CN104117554A - Automatic control system and method for high-precision straightening machine - Google Patents
Automatic control system and method for high-precision straightening machine Download PDFInfo
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- CN104117554A CN104117554A CN201410307230.2A CN201410307230A CN104117554A CN 104117554 A CN104117554 A CN 104117554A CN 201410307230 A CN201410307230 A CN 201410307230A CN 104117554 A CN104117554 A CN 104117554A
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Abstract
The invention relates to an automatic control system and method for a high-precision straightening machine and belongs to the field of automatic control. Through the automatic control system and method, the straightness (curvature) reaches over 0.3 mm/m according to the straightening precision of the high-precision straightening machine; a hardware structure and a software method of the automatic control system for the high-precision straightening machine are designed considering closed-loop control of oil source pressure and oil cylinder piston displacement of a hydraulic system of the high-precision straightening machine, continuous detection of straightening operation process data, stepless speed regulation control for calibrating transmission of all sets of straightening rollers and the like, the international advanced level of three-dimensional rotation straightening under high-precision automatic control is reached, consistency of roller gap precision in the straightening process, stability of evenly distributed and balanced straightening force and reliability of nonlinear variable gain automatic compensation can be guaranteed, the straightness is improved to 0.2 mm/m from 0.3 mm/m according to the straightening precision of the high-precision straightening machine, and the straightening target that straightened materials have no blind area or tiny crack or scratch or oval or bounce is achieved.
Description
Technical field
The invention belongs to automation field, be specifically related to a kind of high-accuracy straightening machine automatic control system and control method.
Background technology
Along with China's industry is fast-developing, rare metal and alloy material thereof are more and more extensive the industrial circle application such as Aero-Space, telecommunications, nuclear power generation, linearity (flexibility) to its tubing, bar requires to reach 0.3mm/m to 0.2mm/m, more than the straightener flattening precision that China produces at present rests on 1mm/m mostly, the highest 0.5mm/m left and right that also can only reach, can not meet the high linearity aligning demand of 0.3mm/m, more cannot meet the aligning demand of the as thin as a wafer wall tube material of wall thickness below 0.5mm; Therefore, the new industry such as finishing production line and nuclear power generation after rare metal and alloy material rolling thereof all needs to configure high accuracy equipment for straightening; And stable high accuracy equipment for straightening must be equipped with high accuracy aligning automatic control system, could realize high accuracy aligning target.
Summary of the invention
For the shortcoming of prior art, the present invention proposes a kind of high-accuracy straightening machine automatic control system and control method, improves flattening precision, reliability to reach, and the object that rear quilt is rectified material non-blind area, rebounded without fine fisssure, no marking, nothing ellipse, nothing is aligned in realization.
A kind of high-accuracy straightening machine automatic control system, comprise mangneto formula displacement transducer, oil pressure sensor, man-machine interface, PLC controller, amplifier, DC speed regulation controller, direct current generator, decelerator, incremental optical-electricity encoder, proportional reversing valve and proportional pressure control valve, wherein, described mangneto formula displacement transducer is installed on the piston rod place of straightener oil cylinder, oil pressure sensor is arranged on the hydraulic valve block of straightener Hydraulic Station, the output of mangneto formula displacement transducer is connected in the first passage analog input end of PLC controller, the output of oil pressure sensor connects the second channel analog input end of PLC controller, man-machine interface connects PLC controller by bus, the first passage analog output end of PLC controller connects the input of proportional reversing valve by amplifier, the second channel analog output end of PLC controller connects the input of proportional pressure control valve by amplifier, PLC controller is connected with DC speed regulation controller by bus, described proportional reversing valve is arranged at straightener oil cylinder side, between straightener oil cylinder and proportional reversing valve, is provided with proportional pressure control valve, the output of described DC speed regulation controller connects direct current generator, one end of the output shaft connection reducer of direct current generator, and the other end of decelerator connects the central shaft of straightener roller by universal-joint spindle, tail end at motor is provided with incremental optical-electricity encoder, and the output of incremental optical-electricity encoder connects the input of DC speed regulation controller.
Described decelerator, it connects the central shaft of multiple smoothing rolls simultaneously.
The number of described proportional reversing valve number, proportional pressure control valve number and mangneto formula displacement transducer is all identical with the number of movable roll in straightener, and the number of oil pressure sensor is 2 times of number of movable roll in straightener.
The control method that adopts high-accuracy straightening machine automatic control system to carry out, comprises the following steps:
Step 1, arrange and rectified the aligning speed of material by man-machine interface according to the actual requirements, realize the setting to direct current generator rotating speed of target; The displacement target value of setting straightener movable roll, comprises spacing and recurvation amount between upper and lower roll; Set according to the actual requirements the protection oil pressure value of being rectified material, i.e. the overflow value of preset proportion overflow valve;
Step 2, the angle of manual adjustments upper and lower roll according to the actual requirements, and manually the movable roll of straightener is moved to bottom carries out zero clearing, be that upper and lower roll spacing is zero, and the lower roll for recurvation is moved to bottom, using the contact position of upper and lower roll now as displacement relative zero;
Step 3, startup straightener, adopt PLC controller to send a control signal to proportional reversing valve, the opening degree of control ratio reversal valve, and then in control oil cylinder, oil pressure drives piston rod movement, realize the displacement target value that is increased to setting of straightener upper and lower roll spacing, and the lower roll displacement that is used in recurvation reaches the recurvation amount of setting;
Step 4, between straightener upper and lower roll, put into by strong material;
In step 5, straightener running, adopt in real time mangneto formula displacement transducer to gather the displacement of piston rod, feed back in PLC controller with the displacement target value of setting do poor, adopt pid control algorithm displacement calculating compensation rate, by amplifier control ratio reversal valve control opening degree, regulate oil mass in oil cylinder, and then the displacement of control straightener movable roll is stabilized in setting displacement target value;
In step 6, straightener running, adopt in real time incremental optical-electricity encoder to gather DC motor speed value, be sent in PLC controller by DC controller, according to the difference of the actual measured value of DC motor speed and the setting of direct current generator rotating speed of target, adopt pid control algorithm to calculate the compensation rate of DC motor speed, and be sent to the adjusting of realization to DC motor speed in DC controller, make DC motor speed be stable at goal-setting value;
In step 7, straightener running, adopt in real time oil pressure sensor to gather the protection oil pressure value of being rectified the material whether interior oil pressure value of oil cylinder exceedes setting, if, PLC controller control ratio overflow valve carries out overflow, oil pressure value in oil cylinder is returned in protection oil pressure value, otherwise, return to step 6 and continue Real-time Collection;
Step 8, when completing all being rectified after the alignings of material, stop.
Spacing between upper and lower roll described in step 1 is rectified the diameter of material.
In pid control algorithm described in step 5, proportionality coefficient is definite, adopts real-time dynamic regulating method, and concrete steps are as follows:
Whether step 6-1, the actual displacement of real-time judge cylinder piston rod are greater than the displacement target value of setting, if so, perform step 6-2, otherwise, execution step 6-3;
Step 6-2, according to the flow pressure yield value of actual measurement oil pressure value and proportional reversing valve in oil cylinder, determine the yield value of control system, and perform step 6-4;
Formula is as follows:
K
x＝K
p/sqrt(ΔP)
Wherein, K
xrepresent the yield value of control system, K
prepresent the flow pressure yield value of proportional reversing valve, now actual measurement oil pressure value in Δ P=oil cylinder, sqrt (.) represents evolution;
Step 6-3, according to actual measurement oil pressure value in oil cylinder and the difference of straightener oil supply pressure value and the flow pressure yield value of proportional reversing valve, determine the yield value of control system, and perform step 6-4;
Formula is as follows:
K
x＝K
p/sqrt(ΔP)
Now, the difference of actual measurement oil pressure value and straightener oil supply pressure value in Δ P=oil cylinder;
Step 6-4, judge control system yield value whether in the scope of setting, this scope is 1～1000, if so, performs step 6-5, otherwise, return to execution step 6-1;
Step 6-5, proportionality coefficient using the yield value of control system obtaining in pid control algorithm.
Advantage of the present invention:
A kind of high-accuracy straightening machine automatic control system of the present invention and control method, make more than the flattening precision linearity (flexibility) of high-accuracy straightening machine reaches 0.3mm/m; The present invention starts with from the continuous detecting of the closed-loop control of high-accuracy straightening machine hydraulic system oil sources pressure and oil cylinder piston displacement, aligning running data, the stepless speed regulation control etc. of demarcating each group of smoothing roll transmission, hardware configuration and the software approach of design high-accuracy straightening machine automatic control system, reach the leading level in the world of the three-dimensional rotation aligning of high precision in control, the present invention can ensure the uniformity of each group roll gap precision in aligning process; The stability of uniform, balanced straightening force; The reliability of non-linear variable gain auto-compensation, makes the flattening precision of high-accuracy straightening machine bring up to 0.2mm/m by linearity 0.3mm/m; The aligning target that has been reached non-blind area by strong material, rebounded without fine fisssure, no marking, nothing ellipse, nothing after aligning.
Brief description of the drawings
Fig. 1 is the system architecture diagram of an embodiment of the present invention;
Fig. 2 is the high accuracy aligning automaton structured flowchart of an embodiment of the present invention, wherein, and 1-man-machine interface, 2-PLC programmable device, 3-operating desk, 4-power cabinet, 5-switch board, 6-workshop management computer;
Fig. 3 is the operating desk structural representation of an embodiment of the present invention;
Fig. 4 is the high-accuracy straightening machine autocontrol method flow chart of an embodiment of the present invention;
Fig. 5 is that the roll gap recurvation piezometric power control coefrficient of an embodiment of the present invention is adjusted flow chart automatically;
Fig. 6 is the automatic adjustment programme flow chart of roll gap recurvation amount Position Control coefficient of an embodiment of the present invention;
Fig. 7 is the proportional pressure control valve pressue-graph of an embodiment of the present invention.
Detailed description of the invention
Below in conjunction with accompanying drawing, an embodiment of the present invention is described further.
In the embodiment of the present invention, as shown in Figure 1, high-accuracy straightening machine automatic control system comprises mangneto formula displacement transducer, oil pressure sensor, man-machine interface (HMI), PLC controller, amplifier, DC speed regulation controller (6RA70), direct current generator, decelerator, incremental optical-electricity encoder, proportional reversing valve, proportional pressure control valve and corresponding amplifier thereof, wherein, described mangneto formula displacement transducer is installed on the piston rod place of straightener oil cylinder, oil pressure sensor is arranged on hydraulic valve block, for detection of the pressure of smoothing roll oil cylinder, the output signal of mangneto formula displacement transducer is connected in the first passage analog input end IW3 of PLC controller, the output of oil pressure sensor connects the second channel analog input end IW5 of PLC controller, man-machine interface (HMI) connects PLC controller by MPI bus, the first passage analog output end QW3 of PLC controller connects the given input N0 of proportional reversing valve amplifier, the second channel analog output end QW7 of PLC controller connects the given input IN0 of proportional pressure control valve amplifier, and PLC controller carries out data communication by the communication board (CBP2) on Profibus bus and DC speed regulation controller (6RA70), described proportional reversing valve is arranged at straightener oil cylinder side, between straightener oil cylinder and proportional reversing valve, is provided with proportional pressure control valve, the output armature of described DC speed regulation controller (6RA70) is connected direct current generator with excitation wire, and the output shaft of motor is by one end of shaft coupling connection reducer, and the other end of decelerator connects the central shaft of straightener roller by universal-joint spindle, tail end at motor is provided with incremental optical-electricity encoder, and the output of encoder is the control panel input to DC speed regulation controller (6RA70) as speed feedback link.
Described decelerator, it connects the central shaft of multiple smoothing rolls simultaneously; The number of described proportional reversing valve number, proportional pressure control valve number and mangneto formula displacement transducer is all identical with the number of movable roll in straightener, and the number of oil pressure sensor is 2 times of number of movable roll in straightener.
In the embodiment of the present invention, proportional reversing valve adopts 4WRA model; Proportional pressure control valve adopts DBETR type direct-acting type proportional overflow valve, and amplifier adopts RT3013 type digital proportional amplifier, and DC speed regulation controller adopts 6RA70 model; PLC controller adopts SIMATIC S7-300 model (comprising 314C type CPU), and man-machine interface adopts MP-277 type, and decelerator adopts ZLY180-18 model, and motor adopts Z4-160-31 (27kw) type; Incremental optical-electricity encoder adopts E6B2-CWZ5B model, and mangneto formula displacement transducer adopts MD10-DC8-2QC model; Oil pressure sensor adopts P20S-GB400CN14M4B model; The corresponding 0-150.00mm of top roll 1-6 roller displacement transducer 4-20mA, the corresponding 0-40mm of lower roll 2,5 roller displacement transducer 4-20mA; Hydraulic system oil pressure detects: the corresponding 0-40MPa of 4-20mA.
As shown in Figure 2, for high accuracy aligning automatic control system structured flowchart, in the present embodiment, be provided with switch board, power cabinet, operating desk, PLC programmable device, MP-277 type man-machine interface and workshop management computer, wherein:
Power cabinet: provide power supply for the present invention aligns automatic control system, simultaneously for the straightener main frame of system support provides power supply.
Switch board: 3 groups of upper and lower DC speed regulation controllers of big roller and 3 groups of upper and lower DC speed regulation controllers of pony roll are installed, are connected with the large and small roller direct current generator of straightener respectively, control the smoothing roll speed of service.
Control system operating desk (MOP) is provided with 314C type CPU: aligning automatic control system of the present invention is used for controlling the high-accuracy straightening machine of 12 rollers " different roll spacing " roll system structure, be configured to big roller 2-2 (3) totally 6 rollers, pony roll 2-2 (3) totally 6 rollers, count 12 rollers, form large and small roller composite roll system.Control system main hardware structure of the present invention is arranged in control system operating desk;
Respectively aligning complete machine is implemented to following control function:
1, control the DC motor speed of 12 smoothing rolls, reach the calibration value of controlling aligning speed;
2, control 6 upper straightening rolls and 2 the lower smoothing rolls that there are elevating function, make the roll gap accuracy value of each 3 groups of large and small roller reach and keep the calibration value of setting;
3, have elevating function 8 smoothing rolls rising and decline by the increasing of the amount of piston displacement of hydraulic jack, subtract the calibration value of realizing roll gap precision.Keeping calibration value is to be measured by the displacement transducer of control system, provides the output signal of positive and negative levelling amount, the oil pressure of automatic adjustment hydraulic jack through PLC controller.
4,, when straightener is applied straightening force to rectifying material, keep uniform, the equilibrium state of straightening force.For this reason, control system of the present invention also will complete following two basic control functions.The one, to control oil supply pressure and be stabilized in pressure calibration value, this names a person for a particular job and all enters under normal condition at straightener and control system, and control system will be aligned calibration value oil supply pressure automatically.The 2nd, in aligning process, due to the variation of many objective factors, the rising of for example hydraulic oil temperature or the meeting that declines affect oil pressure, and this non-linear variable gain is the content that control system of the present invention must be controlled.System non-linear variable gain automatic compensation function, ensure the realization of the straightening function target of uniform, balanced, the roll gap precision of straightening force and the smoothing roll speed of service.
Control system PLC programmable device is connected with control system host computer unit CPU314C of the present invention, is the programming device of automatic control system; Operating desk structured flowchart as shown in Figure 3, i.e. PLC controller block diagram, operating desk connects man-machine interface and programmable device by PROFIBUS bus.
The touch-screen (MP-277 type man-machine interface) of control system: control system of the present invention, according to the straightening function of straightener and control system, has been worked out tens straightening operation menus, calls for client.
Hydraulic proportion valve control section: comprise 8 hydraulic cylinder displacement controls and 4 pressure calibration controls.
Hydraulic cylinder displacement detecting control section: comprise 8 oil pressure sensors, the control voltage of sensor is 0～10V, by correspondence 0～300bar; Change into the real number of four bytes from the analog input detected value of PLC through integer, after being calculated by CPU, then change into analog output, control related fluid pressure valve opening amount.
The speed ring of control system, current loop control part: comprise its feedback mechanism, PLC is connected with DC speed regulation mechanism, processing speed, current feedback signal, reach closed-loop control target in time, realizes each smoothing roll linear velocity consistent, ensures flattening precision.
The logic detection control section of Hydraulic Station I/O input and output: the necessary voltage stabilizing of Hydraulic Station output oil pressure, system oil supply pressure calibration value, feed back detected value by this nominal pressure value by logic detection mechanism, process feedback signal, align at any time the proportional reversing valve of Hydraulic Station output by PLC, keep oil supply pressure stable, the bad phenomenon of oil supply pressure fluctuation does not occur.
In the embodiment of the present invention, control system is also provided with the communication module of CP343-1 type: be connected with Ethernet, the workshop management meter marking machine of control system of the present invention, use for straightener production information and workshop management.
In the embodiment of the present invention, mainly by industrial microcomputer, " programmable controller (PLC) and 6RA70 type all-digital dc speed-regulating system form; whole system hardware configuration adopts EPA structure; operator station, PLC station and factory integrated automation workshop management system are all incorporated in 100,000,000 EPAs, have fabulous communication speed and interference free performance.
In the embodiment of the present invention, upper and lower home roll motor adopts the DC servo drive controller 6RA70 series digital direct current speeder of Siemens to drive main motor-driven, the pulse coder that is 2048 by individual pen pulse detects aligning speed, gives PLC composition negative velocity feedback system by Profiubs-DP network by DC generator speed signal feedback; By Profiubs-DP network, moment of torsion data being sent into PLC by 6RA70 direct current speeder processes, then give an order and control the electric current output of DC servo drive controller-6RA70 series digital direct current speeder, thereby ensure the moment of torsion synchronization accuracy requirement of upper and lower two rollers, ensure that upper and lower two roller speed are synchronous, moment of torsion is synchronous, thereby more than the flattening precision that is ensured to make high-accuracy straightening machine is brought up to 0.2mm/m by linearity (flexibility) 0.3mm/m, also greatly improve the fineness of product surface after aligning.
In the embodiment of the present invention, hydraulic proportional reversal valve coordinates the displacement transducer composition hydraulic servo ratio control system being arranged in hydraulic cylinder piston, has ensured each roller recurvation power uniformity required precision; (resolution ratio is that 5 μ m) will accurately measure the position data of up-down rollers oil cylinder piston to high accuracy mangneto formula displacement transducer, position data is sent into PLC and carry out position closed loop control; Can and carry out the setting (set recurvation amount according to process data, thereby set recurvation power) of recurvation amount according to technological requirement.
In the embodiment of the present invention; the hydraulic system of this equipment is designed with proportional pressure control valve in recurvation cylinder oil circuit; can be according to unlike material, the raw material of different tube diameters is set formula, is not damaged by excessive oil pressure with protection thereby set different pressure protect values by strong material.
The control method that adopts high-accuracy straightening machine automatic control system to carry out, method flow diagram as shown in Figure 4, comprises the following steps:
Step 1, arrange and rectified the aligning speed of material by man-machine interface according to the actual requirements, realize the setting to direct current generator rotating speed of target; The displacement target value of setting straightener movable roll, comprises spacing and recurvation amount between upper and lower roll; Set according to the actual requirements the protection oil pressure value of being rectified material, i.e. the overflow value of preset proportion overflow valve; Spacing between described upper and lower roll is rectified the diameter of material.
In the embodiment of the present invention, respectively align parameter determination method as follows:
1) straightening force is determined:
After roll forming is determined, can press roll gap curve calculation straightening force.
The helical pitch t of pole material smoothing roll roll shape is:
t＝πdtanα (2)
In formula, d is the diameter of pole material, and α is pole material axis and smoothing roll between centers angle.
If the elastic limit moment of flexure of roundwood is M
1, can calculate straightening force and be:
Wherein, F
3represent S '
darrive the straightening force in Sb section; M
3represent S '
darrive the moment of flexure in Sb section; Sb, S '
d, Sd is smoothing roll segmentation flex point value (mm), on smoothing roll in this order gradually near center O point;
Wherein, F
2represent that Sd is to S '
dstraightening force in section; M
2represent that Sd is to S '
dmoment of flexure in section
Wherein, F
1represent that smoothing roll center O arrives the straightening force in Sd section;
2) aligning speed is determined:
Aligning speed proposes according to the daily output, as v=30～60m/min etc., first calculates the helical pitch t=π dtag α of workpiece smoothing roll oblique angle α, then calculates the rotating speed of workpiece according to helical pitch t
calculate smoothing roll speed by workpiece rotational frequency
wherein D is smoothing roll diameter.
N, v, n in formula
gvalue can be adjusted as required.
Step 2, the angle of manual adjustments upper and lower roll according to the actual requirements, and manually the movable roll of straightener is moved to bottom carries out zero clearing, be that upper and lower roll spacing is zero, and the lower roll for recurvation is moved to bottom, using the contact position of upper and lower roll now as displacement relative zero;
In the embodiment of the present invention, when smoothing roll is depressed, displacement transducer reading is P
0, in program, be stored as relative zero, in the time that smoothing roll lifts, displacement sensing reading is P
1, now roll gap is | P
1-P
0|.
Step 3, startup straightener, adopt PLC controller to send a control signal to proportional reversing valve, the opening degree of control ratio reversal valve, and then in control oil cylinder, oil pressure drives piston rod movement, realize the displacement target value that is increased to setting of straightener upper and lower roll spacing, and the lower roll displacement that is used in recurvation reaches the recurvation amount of setting;
Step 4, between straightener upper and lower roll, put into by strong material;
In step 5, straightener running, adopt in real time mangneto formula displacement transducer to gather the displacement of piston rod, feed back in PLC controller with the displacement target value of setting do poor, adopt pid control algorithm displacement calculating compensation rate, by amplifier control ratio reversal valve control opening degree, regulate oil mass in oil cylinder, and then the displacement of control straightener movable roll is stabilized in setting displacement target value;
In the embodiment of the present invention, control system has roll gap recurvation amount automatic regulating function.Roll gap recurvation amount depends on uniform, the balanced straightening force size of being rectified tubing, it is as follows that it adjusts control principle automatically: in the time being set straightening force value by aligning workpiece actual straightening power > (recurvation quantitative change is large), export and increase pressure by Hydrauservo System, hydraulic cylinder fine motion band action roller system is moved down, reduce actual roll gap spacing, thus balance recurvation amount.In the time being set straightening force value by aligning workpiece actual straightening power < (recurvation quantitative change is little), export and reduce pressure by Hydrauservo System, hydraulic cylinder fine motion band action roller is fastened and moved, strengthen actual roll gap spacing, thus balance recurvation amount.Roll gap recurvation piezometric power is adjusted flow process as shown in Figure 5 automatically: in figure: Δ P=Psys-Pcyl, and Psys is oil supply pressure, Pcyl is oil pressure in hydraulic cylinder.
In like manner, roll gap recurvation amount is automatically adjusted and can also automatically be adjusted by position except pressure adjustment.Position is automatically adjusted in processing and has been added variable-gain character factor Kposition_ratio, in order to process the compensation of the non-linear variable gain characteristic in aligning process.
As shown in Figure 6, concrete steps are as follows for the automatic adjustment programme flow process in position:
Whether step 5-1, the actual displacement of real-time judge cylinder piston rod are greater than the displacement target value of setting, if so, perform step 5-2, otherwise, execution step 5-3;
Step 5-2, according to the flow pressure yield value of actual measurement oil pressure value and proportional reversing valve in oil cylinder, determine the yield value of control system, and perform step 5-4;
Formula is as follows:
K
x＝K
p/sqrt(ΔP) (1)
Wherein, K
xrepresent the yield value of control system, K
prepresent the flow pressure yield value of proportional reversing valve, now actual measurement oil pressure value in Δ P=oil cylinder, sqrt (.) represents evolution;
The pass of proportional reversing valve valve port oil flow Q and proportional reversing valve opening degree and valve port pressure differential is:
in formula: A is hydraulic cylinder sectional area, Δ P is proportioning valve both sides pressure reduction (actual measurement oil pressure value in oil cylinder).
In the embodiment of the present invention, when processing, position closed loop adopts pi regulator control, and Δ P is too small or cause Kratio excessive close to 0 when ensureing calculating K ratio, in the time of Δ P < 100, makes Δ P=100.
Step 5-3, according to actual measurement oil pressure value in oil cylinder and the difference of straightener oil supply pressure value and the flow pressure yield value of proportional reversing valve, determine the yield value of control system, and perform step 6-4;
Formula is as follows:
K
x＝K
p/sqrt(△P) (1)
Now, the difference of actual measurement oil pressure value and straightener oil supply pressure value in Δ P=oil cylinder;
Step 5-4, judge control system yield value whether in the scope of setting, this scope is 1～1000, if so, performs step 5-5, otherwise, return to execution step 6-1;
Step 5-5, proportionality coefficient using the yield value of control system obtaining in pid control algorithm.
In step 6, straightener running, adopt in real time incremental optical-electricity encoder to gather DC motor speed value, be sent in PLC controller by DC controller, according to the difference of the actual measured value of DC motor speed and the setting of direct current generator rotating speed of target, adopt pid control algorithm to calculate the compensation rate of DC motor speed, and be sent to the adjusting of realization to DC motor speed in DC controller, make DC motor speed be stable at goal-setting value, specific as follows:
In step 7, straightener running, adopt in real time oil pressure sensor to gather the protection oil pressure value of being rectified the material whether interior oil pressure value of oil cylinder exceedes setting, if, PLC controller control ratio overflow valve carries out overflow, oil pressure value in oil cylinder is returned in protection oil pressure value, otherwise, return to step 6 and continue Real-time Collection;
In the embodiment of the present invention, while there is accident in complete machine running, for example, while aligning material head, tail, rectified scantling when irregular, according to the electric current of 6RA70 device and torque feedback, determine and sting steel (being entered straightener by being rectified material) signal, can set, excessive be overproof.Electric control system controls smoothing roll lifts fast, and hydraulic system overflow valve works, and prevents plant equipment and is rectified material and mutually damage.
In the embodiment of the present invention, the pressure in recurvation cylinder is by proportional pressure control valve as final control, and the pressure set points of proportional pressure control valve is set in proportion according to pressue-graph, as shown in Figure 7.
Step 8, when completing all being rectified after the alignings of material, stop.
High accuracy aligning automatic control system in the embodiment of the present invention is technology, the precision index design for the prompt YC12GJ70 high-precision straightening machine for tantalum niobium alloy pipe of Liaoning silver.The technical program control principle is equally applicable to the high accuracy equipment for straightening demand of other kinds specifications and models.
Claims (6)
1. a high-accuracy straightening machine automatic control system, it is characterized in that: comprise mangneto formula displacement transducer, oil pressure sensor, man-machine interface, PLC controller, amplifier, DC speed regulation controller, direct current generator, decelerator, incremental optical-electricity encoder, proportional reversing valve and proportional pressure control valve, wherein, described mangneto formula displacement transducer is installed on the piston rod place of straightener oil cylinder, oil pressure sensor is arranged on the hydraulic valve block of straightener Hydraulic Station, the output of mangneto formula displacement transducer is connected in the first passage analog input end of PLC controller, the output of oil pressure sensor connects the second channel analog input end of PLC controller, man-machine interface connects PLC controller by bus, the first passage analog output end of PLC controller connects the input of proportional reversing valve by amplifier, the second channel analog output end of PLC controller connects the input of proportional pressure control valve by amplifier, PLC controller is connected with DC speed regulation controller by bus, described proportional reversing valve is arranged at straightener oil cylinder side, between straightener oil cylinder and proportional reversing valve, is provided with proportional pressure control valve, the output of described DC speed regulation controller connects direct current generator, one end of the output shaft connection reducer of direct current generator, and the other end of decelerator connects the central shaft of straightener roller by universal-joint spindle, tail end at motor is provided with incremental optical-electricity encoder, and the output of incremental optical-electricity encoder connects the input of DC speed regulation controller.
2. high-accuracy straightening machine automatic control system according to claim 1, is characterized in that, described decelerator, and it connects the central shaft of multiple smoothing rolls simultaneously.
3. high-accuracy straightening machine automatic control system according to claim 1, it is characterized in that, the number of described proportional reversing valve number, proportional pressure control valve number and mangneto formula displacement transducer is all identical with the number of movable roll in straightener, and the number of oil pressure sensor is 2 times of number of movable roll in straightener.
4. the control method that adopts high-accuracy straightening machine automatic control system claimed in claim 1 to carry out, is characterized in that, comprises the following steps:
Step 1, arrange and rectified the aligning speed of material by man-machine interface according to the actual requirements, realize the setting to direct current generator rotating speed of target; The displacement target value of setting straightener movable roll, comprises spacing and recurvation amount between upper and lower roll; Set according to the actual requirements the protection oil pressure value of being rectified material, i.e. the overflow value of preset proportion overflow valve;
Step 2, the angle of manual adjustments upper and lower roll according to the actual requirements, and manually the movable roll of straightener is moved to bottom carries out zero clearing, be that upper and lower roll spacing is zero, and the lower roll for recurvation is moved to bottom, using the contact position of upper and lower roll now as displacement relative zero;
Step 3, startup straightener, adopt PLC controller to send a control signal to proportional reversing valve, the opening degree of control ratio reversal valve, and then in control oil cylinder, oil pressure drives piston rod movement, realize the displacement target value that is increased to setting of straightener upper and lower roll spacing, and the lower roll displacement that is used in recurvation reaches the recurvation amount of setting;
Step 4, between straightener upper and lower roll, put into by strong material;
In step 5, straightener running, adopt in real time mangneto formula displacement transducer to gather the displacement of piston rod, feed back in PLC controller with the displacement target value of setting do poor, adopt pid control algorithm displacement calculating compensation rate, by amplifier control ratio reversal valve control opening degree, regulate oil mass in oil cylinder, and then the displacement of control straightener movable roll is stabilized in setting displacement target value;
In step 6, straightener running, adopt in real time incremental optical-electricity encoder to gather DC motor speed value, be sent in PLC controller by DC controller, according to the difference of the actual measured value of DC motor speed and the setting of direct current generator rotating speed of target, adopt pid control algorithm to calculate the compensation rate of DC motor speed, and be sent to the adjusting of realization to DC motor speed in DC controller, make DC motor speed be stable at goal-setting value;
In step 7, straightener running, adopt in real time oil pressure sensor to gather the protection oil pressure value of being rectified the material whether interior oil pressure value of oil cylinder exceedes setting, if, PLC controller control ratio overflow valve carries out overflow, oil pressure value in oil cylinder is returned in protection oil pressure value, otherwise, return to step 6 and continue Real-time Collection;
Step 8, when completing all being rectified after the alignings of material, stop.
5. control method according to claim 4, is characterized in that, the spacing between the upper and lower roll described in step 1 is rectified the diameter of material.
6. control method according to claim 4, is characterized in that, the determining of proportionality coefficient in the pid control algorithm described in step 5, and adopt real-time dynamic regulating method, concrete steps are as follows:
Whether step 5-1, the actual displacement of real-time judge cylinder piston rod are greater than the displacement target value of setting, if so, perform step 5-2, otherwise, execution step 5-3;
Step 5-2, according to the flow pressure yield value of actual measurement oil pressure value and proportional reversing valve in oil cylinder, determine the yield value of control system, and perform step 5-4;
Formula is as follows:
K
x＝K
p/sqrt(△P)
Wherein, K
xrepresent the yield value of control system, K
prepresent the flow pressure yield value of proportional reversing valve, now actual measurement oil pressure value in △ P=oil cylinder, sqrt (.) represents evolution;
Step 5-3, according to actual measurement oil pressure value in oil cylinder and the difference of straightener oil supply pressure value and the flow pressure yield value of proportional reversing valve, determine the yield value of control system, and perform step 6-4;
Formula is as follows:
K
x＝K
p/sqrt(ΔP)
Now, the difference of actual measurement oil pressure value and straightener oil supply pressure value in △ P=oil cylinder;
Step 5-4, judge control system yield value whether in the scope of setting, this scope is 1～1000, if so, performs step 5-5, otherwise, return to execution step 6-1;
Step 5-5, proportionality coefficient using the yield value of control system obtaining in pid control algorithm.
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