料块卸下冷却(大小因模具而定)→将压制好的半成品铺上所需花纹、木纹等花纹纸进行压制→将铺好花纹的半成品进行第二次压制→压制完成卸下冷却→经清洗、上普通漆、阻燃漆处理(由专门生产线完成)→根据所需尺寸裁剪成小块→倒角、去毛边处理→打包装箱。 At present, the main production process of the existing plastic floor is to crush the plastic block into fine powder → mix the plastic powder and stone powder in a certain proportion and stir evenly → put the mixed powder on the mold for the first pressing → press into a block The plastic block is unloaded and cooled (the size depends on the mold) → spread the pressed semi-finished product with the required pattern, wood grain and other pattern paper for pressing → press the semi-finished product with the pattern for the second time → unload and cool after pressing →After cleaning, ordinary paint, flame retardant paint treatment (completed by a special production line)→cut into small pieces according to the required size→chamfering, deburring treatment→packing box.

整个生产过程中第二次压制工艺时间较长,且要求机器提供较稳定的压力和较稳定的温度,因此,制造硫化机的重点放在第二次压制工艺上。 The second pressing process takes a long time in the whole production process, and the machine is required to provide relatively stable pressure and temperature. Therefore, the focus of manufacturing vulcanizers is on the second pressing process.

装料完成后根据加工工艺设定各项参数进入如图1所示的流程工作在对成压板加热硫化过程为压力闭环控制。完成第一段压力工艺后直接加压到第二段压力工艺接着是第三段压力工艺,在整个保压过程中蒸汽加热亦同时进行。现有的 After the loading is completed, various parameters are set according to the processing technology to enter the process shown in Figure 1. The process of heating and vulcanizing the forming platen is pressure closed-loop control. After the first stage of pressure process is completed, it is directly pressurized to the second stage of pressure process, followed by the third stage of pressure process, and steam heating is also carried out during the entire pressure maintaining process. current

塑胶地板硫化机的控制系统采用继电器控制,造成在保压过程中压力不稳定,补压精度不高,控制补压电机的接触器容易熔焊。 The control system of the plastic floor vulcanizing machine is controlled by a relay, which causes the pressure to be unstable during the pressure maintaining process, the precision of the pressure supplement is not high, and the contactor controlling the pressure supplement motor is easy to weld.

发明内容 Contents of the invention

本发明的目的在于,针对上述问题,提出一种用于塑胶地板硫化机的PLC控制系统及其控制方法,以实现系统稳定且避免接触器熔焊的优点。 The purpose of the present invention is to solve the above problems and propose a PLC control system and control method for plastic floor vulcanizing machines, so as to realize the advantages of system stability and avoid contactor welding.

为实现上述目的,本发明采用的技术方案是: In order to achieve the above object, the technical scheme adopted in the present invention is:

一种用于塑胶地板硫化机的PLC控制系统,包括熔断器、PLC、触摸屏、压力传感器、A/D转换模块、控制继电器、交流接触器、热过载继电器、温度控制器、晶体管驱动板和开关电源, A PLC control system for plastic floor vulcanizing machine, including fuse, PLC, touch screen, pressure sensor, A/D conversion module, control relay, AC contactor, thermal overload relay, temperature controller, transistor driver board and switch power supply,

所述熔断器,用于控制系统的短路保护; The fuse is used for short circuit protection of the control system;

所述触摸屏,通过RS485通讯与PCL相连,实现参数设置、数据监控以及PLC的I/O监控; The touch screen is connected with PCL through RS485 communication to realize parameter setting, data monitoring and I/O monitoring of PLC;

所述PLC,是整个控制系统控制中心; The PLC is the control center of the entire control system;

所述压力传感器,实现压力信号的检测; The pressure sensor realizes the detection of the pressure signal;

所述A/D转换模块,通过集成排线与PLC相连,A/D转换模块的输入点与传感器相连,用于将压力传感器反馈回来的模拟信号转成数字信号后传送给PLC; The A/D conversion module is connected to the PLC through an integrated cable, the input point of the A/D conversion module is connected to the sensor, and is used to convert the analog signal fed back by the pressure sensor into a digital signal and then transmit it to the PLC;

所述控制继电器,该控制继电器的线圈直接与PLC输出点连接,由PLC直接驱动;控制继电器的常开触点与热过载继电器的常闭触点相连; In the control relay, the coil of the control relay is directly connected to the PLC output point and is directly driven by the PLC; the normally open contact of the control relay is connected with the normally closed contact of the thermal overload relay;

所述交流接触器,用于控制电机的工作;主触头进线端直接与空开相连接,出线端与热过载继电器相连接,线圈与热过载继电器的常闭触点相连接; The AC contactor is used to control the operation of the motor; the incoming line end of the main contact is directly connected to the air switch, the outgoing line end is connected to the thermal overload relay, and the coil is connected to the normally closed contact of the thermal overload relay;

所述热过载继电器,用于硫化机电机的过载保护,进线端与交流接触器的出线端相连,出线端与电机相连,常开触点与PLC输入点相连,常闭触点与交流接触器的线圈相连; The thermal overload relay is used for overload protection of the vulcanizing machine motor, the incoming line end is connected to the outgoing line end of the AC contactor, the outgoing line end is connected to the motor, the normally open contact is connected to the PLC input point, and the normally closed contact is connected to the AC contactor The coil of the device is connected;

所述温度控制器,用于检测硫化机的蒸汽温度;输入端连接K型热电偶,输出端达到控制温度时输出开关信号,温度控制器的输出端与PLC的输入端相连,温度控制器输出的开关信号经PLC处理后由PLC控制硫化机相关气阀的动作; The temperature controller is used to detect the steam temperature of the vulcanizer; the input end is connected to a K-type thermocouple, and the output end outputs a switch signal when it reaches the control temperature, the output end of the temperature controller is connected with the input end of the PLC, and the temperature controller outputs After the switching signal of the PLC is processed by the PLC, the action of the relevant air valve of the vulcanizing machine is controlled by the PLC;

所述晶体管驱动板,晶体管驱动板的b极与PLC输出端相连接,晶体管驱动板的e极与开关电源正极相连接,晶体管驱动板的c极与控制继电器相连接; In the transistor driver board, the b pole of the transistor driver board is connected with the PLC output terminal, the e pole of the transistor driver board is connected with the positive pole of the switching power supply, and the c pole of the transistor driver board is connected with the control relay;

所述开关电源,提供直流电源;开关电源的输入端与熔断器相连接,开关电源的输出端分别与触摸屏、PLC、晶体管驱动板和控制继电器相连接。 The switching power supply provides a DC power supply; the input end of the switching power supply is connected with a fuse, and the output end of the switching power supply is respectively connected with a touch screen, a PLC, a transistor drive board and a control relay.

同时本发明的技术方案还公开一种PLC控制系统的控制方法,包括以下步骤: Simultaneously technical scheme of the present invention also discloses a kind of control method of PLC control system, comprises the following steps:

步骤1、对PLC上电初始化; Step 1. Power on and initialize the PLC;

步骤2、上述PLC判断是否有操作请求,如没有则继续待机,如有操作请求,则检测是否是自动控制请求,如不是自动请求,则转为手动操作; Step 2, the above-mentioned PLC judges whether there is an operation request, if not, continues to stand by, if there is an operation request, then detects whether it is an automatic control request, if not an automatic request, then turns to manual operation;

步骤3、如上述PLC检测为自动控制,则启动油泵工作,对主缸加压到设定压力值,所述油泵分为快速油泵和补压油泵; Step 3, if the above-mentioned PLC detects that it is automatic control, then start the oil pump to work, pressurize the master cylinder to the set pressure value, and the oil pump is divided into a fast oil pump and a pressure boost oil pump;

步骤4、如主缸加压到设定值,则PLC控制塑胶地板硫化机的排气阀、排水阀、疏水阀、蒸汽进入阀和冷却水进入阀的开闭,同时PLC控制快速油泵和补压油泵的运转,从而控制主缸加压到设定值,完成塑胶地板硫化机工作控制; Step 4. If the main cylinder is pressurized to the set value, the PLC controls the opening and closing of the exhaust valve, drain valve, steam trap, steam inlet valve and cooling water inlet valve of the plastic floor vulcanizer. The operation of the pressure oil pump, so as to control the pressure of the main cylinder to the set value, and complete the work control of the plastic floor vulcanizing machine;

步骤5、上述完成塑胶地板硫化机工作控制的油缸在PLC控制下泄压至小于设定压力值。 Step 5. The above-mentioned oil cylinder that has completed the work control of the plastic floor vulcanizing machine is decompressed to less than the set pressure value under the control of PLC.

根据本发明的优选实施例,上述步骤3和步骤5中的设定压力值均为1Mpa。 According to a preferred embodiment of the present invention, the set pressure values in the above step 3 and step 5 are both 1Mpa.

根据本发明的优选实施例,上述步骤4中排气阀、排水阀、疏水阀、蒸汽进入阀和冷却水进入阀的开闭包括以下步骤: According to a preferred embodiment of the present invention, the opening and closing of the exhaust valve, drain valve, steam trap, steam inlet valve and cooling water inlet valve in the above step 4 includes the following steps:

步骤401、通过PLC控制排水阀和疏水阀打开,并设定打开的时间,在打开排水阀和疏水阀的同时计时; Step 401, controlling the opening of the drain valve and steam trap through the PLC, and setting the opening time, and timing while opening the drain valve and steam trap;

步骤402、如上述步骤401计时时间到,则将排水阀关闭,疏水阀继续打开,蒸汽进入阀打开,同时设定时间,并同时计时; Step 402, if the timing is up in the above step 401, then close the drain valve, continue to open the steam trap, open the steam inlet valve, set the time at the same time, and count at the same time;

步骤403、如上述步骤402的计时时间到,则打开排气阀,关闭疏水阀,关闭蒸汽进入阀和打开冷却水进入阀,并设定时间,同时计时; Step 403, as the timing time of the above-mentioned step 402 is up, then open the exhaust valve, close the steam trap, close the steam inlet valve and open the cooling water inlet valve, and set the time and time at the same time;

步骤404、如上述步骤403的计时时间到,则关闭排气阀,打开排水阀,关闭蒸汽进入阀和打开冷却水进入阀,并设定时间,同时计时; Step 404, if the timing time of the above step 403 is up, then close the exhaust valve, open the drain valve, close the steam inlet valve and open the cooling water inlet valve, set the time, and count at the same time;

步骤405、如上述步骤404计时时间到,则将排气阀、排水阀、疏水阀、蒸汽进入阀和冷却水进入阀均关闭。 Step 405, when the timing of the above-mentioned step 404 expires, close the exhaust valve, drain valve, steam trap, steam inlet valve and cooling water inlet valve.

根据本发明的优选实施例,上述步骤4中PLC控制快速油泵和补压油泵的运转,从而控制主缸加压到设定值,完成塑胶地板硫化机工作控制包括以下步骤: According to a preferred embodiment of the present invention, in the above step 4, the PLC controls the operation of the fast oil pump and the booster oil pump, thereby controlling the pressurization of the master cylinder to a set value, and completing the work control of the plastic floor vulcanizing machine includes the following steps:

步骤501、控制快速油泵停止,补压油泵运行,从而加压到第一设定压力值,达到第一设定压力值时,便控制补压油泵关闭,并对第一压力值的工作时间进行计时,判断第一压力值下的工作时间和工作压力; Step 501, control the fast oil pump to stop, and the boost oil pump to operate, thereby pressurizing to the first set pressure value, and when the first set pressure value is reached, control the boost oil pump to turn off, and check the working time of the first pressure value Timing, judging the working time and working pressure under the first pressure value;

步骤502、上述步骤501中的第一压力值下的工作时间和工作压力均符合要求,则启动补压油泵,从而加压到第二设定压力值,达到第二设定压力值时,便控制补压油泵关闭,并对第二压力值的工作时间进行计时,判断第二压力值下的工作时间和工作压力;重复控制补压油泵直到加压到第四设定压力值,完成主缸加压。 Step 502, the working time and working pressure at the first pressure value in the above step 501 meet the requirements, then start the booster oil pump to pressurize to the second set pressure value, and when the second set pressure value is reached, the Control the boost oil pump to close, and count the working time of the second pressure value, and judge the working time and working pressure under the second pressure value; repeat the control of the boost oil pump until it is pressurized to the fourth set pressure value, and the master cylinder is completed. Pressurize.

本发明的技术方案具有以下有益效果: The technical solution of the present invention has the following beneficial effects:

本发明的技术方案,通过用PLC代替原因的继电器控制,并公开一种控制方法,达到控制系统稳定且避免接触器熔焊的目的。 The technical scheme of the present invention uses PLC to replace the relay control of the cause, and discloses a control method, so as to achieve the purpose of stabilizing the control system and avoiding contactor welding.

下面通过附图和实施例,对本发明的技术方案做进一步的详细描述。 The technical solutions of the present invention will be described in further detail below with reference to the accompanying drawings and embodiments.

附图说明 Description of drawings

图1为现有的硫化机工作流程图; Fig. 1 is the working flow diagram of existing vulcanizer;

图2为本发明实施例所述的PLC控制方法的流程图。 Fig. 2 is a flow chart of the PLC control method described in the embodiment of the present invention.

具体实施方式 detailed description

以下结合附图对本发明的优选实施例进行说明,应当理解,此处所描述的优选实施例仅用于说明和解释本发明,并不用于限定本发明。 The preferred embodiments of the present invention will be described below in conjunction with the accompanying drawings. It should be understood that the preferred embodiments described here are only used to illustrate and explain the present invention, and are not intended to limit the present invention.

一种用于塑胶地板硫化机的PLC控制系统,包括熔断器、PLC、触摸屏、压力传感器、A/D转换模块、控制继电器、交流接触器、热过载继电器、温度控制器、晶体管驱动板和开关电源, A PLC control system for plastic floor vulcanizing machine, including fuse, PLC, touch screen, pressure sensor, A/D conversion module, control relay, AC contactor, thermal overload relay, temperature controller, transistor driver board and switch power supply,

熔断器,用于控制系统的短路保护,所有使用单相电源的器件取电均经过熔断器(主要有PLC、温控器、开关电源),取电于A相。 The fuse is used for short-circuit protection of the control system. All devices that use single-phase power supply are powered through the fuse (mainly PLC, thermostat, switching power supply), and the power is taken from phase A.

触摸屏,通过RS485通讯与PCL相连,实现参数设置、数据监控以及PLC的I/O监控; Touch screen, connected to PCL through RS485 communication, to realize parameter setting, data monitoring and PLC I/O monitoring;

PLC是整个控制系统的心脏,所有的动作操作、工作模式选择、以及油缸限位开关、电机保护检测信号、温度检测信号均连接到PLC的输入点;输出点接致晶体管驱动板的b极(PNP管)或是控制继电器的负极。同时PLC还担任着压力控制数据的运算、A/D转换模块数据的处理、控制时间的监控、各动作控制,为控制中心。 PLC is the heart of the entire control system. All action operations, work mode selection, and oil cylinder limit switches, motor protection detection signals, and temperature detection signals are connected to the input points of the PLC; the output points are connected to the b pole of the transistor driver board ( PNP tube) or the negative pole of the control relay. At the same time, PLC is also responsible for the calculation of pressure control data, the processing of A/D conversion module data, the monitoring of control time, and the control of various actions. It is the control center.

压力传感器安装于液压系统的油掣板上与液压缸相联通,通过对绞屏蔽信号线接致A/D转换模块的输入点实现压力的检测。 The pressure sensor is installed on the oil switch plate of the hydraulic system and communicated with the hydraulic cylinder, and is connected to the input point of the A/D conversion module through twisted shielded signal lines to realize pressure detection.

A/D转换模块通过集成排线与PLC的扩展口相连,A/D转换模块的输入点于传感器相连,用于将压力传感器反馈回来的模拟信号转成数字信号后传送给PLC。 The A/D conversion module is connected to the expansion port of the PLC through the integrated cable, and the input point of the A/D conversion module is connected to the sensor, which is used to convert the analog signal fed back by the pressure sensor into a digital signal and then send it to the PLC.

控制继电器起到过渡作用,其线圈为DC24V,继电器线圈直接与PLC输出点连接,由PLC直接驱动;控制继电器的常开触点与AC220V的电磁铁相连接(主要是蒸汽进入阀等)及热过载继电器的常闭触点相连。 The control relay plays a transitional role, and its coil is DC24V. The relay coil is directly connected to the PLC output point and is directly driven by the PLC; the normally open contact of the control relay is connected to the AC220V electromagnet (mainly the steam inlet valve, etc.) The normally closed contacts of the overload relay are connected.

交流接触器用于控制电机的工作;主触头进线端直接与空开相连接,出线端与热过载继电器相连接,线圈与热过载继电器的常闭触点相连接。 The AC contactor is used to control the operation of the motor; the main contact input terminal is directly connected to the air switch, the output terminal is connected to the thermal overload relay, and the coil is connected to the normally closed contact of the thermal overload relay.

热过载继电器用于电机的过载保护,进线端与交流接触器的出线端相连,出线端与电机相连,常开触点与PLC输入点相连,常闭触点与交流接触器的线圈相连。 The thermal overload relay is used for the overload protection of the motor. The incoming terminal is connected to the outgoing terminal of the AC contactor, the outgoing terminal is connected to the motor, the normally open contact is connected to the PLC input point, and the normally closed contact is connected to the coil of the AC contactor.

温度控制器用于检测蒸汽温度;输入端连接K型热电偶(热电偶安装于蒸汽管道上),输出端达到控制温度时输出一开关信号,故输出端与PLC的输入端相连。温控器发出的信号经PLC处理后由PLC控制相关气阀的动作。 The temperature controller is used to detect the steam temperature; the input end is connected to a K-type thermocouple (the thermocouple is installed on the steam pipe), and the output end outputs a switch signal when the control temperature is reached, so the output end is connected to the input end of the PLC. After the signal sent by the thermostat is processed by the PLC, the PLC controls the action of the relevant air valve.

晶体管驱动板也是起过渡作用;其功能控制继电器相同。其b极与PLC输出端相连接,e极与开关电源正极相连接,c极与液压阀电磁铁、工作状态指示灯、控制继电器相连接。 The transistor driver board also plays a transitional role; its function is the same as that of the control relay. The b pole is connected to the PLC output terminal, the e pole is connected to the positive pole of the switching power supply, and the c pole is connected to the hydraulic valve electromagnet, the working status indicator light and the control relay.

开关电源用于为DC24V的直流器件供电;输入端与熔断器相连接,输出端与触摸屏、PLC、晶体管驱动板、控制继电器、液压阀电磁铁工作状态指示灯相连接。 The switching power supply is used to supply power for DC24V DC devices; the input end is connected to the fuse, and the output end is connected to the touch screen, PLC, transistor driver board, control relay, and hydraulic valve electromagnet working status indicator.

一种PLC控制系统的控制方法,包括以下步骤: A control method for a PLC control system, comprising the following steps:

步骤1、对PLC上电初始化; Step 1. Power on and initialize the PLC;

步骤2、上述PLC判断是否有操作请求,如没有则继续待机,如有操作请求,则检测是否是自动控制请求,如不是自动请求,则转为手动操作; Step 2, the above-mentioned PLC judges whether there is an operation request, if not, continues to stand by, if there is an operation request, then detects whether it is an automatic control request, if not an automatic request, then turns to manual operation;

步骤3、如上述PLC检测为自动控制,则启动油泵工作,对主缸加压到设定压力值,所述油泵分为快速油泵和补压油泵; Step 3, if the above-mentioned PLC detects that it is automatic control, then start the oil pump to work, pressurize the master cylinder to the set pressure value, and the oil pump is divided into a fast oil pump and a pressure boost oil pump;

步骤4、如主缸加压到设定值,则PLC控制塑胶地板硫化机的排气阀、排水阀、疏水阀、蒸汽进入阀和冷却水进入阀的开闭,同时PLC控制快速油泵和补压油泵的运转,从而控制主缸加压到设定值,完成塑胶地板硫化机工作控制; Step 4. If the main cylinder is pressurized to the set value, the PLC controls the opening and closing of the exhaust valve, drain valve, steam trap, steam inlet valve and cooling water inlet valve of the plastic floor vulcanizer. The operation of the pressure oil pump, so as to control the pressure of the main cylinder to the set value, and complete the work control of the plastic floor vulcanizing machine;

步骤5、上述完成塑胶地板硫化机工作控制的油缸在PLC控制下泄压至小于设定压力值。 Step 5. The above-mentioned oil cylinder that has completed the work control of the plastic floor vulcanizing machine is decompressed to less than the set pressure value under the control of PLC.

其中,步骤3和步骤5中的设定压力值均为1Mpa。 Wherein, the set pressure values in step 3 and step 5 are both 1Mpa.

步骤4中排气阀、排水阀、疏水阀、蒸汽进入阀和冷却水进入阀的开闭包括以下步骤: The opening and closing of the exhaust valve, drain valve, steam trap, steam inlet valve and cooling water inlet valve in step 4 includes the following steps:

步骤401、通过PLC控制排水阀和疏水阀打开,并设定打开的时间,在打开排水阀和疏水阀的同时计时; Step 401, controlling the opening of the drain valve and steam trap through the PLC, and setting the opening time, and timing while opening the drain valve and steam trap;

步骤402、如上述步骤401计时时间到,则将排水阀关闭,疏水阀继续打开,蒸汽进入阀打开,同时设定时间,并同时计时; Step 402, if the timing is up in the above step 401, then close the drain valve, continue to open the steam trap, open the steam inlet valve, set the time at the same time, and count at the same time;

步骤403、如上述步骤402的计时时间到,则打开排气阀,关闭疏水阀,关闭蒸汽进入阀和打开冷却水进入阀,并设定时间,同时计时; Step 403, as the timing time of the above-mentioned step 402 is up, then open the exhaust valve, close the steam trap, close the steam inlet valve and open the cooling water inlet valve, and set the time and time at the same time;

步骤404、如上述步骤403的计时时间到,则关闭排气阀,打开排水阀,关闭蒸汽进入阀和打开冷却水进入阀,并设定时间,同时计时; Step 404, if the timing time of the above step 403 is up, then close the exhaust valve, open the drain valve, close the steam inlet valve and open the cooling water inlet valve, set the time, and count at the same time;

步骤405、如上述步骤404计时时间到,则将排气阀、排水阀、疏水阀、蒸汽进入阀和冷却水进入阀均关闭。 Step 405, when the timing of the above-mentioned step 404 expires, close the exhaust valve, drain valve, steam trap, steam inlet valve and cooling water inlet valve.

步骤4中PLC控制快速油泵和补压油泵的运转,从而控制主缸加压到设定值,完成塑胶地板硫化机工作控制包括以下步骤: In step 4, the PLC controls the operation of the fast oil pump and the boost oil pump, thereby controlling the pressure of the master cylinder to the set value, and completing the work control of the plastic floor vulcanizing machine includes the following steps:

步骤501、控制快速油泵停止,补压油泵运行,从而加压到第一设定压力值,达到第一设定压力值时,便控制补压油泵关闭,并对第一压力值的工作时间进行计时,判断第一压力值下的工作时间和工作压力; Step 501, control the fast oil pump to stop, and the boost oil pump to operate, thereby pressurizing to the first set pressure value, and when the first set pressure value is reached, control the boost oil pump to turn off, and check the working time of the first pressure value Timing, judging the working time and working pressure under the first pressure value;

步骤502、上述步骤501中的第一压力值下的工作时间和工作压力均符合要求,则启动补压油泵,从而加压到第二设定压力值,达到第二设定压力值时,便控制补压油泵关闭,并对第二压力值的工作时间进行计时,判断第二压力值下的工作时间和工作压力;重复控制补压油泵直到加压到第四设定压力值,完成主缸加压。 Step 502, the working time and working pressure at the first pressure value in the above step 501 meet the requirements, then start the booster oil pump to pressurize to the second set pressure value, and when the second set pressure value is reached, the Control the boost oil pump to close, and count the working time of the second pressure value, and judge the working time and working pressure under the second pressure value; repeat the control of the boost oil pump until it is pressurized to the fourth set pressure value, and the master cylinder is completed. Pressurize.

根据制作工艺控制要求如下: According to the production process control requirements are as follows:

1)整个制作工艺要求能实现三段压力控制且连续,控制压力分辨率为0.1Mpa,波动压力范围±0.3Mpa且波动范围能在0.1~0.3之间设定(如:第一段:8Mpa,25Min;第二段:15Mpa,45Min;第三段:18Mpa,12Min); 1) The whole production process requires three-stage pressure control and continuous, the control pressure resolution is 0.1Mpa, the fluctuating pressure range is ±0.3Mpa and the fluctuating range can be set between 0.1~0.3 (such as: the first stage: 8Mpa, 25Min; second section: 15Mpa, 45Min; third section: 18Mpa, 12Min);

2)三段压力控制时间可在0~99Min99S之间随时设定,且设定完成后立即生效; 2) The three-stage pressure control time can be set at any time between 0~99Min99S, and it will take effect immediately after the setting is completed;

3)各压力设定参数,时间参数均在触摸屏完成,且要具备掉电记忆; 3) Each pressure setting parameter and time parameter are completed on the touch screen, and must have power-off memory;

4)能实时显示机台工作阶段,各工序完成后能发出声光指示信号,机台并自动下降; 4) It can display the working stage of the machine in real time. After each process is completed, it can send out an audible and visual indication signal, and the machine will automatically descend;

5)加热温度能在温度控制器上自由设定。 5) The heating temperature can be set freely on the temperature controller.

硫化机机器分左右两侧两部分且左右对称。左右两侧的油缸直径约600mm(根据工作压力而定)活塞行程约900mm。左右两缸的工作方式相同,但左右两侧油缸不能同时补压。处于两油缸中间的是油箱,快速油泵电机、补压油泵电机、油路集成体和控制箱安装在油箱上。 The vulcanizing machine is divided into two parts on the left and right sides and the left and right sides are symmetrical. The diameter of the oil cylinders on the left and right sides is about 600mm (depending on the working pressure), and the piston stroke is about 900mm. The left and right cylinders work in the same way, but the left and right cylinders cannot be pressurized at the same time. In the middle of the two oil cylinders is the oil tank, on which the fast oil pump motor, pressure boost oil pump motor, oil circuit integrated body and control box are installed.

油缸和油箱均处于地基下,地基深度约1.2m。承压板、控制箱是处于水平地面上约500mm处。 Both the oil cylinder and the oil tank are under the foundation, and the depth of the foundation is about 1.2m. The pressure bearing plate and the control box are about 500mm above the level ground.

机器的工作主体分右侧和左侧。主要由液压缸和承压板组成。液压缸主要提供压制压力(压力要求较稳定),承压板用于盛放需压制的产品,承压板中间装有循环管承压板侧,循环管承压板侧有一个高压蒸汽进入口和一个为排除口。循环管承压板除了需加入循环管外加冷却水同时也须经循环管内冷却。其中左侧工作主体的机台顶部为高压蒸汽进入阀和冷却水进入阀。 The working body of the machine is divided into right side and left side. It is mainly composed of a hydraulic cylinder and a pressure plate. The hydraulic cylinder mainly provides pressing pressure (the pressure requirement is relatively stable), and the pressure bearing plate is used to hold the product to be pressed. and one for exhaust. In addition to adding cooling water to the circulation pipe, the pressure plate of the circulation pipe must also be cooled in the circulation pipe. Among them, the top of the machine table of the left working body is a high-pressure steam inlet valve and a cooling water inlet valve.

控制箱内主要由熔断器、PLC及A/D转换模块、控制继电器、交流接触器、热过载继电器、晶体管驱动板、开关电源组成。 The control box is mainly composed of fuses, PLC and A/D conversion modules, control relays, AC contactors, thermal overload relays, transistor driver boards, and switching power supplies.

左侧地基边缘处为排气阀、排水阀、疏水阀。 At the edge of the foundation on the left are exhaust valves, drain valves, and steam traps.

控制箱可实现左右两缸的手动调整和自动控制两种工作方式,通过操作面板上的选择开关选择。 The control box can realize two working modes of manual adjustment and automatic control of the left and right cylinders, which can be selected through the selection switch on the operation panel.

油箱即整机液压油存储及循环场所,为了散热需要,所以体积应该选择大一些。本技术方案选择体积大于1m3。 The oil tank is the place where the hydraulic oil of the whole machine is stored and circulated. For the sake of heat dissipation, the volume should be larger. The selected volume of this technical solution is greater than 1m3.

以PLC为核心的控制系统设计、安装和程序编写调试完成后,机器的功能亦能实现,但机器的油缸压力控制欠精确。要到达精确压力控制相当困难。使用比例阀则容易实现精确压力控制,调试过程中本方案进行了相应改进如下: After the design, installation, program writing and debugging of the control system with PLC as the core are completed, the functions of the machine can also be realized, but the pressure control of the oil cylinder of the machine is not accurate. It is quite difficult to achieve precise pressure control. It is easy to achieve precise pressure control by using a proportional valve. During the commissioning process, this solution has been improved as follows:

对补压电机的改进 Improvement on Supplementary Pressure Motor

对补压电机的要求是当出现需要补压动作时能及时将压力补上。如果把设定压力定n,主缸实际压力为m。当补压后压力出现m>(n+0.3)即实际压力大于设定压力上限,此时应当进行卸压。当卸压阀动作后出现m<(n-0.3)这样实际压力低于设定压力下限,此时应该补压。如此反反复复,接触器频繁动作,电机频繁启动。 The requirement for the pressure supplement motor is that the pressure can be supplemented in time when the pressure supplement action is required. If the set pressure is set to n, the actual pressure of the master cylinder is m. When the pressure appears m>(n+0.3) after pressure replenishment, that is, the actual pressure is greater than the upper limit of the set pressure, and the pressure should be relieved at this time. When m<(n-0.3) appears after the pressure relief valve operates, the actual pressure is lower than the lower limit of the set pressure, and the pressure should be supplemented at this time. Repeatedly like this, the contactor moves frequently, and the motor starts frequently.

在调试的过程中发现补压电机转速是影响压力控制精度的关键因素。如果补压电机速度慢,则油泵排量低,补压慢,PLC检测时间长,则精度高。反之则精度低。刚开始补压油泵采用7.5KW4极电机,电机转速高油泵流量大。补压时很难控制流量,改用6极电机后,转速降低流量亦变低,补压速度变慢,压力控制精度明显提高。 In the process of debugging, it is found that the speed of the pressure supplement motor is a key factor affecting the accuracy of pressure control. If the speed of the pressure supplement motor is slow, the displacement of the oil pump will be low, the pressure supplement will be slow, and the PLC detection time will be long, resulting in high precision. Otherwise, the accuracy is low. At the beginning, the supplementary pressure oil pump adopts a 7.5KW 4-pole motor, and the motor speed is high and the oil pump flow rate is large. It is difficult to control the flow rate during pressure supplementation. After switching to a 6-pole motor, the flow rate becomes lower as the speed decreases, the pressure supplementation speed becomes slower, and the pressure control accuracy is significantly improved.

对液压系统进行改进 Improvements to the hydraulic system

调试过程中出现卸压速度过快的现象是因为卸压阀流量较大的原因造成的。采用比例流量阀控制成本会变高,因此不考虑使用。此时我们采用了以下几种方法控制卸压速度。 The phenomenon that the pressure relief speed is too fast during the debugging process is caused by the large flow rate of the pressure relief valve. The cost of using proportional flow valve control will become higher, so it is not considered to be used. At this time, we have adopted the following methods to control the pressure relief speed.

1)卸压回路加装节流阀;加装节流阀可以手动调节卸压速度,具有较大的灵活性,卸压速度可根据实际情况调整。 1) A throttle valve is installed in the pressure relief circuit; the pressure relief speed can be manually adjusted by installing a throttle valve, which has greater flexibility, and the pressure relief speed can be adjusted according to the actual situation.

2)加装阻尼板;即制作一块垫板加装在卸压阀下,在垫板上另打一个比阀体上通孔小的通孔以此当节流用,这种做法成本低。但卸压速度不可调,灵活性不高。 2) Install a damping plate; that is, make a backing plate and install it under the pressure relief valve, and drill another through hole on the backing plate that is smaller than the through hole on the valve body to use as throttling. This method is low in cost. But the pressure relief speed is not adjustable, and the flexibility is not high.

3)在液压控制部分设计成回程卸压和工作卸压两部分,两部分独立工作。即工作时的卸压使用慢卸压,则能很好控制压力。工作完成后使用快卸压,这样就不会影响整体的工作效率了。 3) The hydraulic control part is designed into two parts, the return pressure relief and the working pressure relief, and the two parts work independently. That is, if the pressure relief during work is slow pressure relief, the pressure can be well controlled. Use quick pressure relief after the work is completed, so that it will not affect the overall work efficiency.

以上第一和第二种方法对卸压的速度能起到很好的控制作用,但同时也直接影响工作完成后卸压的时间,这样对整体工作效率还是产生了影响。在这种情况下可以考虑采用第三方法。 The above first and second methods can play a good control effect on the speed of pressure relief, but also directly affect the time of pressure relief after the work is completed, which still has an impact on the overall work efficiency. In this case, the third method can be considered.

对补压控制方法改进 Improvement of pressure supplement control method

为维持相对稳定的压力,系统要求补压速度较快,因此电机难免会频繁启动,并且电机为带负载启动。这就很容易造成电机损坏,亦影响了电网使电网电压经常波动。 In order to maintain a relatively stable pressure, the system requires a fast filling speed, so the motor will inevitably start frequently, and the motor starts with load. This is easy to cause damage to the motor, and also affects the power grid so that the grid voltage often fluctuates.

由于电机从启动到稳定运行需要一定的时间。可以考虑在编写程序时编写成电机启动且稳定运行后补压电磁阀才开始动作,即电磁阀延时动作不跟控制接触器同步动作。这样既可以减轻电机启动时的负载,也可以降低选择接触器的容量。当然这样情况要看液压系统的设计,当液压系统设计成带负载启动时则接触器的容量就要选择大一些即至少为额定电流的5倍。 Since the motor takes a certain amount of time from startup to stable operation. It can be considered that when writing the program, it is written that the supplementary pressure solenoid valve starts to act after the motor starts and runs stably, that is, the delayed action of the solenoid valve does not act synchronously with the control contactor. This can not only reduce the load when the motor starts, but also reduce the capacity of the selected contactor. Of course, this situation depends on the design of the hydraulic system. When the hydraulic system is designed to start with load, the capacity of the contactor should be selected to be larger, that is, at least 5 times the rated current.

对补压电机保护器件的选择 Selection of Protective Devices for Supplemented Pressure Motors

一般情况会选择热过载继电器保护电机,但在这样的场合就不适用了。因为电机频繁启动,所以我们不能忽略接触器触头熔焊问题。万一出现触头熔焊即补压完成后PLC仍控制接触器断开,但此时由于电机缺相,虽然热过载能发出过载信号但也是无济于事。因此,电机保护部分宜采用电动机热磁断路器及辅助触点取代热过载继电器作为电动机的保护器件。 In general, a thermal overload relay is selected to protect the motor, but it is not suitable for such occasions. Because the motor starts frequently, we cannot ignore the contactor contact welding problem. In case of contact welding, the PLC still controls the contactor to disconnect after the pressure supplement is completed, but at this time, due to the lack of phase of the motor, although the thermal overload can send an overload signal, it will not help. Therefore, the motor protection part should use motor thermal magnetic circuit breakers and auxiliary contacts instead of thermal overload relays as motor protection devices.

最后应说明的是:以上所述仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。 Finally, it should be noted that: the above is only a preferred embodiment of the present invention, and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, for those skilled in the art, it still The technical solutions recorded in the foregoing embodiments may be modified, or some technical features thereof may be equivalently replaced. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included within the protection scope of the present invention.

Claims (5)

1.一种用于塑胶地板硫化机的PLC控制系统,其特征在于,包括熔断器、PLC、触摸屏、压力传感器、A/D转换模块、控制继电器、交流接触器、热过载继电器、温度控制器、晶体管驱动板和开关电源, 1. A PLC control system for plastic floor vulcanizing machines, characterized in that it includes fuses, PLC, touch screen, pressure sensor, A/D conversion module, control relay, AC contactor, thermal overload relay, temperature controller , transistor driver board and switching power supply, 所述熔断器,用于控制系统的短路保护; The fuse is used for short circuit protection of the control system; 所述触摸屏,通过RS485通讯与PLC相连,实现参数设置、数据监控以及PLC的I/O监控; The touch screen is connected to the PLC through RS485 communication to realize parameter setting, data monitoring and I/O monitoring of PLC; 所述PLC,是整个控制系统控制中心; The PLC is the control center of the entire control system; 所述压力传感器,实现压力信号的检测; The pressure sensor realizes the detection of the pressure signal; 所述A/D转换模块,通过集成排线与PLC相连,A/D转换模块的输入点与传感器相连,用于将压力传感器反馈回来的模拟信号转成数字信号后传送给PLC; The A/D conversion module is connected to the PLC through an integrated cable, the input point of the A/D conversion module is connected to the sensor, and is used to convert the analog signal fed back by the pressure sensor into a digital signal and then transmit it to the PLC; 所述控制继电器,该控制继电器的线圈直接与PLC输出点连接,由PLC直接驱动;控制继电器的常开触点与热过载继电器的常闭触点相连; In the control relay, the coil of the control relay is directly connected to the PLC output point and is directly driven by the PLC; the normally open contact of the control relay is connected with the normally closed contact of the thermal overload relay; 所述交流接触器,用于控制电机的工作;主触头进线端直接与空开相连接,出线端与热过载继电器相连接,线圈与热过载继电器的常闭触点相连接; The AC contactor is used to control the operation of the motor; the incoming line end of the main contact is directly connected to the air switch, the outgoing line end is connected to the thermal overload relay, and the coil is connected to the normally closed contact of the thermal overload relay; 所述热过载继电器,用于硫化机电机的过载保护,进线端与交流接触器的出线端相连,出线端与电机相连,常开触点与PLC输入点相连,常闭触点与交流接触器的线圈相连; The thermal overload relay is used for overload protection of the motor of the vulcanizing machine. The incoming line end is connected to the outgoing line end of the AC contactor, the outgoing line end is connected to the motor, the normally open contact is connected to the PLC input point, and the normally closed contact is connected to the AC contactor. The coil of the device is connected; 所述温度控制器,用于检测硫化机的蒸汽温度;输入端连接K型热电偶,输出端达到控制温度时输出开关信号,温度控制器的输出端与PLC的输入端相连,温度控制器输出的开关信号经PLC处理后由PLC控制硫化机相关气阀的动作; The temperature controller is used to detect the steam temperature of the vulcanizing machine; the input end is connected to a K-type thermocouple, and the output end reaches the control temperature to output a switch signal, the output end of the temperature controller is connected to the input end of the PLC, and the temperature controller outputs After the switching signal of the PLC is processed by the PLC, the action of the relevant air valve of the vulcanizing machine is controlled by the PLC; 所述晶体管驱动板,晶体管驱动板的b极与PLC输出端相连接,晶体管驱动板的e极与开关电源正极相连接,晶体管驱动板的c极与控制继电器相连接; In the transistor driver board, the b pole of the transistor driver board is connected with the PLC output terminal, the e pole of the transistor driver board is connected with the positive pole of the switching power supply, and the c pole of the transistor driver board is connected with the control relay; 所述开关电源,提供直流电源;开关电源的输入端与熔断器相连接,开关电源的输出端分别与触摸屏、PLC、晶体管驱动板和控制继电器相连接。 The switching power supply provides a DC power supply; the input end of the switching power supply is connected with a fuse, and the output end of the switching power supply is respectively connected with a touch screen, a PLC, a transistor drive board and a control relay. 2.一种权利要求1所述的PLC控制系统的控制方法,其特征在于,包括以下步骤: 2. a control method of the PLC control system according to claim 1, is characterized in that, comprises the following steps: 步骤1、对PLC上电初始化; Step 1. Power on and initialize the PLC; 步骤2、上述PLC判断是否有操作请求,如没有则继续待机,如有操作请求,则检测是否是自动控制请求,如不是自动请求,则转为手动操作; Step 2, the above-mentioned PLC judges whether there is an operation request, if not, continues to stand by, if there is an operation request, then detects whether it is an automatic control request, if not an automatic request, then turns to manual operation; 步骤3、如上述PLC检测为自动控制,则启动油泵工作,对主缸加压到设定压力值,所述油泵分为快速油泵和补压油泵; Step 3, if the above-mentioned PLC detects that it is automatic control, then start the oil pump to work, pressurize the master cylinder to the set pressure value, and the oil pump is divided into a fast oil pump and a boost oil pump; 步骤4、如主缸加压到设定值,则PLC控制塑胶地板硫化机的排气阀、排水阀、疏水阀、蒸汽进入阀和冷却水进入阀的开闭,同时PLC控制快速油泵和补压油泵的运转,从而控制主缸加压到设定值,完成塑胶地板硫化机工作控制; Step 4. If the main cylinder is pressurized to the set value, the PLC controls the opening and closing of the exhaust valve, drain valve, steam trap, steam inlet valve and cooling water inlet valve of the plastic floor vulcanizer. The operation of the pressure oil pump, so as to control the pressure of the main cylinder to the set value, and complete the work control of the plastic floor vulcanizing machine; 步骤5、上述完成塑胶地板硫化机工作控制的油缸在PLC控制下泄压至小于设定压力值。 Step 5. The above-mentioned oil cylinder that has completed the work control of the plastic floor vulcanizing machine is decompressed to less than the set pressure value under the control of PLC. 3.根据权利要求2所述的PLC控制系统的控制方法,其特征在于,上述步骤3和步骤5中的设定压力值均为1Mpa。 3. the control method of PLC control system according to claim 2, is characterized in that, the set pressure value in above-mentioned step 3 and step 5 is 1Mpa. 4.根据权利要求3所述的PLC控制系统的控制方法,其特征在于,上述步骤4中排气阀、排水阀、疏水阀、蒸汽进入阀和冷却水进入阀的开闭包括以下步骤: 4. the control method of PLC control system according to claim 3 is characterized in that, the opening and closing of exhaust valve, drain valve, water trap, steam inlet valve and cooling water inlet valve in the above-mentioned step 4 comprises the following steps: 步骤401、通过PLC控制排水阀和疏水阀打开,并设定打开的时间,在打开排水阀和疏水阀的同时计时; Step 401, controlling the opening of the drain valve and steam trap through the PLC, and setting the opening time, and timing while opening the drain valve and steam trap; 步骤402、如上述步骤401计时时间到,则将排水阀关闭,疏水阀继续打开,蒸汽进入阀打开,同时设定时间,并同时计时; Step 402, if the timing is up in the above step 401, then close the drain valve, continue to open the steam trap, open the steam inlet valve, set the time at the same time, and count at the same time; 步骤403、如上述步骤402的计时时间到,则打开排气阀,关闭疏水阀,关闭蒸汽进入阀和打开冷却水进入阀,并设定时间,同时计时; Step 403, as the timing time of the above-mentioned step 402 is up, then open the exhaust valve, close the steam trap, close the steam inlet valve and open the cooling water inlet valve, and set the time and time at the same time; 步骤404、如上述步骤403的计时时间到,则关闭排气阀,打开排水阀,关闭蒸汽进入阀和打开冷却水进入阀,并设定时间,同时计时; Step 404, if the timing time of the above step 403 is up, then close the exhaust valve, open the drain valve, close the steam inlet valve and open the cooling water inlet valve, set the time, and count at the same time; 步骤405、如上述步骤404计时时间到,则将排气阀、排水阀、疏水阀、蒸汽进入阀和冷却水进入阀均关闭。 Step 405, when the timing of the above-mentioned step 404 expires, close the exhaust valve, drain valve, steam trap, steam inlet valve and cooling water inlet valve. 5.根据权利要求3所述的PLC控制系统的控制方法,其特征在于,上述步骤4中PLC控制快速油泵和补压油泵的运转,从而控制主缸加压到设定值,完成塑胶地板硫化机工作控制包括以下步骤: 5. The control method of the PLC control system according to claim 3, characterized in that, in the above step 4, the PLC controls the operation of the fast oil pump and the boost oil pump, thereby controlling the pressurization of the master cylinder to a set value, and completing the vulcanization of the plastic floor Machine work control includes the following steps: 步骤501、控制快速油泵停止,补压油泵运行,从而加压到第一设定压力值,达到第一设定压力值时,便控制补压油泵关闭,并对第一压力值的工作时间进行计时,判断第一压力值下的工作时间和工作压力; Step 501, control the fast oil pump to stop, and the boost oil pump to operate, thereby pressurizing to the first set pressure value, and when the first set pressure value is reached, control the boost oil pump to turn off, and calculate the working time of the first pressure value Timing, judging the working time and working pressure under the first pressure value; 步骤502、上述步骤501中的第一压力值下的工作时间和工作压力均符合要求,则启动补压油泵,从而加压到第二设定压力值,达到第二设定压力值时,便控制补压油泵关闭,并对第二压力值的工作时间进行计时,判断第二压力值下的工作时间和工作压力;重复控制补压油泵直到加压到第四设定压力值,完成主缸加压。 Step 502, the working time and working pressure at the first pressure value in the above step 501 meet the requirements, then start the booster oil pump to pressurize to the second set pressure value, and when the second set pressure value is reached, the Control the boost oil pump to close, and time the working time of the second pressure value, and judge the working time and working pressure under the second pressure value; repeat the control of the boost oil pump until it is pressurized to the fourth set pressure value, and the master cylinder is completed. Pressurize.
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