CN104646565A - Real-time monitoring system for full-automatic stamping production line - Google Patents

Abstract

The invention is a real-time monitoring system for a full-automatic stamping production line. It includes an industrial control machine and a master station PLC that controls the work of the stamping machine on the stamping production line. The signal input terminals of the master station PLC are respectively connected to the temperature sensor and pressure sensor installed on the stamping production line to detect the work of the stamping machine. The signal of the master station PLC The output terminal is connected with the industrial control machine through the communication interface. The invention ensures the synchronous coordination between each unit and the controller on the production line under the high-speed stamping environment, and ensures the reliable and safe production of the stamping machine production line. The invention is a real-time monitoring system for a full-automatic punching production line that can improve production efficiency and reduce energy consumption.

Description

A real-time monitoring system for a fully automatic stamping production line

technical field

The invention relates to a real-time monitoring system for a full-automatic stamping production line, which belongs to the innovative technology of the real-time monitoring system for a full-automatic stamping production line.

Background technique

Forging equipment is one of the most important mechanical equipment. The equipment manufacturing industry is a basic industry that provides technical equipment for national economic development and national defense construction. The level of the equipment manufacturing industry is an important indicator of a country's industrial development. All kinds of machine tools are the working machines of the manufacturing industry and the basis for the development of the equipment manufacturing industry. Their development level represents the core competitiveness of the country. Forging machine tools account for 1/4-1/3 of the total machine tool output, and are one of the most important mechanical equipment in modern manufacturing. They are widely used in the processing of industries such as automobiles, aerospace, wind power, communications, and home appliances. The technical level, production capacity and automation degree of forging equipment directly affect the development and technological progress of my country's industry, agriculture, national defense, aerospace and other industries, and affect the modernization process of our country. Since 2002, my country has become the world's largest machine tool consumer for ten consecutive years, with an average annual growth rate exceeding GDP growth, reaching about 20%. In 2009, the sales volume has reached 19.79 billion US dollars, of which forging machine tools accounted for about a quarter of all machine tool sales.

The needs of economic, social and national defense development in the new century put forward higher requirements for forging equipment. The general development trend of today's forging equipment technology is: intelligent, precise, high-speed and high-efficiency, integrated, and green. The main technical problems in my country's high-precision fully automated stamping machine production line system are:

(1) At present, my country mainly uses single-board computer control systems, one PLC controls one punching machine, which has many shortcomings such as high cost, inconvenient management, and difficult maintenance;

(2) The safety and fault detection of existing stamping machines mainly rely on on-site real-time fault alarms, and manual monitoring of on-site instrument parameters. The main problem is that the cost of human resources is high, it depends on the experience of the operator, and the detection lacks real-time and accuracy;

(3) In the high-speed stamping environment, the synchronization and coordination between various units and controllers on the production line is extremely critical. Establishing a high-speed and reliable fieldbus communication network is the key to ensuring reliable and safe production of the stamping machine production line. Traditional stamping machines mainly use mechanical loading and unloading devices, or semi-automatic loading and unloading. The disadvantage is that the materials must be placed in a fixed position manually, and the work cycle is slow, which cannot meet the environmental requirements of high-speed stamping production lines.

Therefore, applying network technology to the stamping machine system to realize network monitoring and control, applying real-time monitoring data remote transmission, remote intelligent fault diagnosis system to the stamping machine production line and realizing high-speed field bus communication network and automatic robot loading and unloading will be the key points of the stamping production line. development trend.

Contents of the invention

The purpose of the present invention is to provide a real-time monitoring system for a fully automatic stamping production line that ensures the synchronization and coordination between each unit and the controller on the production line in a high-speed stamping environment and ensures the reliability and safety of the stamping machine production line. The invention can improve production efficiency and reduce energy consumption.

The present invention adopts the following technical scheme: the real-time monitoring system of the automatic stamping production line of the present invention includes an industrial control machine and a main station PLC controlling the work of the main station stamping machine on the stamping production line, wherein the signal input terminals of the main station PLC are respectively connected to the stamping production line The temperature sensor and pressure sensor installed on the upper installation to detect the work of the stamping machine are connected, and the signal output end of the main station PLC is connected to the industrial control machine through the communication interface.

The signal output end of the above-mentioned master station PLC is also connected with the signal input end of the slave station PLC of the slave station stamping machine on the stamping production line and connected with the signal input end of the industrial robot controller.

The signal input terminals of the slave station PLC are respectively connected to the temperature sensor and pressure sensor installed on the stamping production line to detect the operation of the stamping machine of the slave station. Temperature sensor for temperature and gear lube oil temperature.

The above-mentioned pressure sensors for detecting the stamping machine of the master station and the stamping machine of the slave station all include pressure sensors with two pressure detection points.

The signal input end of the above-mentioned industrial control machine is also connected with a vibration sensor, and the vibration sensor includes sensors for respectively detecting the vibration of the base of the punching machine and the vibration of the body of the punching machine.

The signal input end of the above-mentioned industrial control machine is also connected with a displacement sensor, and the displacement sensor detects the displacement of the slider of the punching machine.

Compared with the required technology, the present invention has the following advantages:

1) The present invention can realize real-time monitoring, recording and storage of various state parameters (pressure, temperature, displacement, vibration, etc.) in the stamping process, so as to coordinate and control the actions between industrial robots and precision presses synchronously;

2) The present invention can realize coordinated communication and seamless connection among various components of the entire system, so as to ensure the reliability, stability and security of communication;

3) The present invention can realize the monitoring and information management system of the overall stamping production line, maximize production efficiency and reduce energy consumption;

4) The present invention can ensure personal safety, equipment safety, and real-time fault alarm in the stamping production process.

The invention develops from single-machine automation to multi-machine automatic stamping line and flexible production line. The CNC automatic production line based on multiple high-precision multi-station presses not only greatly improves production efficiency and product quality, but also greatly reduces the floor area and the number of workers. It has high intelligence, high precision and high reliability. , high efficiency, energy saving, material saving and a series of advantages.

Description of drawings

Fig. 1 is the schematic diagram of the real-time monitoring system of the automatic stamping production line of the present invention;

Fig. 2 is the schematic diagram of master station PLC real-time data acquisition unit of the present invention;

Fig. 3 is the flow chart of master station PLC data acquisition of the present invention;

Fig. 4 is a schematic diagram of communication interaction between master and slave stations of the present invention;

Fig. 5 is the master-slave communication interaction flowchart of the present invention;

Fig. 6 is the real-time displacement monitoring curve of displacement sensor among the present invention;

Fig. 7 is the real-time temperature monitoring curve of the temperature sensor in the present invention.

Detailed ways

The implementation of the patent of the present invention is described in detail below with reference to the accompanying drawings and specific examples:

Fig. 1 is the functional block diagram of the real-time monitoring system of the full-automatic stamping production line, the real-time monitoring system of the full-automatic stamping production line of the present invention, it is characterized in that comprising the master station PLC that two stamping machines work on the industrial control machine, control stamping production line, wherein The signal input terminal of the main station PLC is respectively connected to the sensor and pressure sensor installed on the stamping production line to detect the working temperature of the stamping machine, and the signal output terminal of the main station PLC is connected to the industrial control machine through the communication interface.

In this embodiment, the signal output end of the above-mentioned master station PLC is also connected to the signal input end of the slave station PLC of the slave station stamping machine on the stamping production line and connected to the signal input end of the industrial robot controller.

In this embodiment, the above-mentioned master station PLC is connected with the industrial control machine through the RS232 bus. Through the RS232 bus, the various status data collected by the PLC of the information perception layer are transmitted to the industrial control machine of the execution layer to realize remote data monitoring and information management.

In this embodiment, the above-mentioned master station PLC is connected with a touch screen. The touch screen is used as the human-computer interaction control unit.

In this embodiment, the signal input terminals of the slave station PLC are respectively connected to the sensor and the pressure sensor installed on the stamping production line to detect the working temperature of the stamping machine of the slave station. The temperature sensor for detecting the stamping machine of the master station and the stamping machine of the slave station includes a temperature sensor for detecting the temperature of the main shaft bearing of the stamping machine and the temperature of the gear lubricating oil. One stamping machine has two temperature detection points, and two stamping machines have four temperature measurement points, totaling four temperature sensors. The four temperature sensors detect the real-time temperature of the four temperature detection points in real time, and the real-time temperature can be displayed on the touch screen. The upper and lower limits of the temperature detection of the four temperature sensors can be set by the master station PLC and the slave station PLC, and the industrial control machine can also set four The temperature detection upper and lower limits of a temperature sensor.

In this embodiment, the pressure sensor for detecting the stamping machine of the master station and the stamping machine of the slave station includes two pressure sensors. One punching machine has one pressure detection point, and two punching machines have two pressure measuring points in total. The upper and lower pressure limit parameters of the pressure sensor can be set by the master station PLC and the slave station PLC, and the upper and lower pressure limit parameters of the pressure sensor can also be set by the industrial control machine. parameter. The pressure of the two pressure detection points can be displayed on the touch screen.

In this embodiment, the signal input end of the above-mentioned industrial control machine is also connected with a vibration measurement sensor, and the vibration sensor includes sensors for respectively detecting the vibration of the base of the punching machine and the vibration of the body of the punching machine. One stamping machine has two vibration detection points, and two stamping machines have four vibration detection points. There are four vibration sensors in total, which detect the signals of the four vibration test points respectively. The signals of the vibration test points can be displayed on the industrial control machine. And the vibration signal can be analyzed and processed on the industrial control machine, and the upper and lower limits of the vibration sensor amplitude can be set by the industrial control machine.

In this embodiment, the signal input end of the above-mentioned industrial control machine is also connected with a displacement sensor, and the displacement sensor detects the displacement of the punch slider of the punching machine. The industrial control machine can set the displacement parameters of the displacement sensor and the upper and lower limits of displacement. Since the output of the displacement sensor is already a digital signal, it is enough to communicate directly with the industrial control machine through RS232, and the upper and lower limits of the displacement of the displacement sensor are set by the industrial control machine.

In this embodiment, the signal input terminals of the above-mentioned master station PLC and slave station PLC are also connected with safety gratings. The safety light barrier detects the intrusion of foreign objects (including the operator's hand, arm and foreign objects) on the workbench of the stamping machine, and when there is an abnormality at the detection point, it will alarm in time and immediately enter the emergency stop state to ensure the safety of the operator and equipment.

In this embodiment, the above-mentioned temperature sensor is a platinum resistance temperature sensor, and the temperature analog quantities of the 4-way platinum resistance temperature sensors are converted into corresponding digital quantities through the temperature acquisition module Q64RD and enter the master station PLC and the slave station PLC respectively; the signals of the two pressure sensors pass through The A/D conversion module Q64AD converts the pressure signal into the corresponding digital quantity and enters the master station PLC and the slave station PLC respectively; the six vibration signals of the stamping machine base and the body directly enter the industrial control machine through the PCI-1716 data acquisition card; the displacement sensor detects the stamping The displacement of the slider of the machine punch, and its digital signal enters the industrial control machine through the RS232 interface.

In this embodiment, the master station PLC and the slave station PLC are also connected with a digital input and output device, and the digital input and output device mainly monitors the switches of other positions and various sound and light alarms and emergency stops of the stamping machine during the stamping process. volume signal. During the stamping process, various sound and light alarms, emergency stops and other signals are driven and output by the output module QY41P 32-point transistor. Figure 2 is the structure of the real-time data acquisition unit of the PLC of the system master station, and Figure 3 is the data acquisition process of the PLC of the system master station.

The present invention adopts a two-layer network architecture: the first layer is the information perception layer, that is, the real-time data collection and coordination control layer; the second layer is the field bus layer, that is, the industrial control machine in the workshop is the core, and the field bus CClink is networked to meet the production requirements. The real-time interaction between the master station PLC, each slave station PLC and the robot controller on the on-site stamping machine production line constitutes the real-time execution layer of the workshop production line. The master station of the system completes real-time monitoring and coordinated control of the stamping machines and industrial robots of the slave stations, and monitors various physical quantities and working conditions such as the pressure of the stamping process, the temperature rise of the bearing, the position of the punch, and the vibration of the fuselage, as well as data storage, display and monitoring. Record, and interactive communication with the local industrial computer.

The above-mentioned master station PLC is connected with a touch screen. The touch screen is used as the human-computer interaction control unit. The above touch screen is GT1055-QSBD-C, GT1055-QSBD-C is used as a human-computer interaction terminal, and uses RS232 communication with the main station PLC, which can display monitoring parameters in real time and set touch key parameters, etc. The communication protocol is Mitsubishi's built-in MELSEC communication protocol. The main functions are real-time monitoring parameter display, touch keys to realize parameter setting, etc.

Figure 4 is a schematic diagram of the communication between the master and slave stations of the system. The communication between two stamping machines, one industrial robot, and other equipment on each stamping production line interacts in real time through the field bus CClink. No. 1 stamping machine is the main control PLC, and the system is set as the master station, robot controller or other equipment The PLC is set as a slave station. The real-time communication between the system master station and each slave station mainly monitors the PLC data information of the system slave station and the status information of industrial robots, and at the same time meets the real-time control requirements of the stamping production line. The master station adopts Mitsubishi CClink communication module QJ61BT11, which is connected with the industrial robot controller and other slave stations through three-axis CClink communication cables and terminal resistors. In the schematic diagram of communication between the master and slave stations of the system (Figure 4), X, Y, and D are PLC CPU internal input, output, and 16-bit register soft components; RX, RY, RWw, and RWr are Cclink communication module QJ61BT11 internal cache soft components, respectively Remote input buffer bit device, remote output buffer bit device, remote input 16-bit register device, remote output 16-bit register device.

Figure 5 is a flow chart of communication between master and slave stations of the system. Fig. 6 is the real-time displacement monitoring curve of the displacement monitoring module, and Fig. 7 is the real-time temperature monitoring curve of the temperature monitoring module. The real-time monitoring system of the automatic stamping production line of the present invention takes the industrial control machine as the core of the execution layer and the programmable logic controller (PLC) as the core of the information perception layer, and is composed of pressure sensors, temperature sensors, vibration sensors, displacement sensors and travel switches. Signal measurement unit; the touch screen is used as the human-computer interaction control unit, and various state data collected by the information perception layer PLC are transmitted to the industrial control machine through the RS232 bus to realize remote data monitoring and information management. In addition, real-time data monitoring and automatic early warning and alarm can be realized, and the synchronization and coordination between various units and controllers on the production line in the high-speed stamping environment can ensure reliable and safe production of the stamping machine production line, improve production efficiency and reduce energy consumption.

The real-time monitoring system of the automatic stamping production line has the following main functions:

(1) Main control function: it is the core function of the whole system, and the system master is responsible for the slave station

The real-time monitoring and coordinated control of stamping machines, industrial robots and other units are responsible for the monitoring of various physical quantities and working conditions such as the pressure of the stamping process, the temperature rise of the bearings, the position of the punch, and the vibration of the fuselage, as well as data storage, display and recording. With the interactive communication with the local industrial computer.

(2) Data acquisition function: temperature, pressure, vibration, displacement, etc. in the stamping production process

Signal conditioning, acquisition, scale transformation, error correction, and corresponding signal analysis and processing.

(3) Network communication function: adopt CClink bus communication and RS232 bus communication standard

Accurately establish the network communication framework of the information perception layer and the field bus layer, mainly coordinate the control of the two stamping units, robot loading and unloading and other units, and transmit the data collected and monitored by the PLC to the industrial control machine in real time to realize data storage and Record.

(4) Fault detection and alarm function: establish safety isolation measures for the stamping unit,

The machine workbench implements photoelectric monitoring. Once abnormal conditions such as foreign matter intrusion are detected, the system will automatically alarm in real time and implement an emergency stop to ensure the safety of on-site operators and equipment. At the same time, the fault information will be displayed on the human-computer interaction terminal.

Claims (10)

1. A real-time monitoring system for a full-automatic stamping production line, characterized in that it includes an industrial control machine, a master station PLC controlling the work of the main station stamping machine on the stamping production line, wherein the signal input terminals of the master station PLC are respectively connected to the stamping production line. The temperature sensor and pressure sensor used to detect the work of the stamping machine are connected, and the signal output terminal of the main station PLC is connected to the industrial control machine through the communication interface. 2. The real-time monitoring system of the fully automatic stamping production line according to claim 1, characterized in that the master station PLC is connected to the industrial control machine through the RS232 bus. 3. The real-time monitoring system of a fully automatic stamping production line according to claim 1, characterized in that the master station PLC is connected with a touch screen. 4. The real-time monitoring system of the fully automatic stamping production line according to any one of claims 1 to 3, characterized in that the signal output terminal of the above-mentioned master station PLC is also connected with the signal of the slave station PLC of the slave station stamping machine on the stamping production line The input terminal is connected and connected with the signal input terminal of the industrial robot controller. 5. The real-time monitoring system of the fully automatic stamping production line according to claim 4, wherein the signal input terminals of the above-mentioned slave station PLC are respectively connected with temperature sensors and pressure sensors installed on the stamping production line to detect the operation of the slave station stamping machine The temperature sensor for detecting the stamping machine of the master station and the stamping machine of the slave station includes a temperature sensor for detecting the temperature of the main shaft bearing of the stamping machine and the temperature of the gear lubricating oil. 6. The real-time monitoring system of a fully automatic stamping production line according to claim 5, wherein the pressure sensors for detecting the stamping machines of the master station and the stamping machines of the slave station include pressure sensors with two pressure detection points. 7. The real-time monitoring system of a fully automatic stamping production line according to claim 6, wherein the signal input end of the above-mentioned industrial control machine is also connected with a vibration sensor, and the vibration sensor includes detecting the vibration of the base of the stamping machine and the vibration of the body of the stamping machine respectively. sensor. 8. The real-time monitoring system of the fully automatic stamping production line according to claim 7, characterized in that the signal input end of the industrial control machine is also connected with a displacement sensor, and the displacement sensor detects the displacement of the slider of the stamping machine. 9. The real-time monitoring system of a fully automatic stamping production line according to claim 8, characterized in that the signal input terminals of the master station PLC and the slave station PLC are also connected with safety gratings. 10. The real-time monitoring system of a fully automatic stamping production line according to claim 9, wherein the above-mentioned temperature sensor is a platinum resistance temperature sensor, and the temperature analog quantity of the platinum resistance temperature sensor is converted into a corresponding digital quantity by the temperature acquisition module Q64RD and enters respectively The master station PLC and the slave station PLC; the signal of the pressure sensor is converted into the corresponding digital quantity through the A/D conversion module Q64AD and enters the master station PLC and the slave station PLC respectively; the vibration signal of the vibration sensor is directly transmitted through the PCI-1716 data acquisition card Enter the industrial control machine; the digital signal of the displacement sensor enters the industrial control machine through RS232.