CN111890669A - Spiral core-spun product processing device and method based on single-board computer control - Google Patents
Spiral core-spun product processing device and method based on single-board computer control Download PDFInfo
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- CN111890669A CN111890669A CN202010417502.XA CN202010417502A CN111890669A CN 111890669 A CN111890669 A CN 111890669A CN 202010417502 A CN202010417502 A CN 202010417502A CN 111890669 A CN111890669 A CN 111890669A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/80—Component parts, details or accessories; Auxiliary operations
- B29C53/8008—Component parts, details or accessories; Auxiliary operations specially adapted for winding and joining
- B29C53/8041—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/56—Winding and joining, e.g. winding spirally
- B29C53/58—Winding and joining, e.g. winding spirally helically
- B29C53/60—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels
- B29C53/62—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels rotatable about the winding axis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/80—Component parts, details or accessories; Auxiliary operations
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- Controlling Rewinding, Feeding, Winding, Or Abnormalities Of Webs (AREA)
Abstract
The invention discloses a spiral core-spun product processing device and a processing method based on single-board computer control, which comprises the following steps: the core layer feeding mechanism is used for conveying the core layer raw materials; the core-spun layer feeding and forming mechanism is used for conveying the core-spun layer raw material and processing and forming the spiral core-spun structure; a winding mechanism for receiving a spiral core-spun structural article; and the intelligent control mechanism is used for carrying out real-time monitoring and automatic linkage control on the whole processing device. The core layer feeding mechanism, the core layer feeding and forming mechanism and the winding mechanism are sequentially arranged from bottom to top, and the intelligent control mechanism is installed on one side of the power mechanism far away from the motor and the like. The key technology of the processing device is that a single-board computer is used as a core, automatic control and image recognition means are combined, the advantages of high automation, intelligence and flexibility are given to the equipment, the operation is safe and stable, high-quality core-spun structure products with good consistency can be produced, the implementation is convenient, the cost is low, and the processing device is suitable for continuous production and popularization and application.
Description
Technical Field
The invention relates to the technical field of intelligent manufacturing, in particular to a spiral core-spun product processing device and method based on single-board computer control.
Background
With the continuous progress of science and technology, the degree of automation and intelligence is higher and higher, and each field faces the challenge of technology upgrading, and the upgrading of manufacturing equipment is one of the core factors for reducing the production cost and improving the product competitiveness. Therefore, compared with the traditional core-spun processing equipment, the processing device and the method for manufacturing the spiral core-spun structural product have the advantages that the inefficient method of performing parameter adjustment strategies without stopping observation is adopted on the aspect of solving the problem of product consistency, the real-time observation and automatic parameter adjustment on the product form can be realized simultaneously by combining the single-board control technology and the image recognition technology, the problem of product consistency is effectively solved, and the quality and the production efficiency of the product are guaranteed.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a spiral core-spun product processing device and a processing method based on single-board computer control.
In order to achieve the above purpose, the technical solution for solving the technical problem is as follows:
the invention discloses a spiral core-spun product processing device based on single board computer control, which comprises:
a core layer feeding mechanism (1) for conveying the core layer raw material;
a core-spun layer feeding and forming mechanism (2) for conveying the core-spun layer raw material and processing and forming the spiral core-spun structure;
a winding mechanism (3) for receiving the spiral core-spun structural product;
and an intelligent control mechanism (4) which takes a single-board computer as a core and is used for carrying out real-time monitoring and automatic linkage control on the whole processing device;
sandwich layer feeding mechanism (1), core-spun layer pay-off and forming mechanism (2) and winding mechanism (3) set gradually from bottom to top, intelligent control mechanism (4) install in keeping away from power unit one side of sandwich layer feeding mechanism (1), core-spun layer pay-off and forming mechanism (2) and winding mechanism (3).
Further, the core layer feeding mechanism (1) comprises a first feeding roller (101), a second feeding roller (102), a core layer raw material (103), a first driving motor (104), a first transmission belt (105), a first speed encoder (106), a first driven gear (107), a first support (108), a first rotating shaft (109) and a first driving gear (110), wherein:
the core layer raw material (103) is arranged above the first feeding roller (101) and the second feeding roller (102), the first feeding roller (101) rotates under the transmission of the first driving motor (104) and the first transmission belt (105), the first feeding roller (101) and the second feeding roller (102) are fixed on a first support (108) through a first rotating shaft (109), the rotating speed of the first feeding roller (101) is determined by the gear ratio of the first driving gear (110) and the first driven gear (107), and the real-time rotating speed can be measured through the first rotating speed encoder (106) and transmitted to the intelligent control mechanism (4) for closed-loop control in the operation process.
Further, core-spun layer pay-off and forming mechanism (2) are including core-spun layer raw materials (201), second driving motor (202), reduction gear box (203), second speed encoder (204), baffle pipe (207), second grade reduction gear (208), baffle pipe fixed pin (209), one-level reduction gear (210) and power gear (211), wherein:
install in baffle pipe (207) on baffle pipe fixed pin (209) will bend and have the radian core layer raw materials (103) carry out sharp moulding, the power of second driving motor (202) passes through reduction gear box (203) is passed to core-spun layer raw materials (201) make it rotatory and accomplish the package to the core layer according to predetermined rotational speed, real-time package speed passes through second rotational speed encoder (204) are gathered and are conveyed intelligence control mechanism (4) carry out closed-loop control, reduction gear box (203) comprise one-level reduction gear (210), second grade reduction gear (208), power gear (211).
Further, the core-spun layer feeding and forming mechanism (2) further comprises a cable (205) and a high-speed camera (206), wherein the high-speed camera (206) is arranged at the outlet of the material guide pipe (207) and transmits a video signal acquired in real time to the intelligent control mechanism (4) through the cable (205).
Further, the winding mechanism (3) comprises a winding drum (301), a third driving motor (302), a second transmission belt (303), a third speed encoder (304), a linear motor (305), a product winding drum (306), a second bracket (307), a spring connecting rib (308), a second rotating shaft (309), a material guiding sliding block (310), a second driving gear (311) and a second driven gear (312), wherein:
under the rotation of the third driving motor (302), the power is transmitted to the winding drum (301) through the second driving gear (311) and the second driven gear (312) connected with the second transmission belt (303); the product winding drum (306) clamped by the spring connecting ribs (308) is tightly attached to the winding drum (301) under the dual effects of elasticity and gravity and rotates along with the winding drum to complete winding of a finished product, the product winding drum (306) is fixed on a second support (307) through a second rotating shaft (309), the linear motor (305) drives the material guide sliding block (310) to reciprocate under the effect of a control signal to enable the finished product to be uniformly wound on the product winding drum (306), and the winding rotation speed can be acquired through the third rotation speed encoder (304) and transmitted to the intelligent control mechanism (4) to be controlled in a closed loop mode in the operation process.
Further, the spring connecting rib (308) rotates around the second rotating shaft (309).
Further, the intelligent control mechanism (4) comprises a single board computer system (401), a touch screen (402), an emergency stop button (403), an operation indicator lamp (404), an alarm indicator lamp (405) and a switch (406), wherein:
the single board computer system (401) is used for receiving the video signal in the high-speed camera (206), intercepting the video signal into a picture according to a video frame rate, then carrying out image recognition on a finished product, further calculating real-time product process parameters, and comparing the real-time process parameters with preset parameters by a control algorithm programmed and set in the single board computer system to obtain a real-time adjusting instruction so as to adjust the real-time rotating speeds of the first driving motor (104), the second driving motor (202) and the third driving motor (302);
the touch screen (402) is used for an operator to complete the setting of processing technological parameters and observe the real-time production state;
the emergency stop button (403) is used for forcibly stopping the vehicle when an emergency accident or fault occurs;
the operation indicator lamp (404) and the alarm indicator lamp (405) are respectively used for indicating the operation state and the alarm state of the system;
the switch (406) is used for switching on or off the power supply of the first driving motor (104), the second driving motor (202) and the third driving motor (302).
The invention also discloses a processing method of the spiral core-spun product based on the single board computer control, which utilizes the processing device of the spiral core-spun product based on the single board computer control to process and comprises the following steps:
step 1: installing the core-spun layer raw material (201) at a corresponding position on a reduction gear box (203) of the core-spun layer feeding and forming mechanism (2);
step 2: after confirming that no foreign matter exists on a feeding roller (101) of the core layer feeding mechanism (1), placing the core layer raw material (103) above, and drawing a stub bar of the core layer raw material (103) to penetrate through a material guide pipe (207) of the core layer feeding and forming mechanism (2) and winding the stub bar on a product winding barrel (306) of the winding mechanism (3), so that subsequent finished products can be smoothly received;
and step 3: setting production process parameters on a touch screen (402) of an intelligent control mechanism (4), and turning on a switch (406) to start production after the process is confirmed to be correct;
and 4, step 4: after the core-spun layer is started to be produced, under the control of the intelligent control mechanism (4), the core layer feeding mechanism (1) and a first driving motor (104) and a third driving motor (302) corresponding to the winding mechanism (3) start to operate to adjust the tension of the core layer raw material (103), and when the tension of the core layer raw material (103) stably reaches a preset value, a second driving motor (202) of the core-spun layer feeding and forming mechanism (2) starts to be produced according to the operation of preset parameters;
and 5: in the manufacturing process, the real-time shape of the finished product acquired by the high-speed camera (206) and the acquisition value of each mechanism encoder are transmitted to the intelligent control mechanism (4) for automatic regulation and control, so that the quality of the product and the safety of personnel and equipment are guaranteed when external interference or internal failure occurs;
step 6: if a mechanical failure or other human accident occurs during the machining process, the machine can be stopped emergently by pressing the emergency stop button (403).
Furthermore, in the step 2, the feeding mode of the core layer feeding mechanism (1) is driven by the friction force generated by the direct contact of the core layer raw material (103) with the first feeding roller (101) and the second feeding roller (102), and the core layer raw material, the first feeding roller and the second feeding roller are in direct contact, and the rotating linear speed is the same.
Furthermore, in step 4, the control algorithm of the intelligent control mechanism (4) is implemented by adopting a cascade PID controller, the process parameter is used as an input value of the outer ring, the real-time process parameter obtained by the image recognition algorithm is used as a feedback value of the outer ring, an output value of the outer ring PID controller is used as an input value of the inner ring PID controller, the real-time rotating speed of the motor returned by the encoder is used as a feedback value, and finally the processing of the preset process parameter is completed by controlling the rotating speed of the motor in real time.
Further, in step 5, the real-time form of the finished product collected in the high-speed camera (206) is captured into a picture according to the video frame rate, and then the image recognition of the finished product is performed, so as to calculate the real-time product process parameters, and the real-time process parameters are compared with preset parameters by a control algorithm programmed and set in the single board computer system to obtain a real-time adjustment instruction so as to adjust the real-time rotating speeds of the first driving motor (104), the second driving motor (202) and the third driving motor (302), wherein the image recognition is mainly realized by the following three steps: firstly, binarization processing is carried out on an intercepted picture, then filtering is carried out on the image after binarization so as to remove noise points, and finally, each process parameter of the core-spun finished product is obtained in an edge identification mode and is output to a control algorithm unit for control.
Due to the adoption of the technical scheme, compared with the prior art, the invention has the following advantages and positive effects:
1. the key point of the invention is to decouple the structure of each link in the manufacturing process, greatly improve the maintainability of the equipment, reduce the manufacturing and maintenance cost, add automatic control in each link and enable the equipment to operate accurately and stably. And image recognition is added at the tail end of the produced product, so that the product quality is ensured.
2. Each link of the mechanical structure of the spiral core-spun structure product processing device takes the functional unit as a module, and the spiral core-spun structure product processing device has the advantages of low mechanical coupling degree, high adjustability and maintainability, low manufacturing difficulty and strong universality.
3. The invention adds a single-board computer system, adopts the leading-edge technologies of automatic control, image recognition and the like, and greatly improves the consistency and the product quality of the produced products by combining a camera and an encoder and adopting a control algorithm of cascade PID.
4. The processing equipment for the spiral core-spun structural product has the advantages of simple operation flow, low technical requirement on operators and great labor cost saving; meanwhile, the equipment has wide raw material range and high flexibility, is suitable for application occasions such as core-spun textile products and cable cladding, and has wide application range.
5. The key technology of the processing device is that a single-board computer is used as a core, automatic control and image recognition means are combined, the advantages of high automation, intelligence and flexibility are given to the equipment, the operation is safe and stable, high-quality core-spun structure products with good consistency can be produced, the implementation is convenient, the cost is low, and the processing device is suitable for continuous production and popularization and application.
6. The processing device can realize the fast, high-quality and low-cost processing of the product with the spiral core-spun structure, and particularly realizes the real-time monitoring and control of the wrapping density and the product form by using a single board computer as a control system.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. It is obvious that the drawings in the following description are only some embodiments of the invention, and that for a person skilled in the art, other drawings can be derived from them without inventive effort. In the drawings:
FIG. 1 is a front view of a spiral core-spun product processing device based on single board control according to the present invention;
FIG. 2 is a core layer feeding mechanism of a spiral core-spun product processing device based on single board computer control according to the present invention;
FIG. 3 is a core-spun layer feeding and forming mechanism of a spiral core-spun product processing device based on single board control according to the present invention;
FIG. 4 is a cross-sectional view of the A-A side of a core-spun layer feeding and forming mechanism of a spiral core-spun product processing device based on single board control according to the present invention;
FIG. 5 is a winding mechanism of a spiral core-spun product processing device based on single board control according to the present invention;
FIG. 6 is an intelligent control mechanism of a spiral core-spun product processing device based on single board computer control according to the present invention;
FIG. 7 is a structural block diagram of an intelligent control mechanism of a spiral core-spun product processing device based on single board computer control according to the invention;
FIG. 8 is a schematic diagram of an automatic control of a spiral core-spun product processing device based on single board control according to the present invention;
FIG. 9 is a man-machine interface of a spiral core-spun product processing device based on single board computer control according to the present invention;
FIG. 10 is a flowchart of an automatic control process of a spiral core-spun product processing device based on single board computer control according to the present invention;
[ description of main symbols ]
1-a core layer feeding mechanism, 101-a first feeding roller, 102-a second feeding roller, 103-a core layer raw material, 104-a first driving motor, 105-a first transmission belt, 106-a first rotating speed encoder, 107-a first driven gear, 108-a first bracket, 109-a first rotating shaft and 110-a first driving gear;
2-core-spun layer feeding and forming mechanism, 201-core-spun layer raw material, 202-second driving motor, 203-reduction gear box, 204-second rotating speed encoder, 205-cable, 206-high speed camera, 207-guide pipe, 208-second reduction gear, 209-guide pipe fixing pin, 210-first reduction gear, 211-power gear;
3-winding mechanism, 301-winding roller, 302-third driving motor, 303-second transmission belt, 304-third rotating speed encoder, 305-linear motor, 306-product winding drum, 307-second bracket, 308-spring connecting rib, 309-second rotating shaft, 310-material guiding slide block, 311-second driving gear and 312-second driven gear;
4-intelligent control mechanism, 401-single board computer system, 402-touch screen, 403-emergency stop button, 404-running indicator lamp, 405-alarm indicator lamp and 406-switch.
Detailed Description
While the embodiments of the present invention will be described and illustrated in detail with reference to the accompanying drawings, it is to be understood that the invention is not limited to the specific embodiments disclosed, but is intended to cover various modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
Example one
As shown in fig. 1-6, the invention discloses a spiral core-spun product processing device based on single board computer control, comprising:
a core layer feeding mechanism 1 for conveying a core layer raw material 103, wherein the core layer feeding mechanism 1 comprises a first feeding roller 101, a second feeding roller 102, the core layer raw material 103, a first driving motor 104, a first driving belt 105, a first rotary encoder 106, a first driven gear 107, a first support 108, a first rotating shaft 109 and a first driving gear 110, and wherein: the core layer raw material 103 is arranged above the first feeding roller 101 and the second feeding roller 102, the first feeding roller 101 rotates under the transmission of the first driving motor 104 and the first transmission belt 105, the first feeding roller 101 and the second feeding roller 102 are fixed on the first support 108 through the first rotating shaft 109, the rotating speed of the first feeding roller 101 is determined by the gear ratio of the first driving gear 110 and the first driven gear 107, and the real-time rotating speed can be measured through the first rotating speed encoder 106 and transmitted to the intelligent control mechanism 4 for closed-loop control in the operation process; in this embodiment, the core layer feeding mechanism 1 supports the core layer raw material 103 through two rollers, and simultaneously, under the rotation of the first driving motor 104, the core layer raw material 103 is rotationally conveyed to the first feeding roller 101 and the second feeding roller 102 through the first driving belt 105, and the core layer raw material 103 is driven to rotationally spit under the action of the friction force between the core layer raw material 103 and the two rollers, and since the two rollers are driven in a friction contact manner, the speed of spitting at a constant rotation speed is not affected as the package radius of the core layer raw material 103 becomes smaller, and in order to strictly ensure the accuracy and stability of the process parameters as much as possible, the real-time feeding speed is measured by the first rotation speed encoder 106 and conveyed to the microcomputer for closed-loop control.
A cladding layer pay-off and forming mechanism 2 that is used for cladding layer raw materials 201 to carry and spiral core-spun structure machine-shaping, cladding layer pay-off and forming mechanism 2 includes cladding layer raw materials 201, second driving motor 202, reduction gear 203, second speed encoder 204, cable 205, high-speed camera 206, baffle pipe 207, second grade reduction gear 208, baffle pipe fixed pin 209, one-level reduction gear 210 and power gear 211, wherein: the core layer raw material 103 bent with radian is linearly shaped by the guide pipe 207 arranged on the guide pipe fixing pin 209, the power of the second driving motor 202 is transmitted to the core layer raw material 201 through the reduction gear box 203 to enable the core layer raw material to rotate according to a preset rotating speed and complete the wrapping of the core layer, the real-time wrapping speed is collected and transmitted to the intelligent control mechanism 4 through the second rotating speed encoder 204 to carry out closed-loop control, and the reduction gear box 203 is composed of a primary reduction gear 210, a secondary reduction gear 208 and a power gear 211; in this embodiment, the key for completing the core-spun of the core-spun layer feeding and forming mechanism 2 is as follows: the second driving motor 202 rotates at a high speed to drive the core-spun raw material 201 to perform package rotation, and the core-spun raw material 201 is rotationally wound on the core layer under the action of inertia. The high-speed camera 206 is disposed at the outlet of the material guiding tube 207, and transmits the video signal collected in real time to the intelligent control mechanism 4 through the cable 205.
And a winding mechanism 3 for receiving the spiral core-spun structural product and finishing final collection and winding of the finished product. The winding mechanism 3 comprises a winding drum 301, a third driving motor 302, a second driving belt 303, a third speed encoder 304, a linear motor 305, a product winding drum 306, a second bracket 307, a spring connecting rib 308, a second rotating shaft 309, a material guiding slide block 310, a second driving gear 311 and a second driven gear 312, wherein: under the rotation of the third driving motor 302, the power is transmitted to the winding drum 301 through the second driving gear 311 and the second driven gear 312 connected to the second transmission belt 303; the product winding drum 306 clamped by the spring connecting rib 308 clings to the winding drum 301 under the dual action of elasticity and gravity and rotates along with the winding drum to complete winding of a finished product, the product winding drum 306 is fixed on a second bracket 307 through the second rotating shaft 309, and the linear motor 305 drives the material guide sliding block 310 to reciprocate under the action of a control signal so that the finished product is uniformly wound on the product winding drum 306 to meet uniform winding. The winding rotation speed in the operation process can be acquired by the third rotation speed encoder 304 and transmitted to the intelligent control mechanism 4 for closed-loop control; the high speed camera 206 transmits the real time product morphology in the form of a video stream to the intelligent control mechanism 4 for image recognition and for parameter adjustment control. In this embodiment, the spring connecting rib 308 rotates around the second rotating shaft 309, and as the diameter of the collected finished product is gradually increased, the winding device will float up around the rotating shaft under the connection of the spring connecting rib 308 to prevent the product from being damaged by extrusion.
And an intelligent control mechanism 4 which takes a single board computer as a core and is used for carrying out real-time monitoring and automatic linkage control on the whole processing device, wherein the intelligent control mechanism 4 comprises a single board computer system 401, a touch screen 402, an emergency stop button 403, an operation indicator lamp 404, an alarm indicator lamp 405 and a switch 406, wherein: the single board computer system 401 is configured to receive the video signal in the high-speed camera 206, intercept the video signal into a picture according to a video frame rate, perform image recognition on the finished product, further calculate real-time product process parameters (wrapping distance, wrapping angle, and the like), and compare the real-time process parameters with preset parameters by using a control algorithm programmed in the single board computer system 401 to obtain a real-time adjustment instruction to adjust the real-time rotation speeds of the first driving motor 104, the second driving motor 202, and the third driving motor 302, so that the product process meets the demand and improves the product quality; the touch screen 402 is used for an operator to complete setting of processing technological parameters and observe a real-time production state; the emergency stop button 403 is used for forcibly stopping the vehicle in case of an emergency accident or failure; the operation indicator lamp 404 and the alarm indicator lamp 405 are respectively used for indicating the operation state and the alarm state of the system; the switch 406 is used for switching on or off the power supply of the first drive motor 104, the second drive motor 202 and the third drive motor 302; specifically, the first, second and third speed encoders 106, 204 and 304 respectively feed back the rotation speeds of the first, second and third driving motors 104, 202 and 302 in real time so that the motors can still rotate at a preset rotation speed under the condition of interference, and the high-speed camera 206 feeds back the real-time form of the finished product to the single board computer system 401 to monitor the real-time process parameters and unexpected conditions such as material breakage and material failure, so that the system can timely make corresponding actions. In this embodiment, the parameter setting (including the process parameter setting, the system setting, and the like) of the intelligent control mechanism 4 is implemented by a human-computer interface of the touch screen 402. The human-computer interaction interface comprises a finished product preview, product process parameter setting, product real-time form, system setting, equipment correction and the like. In addition, the processing parameters can also be processed in a single parameter or variable parameter mode through programming.
As shown in fig. 7, the intelligent control mechanism 4 is a microcomputer system with a single board computer as a core, and is used for managing and controlling the operation of the whole system; the human-computer interface is an important way for an operator to interact with the equipment, and as shown in fig. 9, the basic production conditions such as real-time running time and the like can be seen on a touch screen, and in addition, the production process can be set, and the equipment can be set, such as parameter adjustment equipment correction and the like. Meanwhile, the image information acquired by the high-speed camera 206 in real time and the image information processed by the image recognition program can be observed in real time; all motors of the equipment are uniformly isolated by a motor driver to carry out strong current and weak current, and encoders are installed at rotating places of all the motors to acquire real-time rotating speeds of the motors; the control signal of the motor, the signal of the high-speed camera 206 and the acquisition value of the encoder are subjected to information interaction with the system through a hardware driving program, the hardware driving program provides a basic encoding sensor data reading interface and a motor output interface for an automatic control program, the high-speed camera 206 data reading interface is provided for an image recognition program, and the image recognition program provides real-time process parameter values for the automatic control program. The single board computer system 401 in the intelligent control mechanism 4 is loaded with a Linux operating system, and the docking with the hardware driver is completed by using the related interface provided by the Linux system. Because the raw materials are conveyed and operated at a high speed during the starting operation, the camera head needs to adopt an industrial-grade high-speed camera 206 in order to capture the state under the high-speed operation.
The core layer feeding mechanism 1, the core-spun layer feeding and forming mechanism 2 and the winding mechanism 3 are sequentially arranged from bottom to top, and the intelligent control mechanism 4 is installed on a support far away from one side of the power mechanism of the core layer feeding mechanism 1, the core-spun layer feeding and forming mechanism 2 and the winding mechanism 3.
Example two
As shown in fig. 10, the present invention further discloses a processing method of a spiral core-spun product based on single board computer control, which performs processing by using the processing apparatus of a spiral core-spun product based on single board computer control, and comprises the following steps:
step 1: installing the core-spun layer raw material 201 on the corresponding position on the reduction gear box 203 of the core-spun layer feeding and forming mechanism 2;
step 2: after confirming that no foreign matter exists on the feeding roller 101 of the core layer feeding mechanism 1, the core layer raw material 103 is placed above, and the stub bar of the core layer raw material 103 is pulled to pass through the material guide pipe 207 of the core layer feeding and forming mechanism 2 and is wound on the product winding barrel 306 of the winding mechanism 3, so that subsequent finished products can be smoothly received;
and step 3: setting production process parameters on a touch screen 402 of the intelligent control mechanism 4, and turning on a switch 406 to start production after the process is confirmed to be correct;
and 4, step 4: after the core layer feeding mechanism 1 and the winding mechanism 3 are started to produce, under the control of the intelligent control mechanism 4, the first driving motor 104 and the third driving motor 302 corresponding to each other start to operate and adjust the tension of the core layer raw material 103, and when the tension of the core layer raw material 103 stably reaches a preset value, the second driving motor 202 of the core layer feeding and forming mechanism 2 starts to produce according to preset parameters;
and 5: in the manufacturing process, the real-time shape of the finished product acquired by the high-speed camera 206 and the acquisition value of each mechanism encoder are transmitted to the intelligent control mechanism 4 for automatic regulation and control, so that the quality of the product and the safety of personnel and equipment are guaranteed when external interference or internal failure occurs;
step 6: if a mechanical failure or other human accident occurs during the machining process, the machine can be stopped urgently by pressing the emergency stop button 403.
Further, in step 2, the feeding manner of the core layer feeding mechanism 1 is driven by friction force generated by direct contact between the core layer raw material 103 itself and the first feeding roller 101 and the second feeding roller 102, and the three are in direct contact, and the rotating linear speed is the same, so that the feeding speed influence caused by the fact that the package radius of the core layer raw material 103 is reduced along with continuous feeding is avoided, and the precision is improved in a mechanical manner.
Further, in step 4, the control algorithm of the intelligent control mechanism 4 is implemented by using a cascade PID controller, the process parameter is used as an input value of the outer ring, the real-time process parameter obtained by the image recognition algorithm is used as a feedback value of the outer ring, an output value of the outer ring PID controller is used as an input value of the inner ring PID controller, the real-time rotating speed of the motor returned by the encoder is used as a feedback value, and finally the processing of the predetermined process parameter is completed by controlling the rotating speed of the motor in real time. Specifically, as shown in fig. 8, a cascade PID control method is adopted to improve the stability and accuracy of product processing. After an operator sets a processed process parameter through the touch screen 402 and starts up, the process parameter is preset as an input value of an outer ring PID controller, the high-speed camera 206 acquires a product form in real time, a video is transmitted to the single board computer system 401, a built-in automatic control program extracts a video image into a picture according to a video frame rate, the actual process parameter of the product is analyzed and acquired as a feedback value through an edge identification method, an output value passing through the PID controller is used as an input value of the inner ring PID controller, an acquisition value of each mechanism encoder is used as a feedback value of the inner ring PID controller and outputs a real-time rotating speed value of a motor, and stable and accurate control of the product process parameter is finally achieved. The specific parameters of the above PID controller need to be adjusted and corrected according to the specific equipment. In addition, the parameters of the PID controller can be modified and debugged within a small range by a debugging person through a human-computer interaction interface to enable the equipment to reach the optimal state.
Further, in step 5, the real-time form of the finished product collected by the high-speed camera 206 is captured as a picture according to the video frame rate, and then the image recognition of the finished product is performed, so as to calculate real-time product process parameters, and the real-time process parameters are compared with preset parameters by a control algorithm programmed and set in the single board computer system 401, so as to obtain a real-time adjustment instruction to adjust the real-time rotation speeds of the first driving motor 104, the second driving motor 202, and the third driving motor 302, wherein the image recognition is mainly realized by the following three steps: firstly, binarization processing is carried out on an intercepted picture, then filtering is carried out on the image after binarization so as to remove noise points, and finally, each process parameter of the core-spun finished product is obtained in an edge identification mode and is output to a control algorithm unit for control.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (11)
1. A spiral core-spun product processingequipment based on single board computer control which characterized in that includes:
a core layer feeding mechanism (1) for conveying the core layer raw material;
a core-spun layer feeding and forming mechanism (2) for conveying the core-spun layer raw material and processing and forming the spiral core-spun structure;
a winding mechanism (3) for receiving the spiral core-spun structural product;
and an intelligent control mechanism (4) which takes a single-board computer as a core and is used for carrying out real-time monitoring and automatic linkage control on the whole processing device;
sandwich layer feeding mechanism (1), core-spun layer pay-off and forming mechanism (2) and winding mechanism (3) set gradually from bottom to top, intelligent control mechanism (4) install in keeping away from power unit one side of sandwich layer feeding mechanism (1), core-spun layer pay-off and forming mechanism (2) and winding mechanism (3).
2. The single board machine control-based spiral core-spun product processing device according to claim 1, wherein the core layer feeding mechanism (1) comprises a first feeding roller (101), a second feeding roller (102), a core layer raw material (103), a first driving motor (104), a first driving belt (105), a first rotary speed encoder (106), a first driven gear (107), a first bracket (108), a first rotary shaft (109) and a first driving gear (110), wherein:
the core layer raw material (103) is arranged above the first feeding roller (101) and the second feeding roller (102), the first feeding roller (101) rotates under the transmission of the first driving motor (104) and the first transmission belt (105), the first feeding roller (101) and the second feeding roller (102) are fixed on a first support (108) through a first rotating shaft (109), the rotating speed of the first feeding roller (101) is determined by the gear ratio of the first driving gear (110) and the first driven gear (107), and the real-time rotating speed can be measured through the first rotating speed encoder (106) and transmitted to the intelligent control mechanism (4) for closed-loop control in the operation process.
3. The spiral core-spun product processing device based on the single board computer control as claimed in claim 2, wherein the core-spun layer feeding and forming mechanism (2) comprises a core-spun layer raw material (201), a second driving motor (202), a reduction gear box (203), a second rotary speed encoder (204), a material guide pipe (207), a second reduction gear (208), a material guide pipe fixing pin (209), a first reduction gear (210) and a power gear (211), wherein:
install in baffle pipe (207) on baffle pipe fixed pin (209) will bend and have the radian core layer raw materials (103) carry out sharp moulding, the power of second driving motor (202) passes through reduction gear box (203) is passed to core-spun layer raw materials (201) make it rotatory and accomplish the package to the core layer according to predetermined rotational speed, real-time package speed passes through second rotational speed encoder (204) are gathered and are conveyed intelligence control mechanism (4) carry out closed-loop control, reduction gear box (203) comprise one-level reduction gear (210), second grade reduction gear (208), power gear (211).
4. The spiral core-spun product processing device based on the single board computer control as claimed in claim 3, wherein the core-spun layer feeding and forming mechanism (2) further comprises a cable (205) and a high-speed camera (206), the high-speed camera (206) is arranged at the outlet of the material guide pipe (207), and transmits a video signal collected in real time to the intelligent control mechanism (4) through the cable (205).
5. The single board machine control-based spiral core-spun product processing device according to claim 4, wherein the winding mechanism (3) comprises a winding drum (301), a third driving motor (302), a second driving belt (303), a third speed encoder (304), a linear motor (305), a product winding drum (306), a second bracket (307), a spring connecting rib (308), a second rotating shaft (309), a material guiding slider (310), a second driving gear (311) and a second driven gear (312), wherein:
under the rotation of the third driving motor (302), the power is transmitted to the winding drum (301) through the second driving gear (311) and the second driven gear (312) connected with the second transmission belt (303); the product winding drum (306) clamped by the spring connecting ribs (308) is tightly attached to the winding drum (301) under the dual effects of elasticity and gravity and rotates along with the winding drum to complete winding of a finished product, the product winding drum (306) is fixed on a second support (307) through a second rotating shaft (309), the linear motor (305) drives the material guide sliding block (310) to reciprocate under the effect of a control signal to enable the finished product to be uniformly wound on the product winding drum (306), and the winding rotation speed can be acquired through the third rotation speed encoder (304) and transmitted to the intelligent control mechanism (4) to be controlled in a closed loop mode in the operation process.
6. A spiral core-spun product processing device based on single board computer control as claimed in claim 5, characterized in that the spring connecting rib (308) rotates around the second rotating shaft (309).
7. The spiral core-spun product processing device based on single board computer control of claim 5, wherein the intelligent control mechanism (4) comprises a single board computer system (401), a touch screen (402), an emergency stop button (403), an operation indicator lamp (404), an alarm indicator lamp (405) and a switch (406), wherein:
the single board computer system (401) is used for receiving the video signal in the high-speed camera (206), intercepting the video signal into a picture according to a video frame rate, then carrying out image recognition on a finished product, further calculating real-time product process parameters, and comparing the real-time process parameters with preset parameters by a control algorithm programmed and set in the single board computer system to obtain a real-time adjusting instruction so as to adjust the real-time rotating speeds of the first driving motor (104), the second driving motor (202) and the third driving motor (302);
the touch screen (402) is used for an operator to complete the setting of processing technological parameters and observe the real-time production state;
the emergency stop button (403) is used for forcibly stopping the vehicle when an emergency accident or fault occurs;
the operation indicator lamp (404) and the alarm indicator lamp (405) are respectively used for indicating the operation state and the alarm state of the system;
the switch (406) is used for switching on or off the power supply of the first driving motor (104), the second driving motor (202) and the third driving motor (302).
8. A method for processing spiral core-spun products based on single board machine control, which is characterized in that the processing device based on single board machine control of any one of the claims 1-7 is used for processing, and comprises the following steps:
step 1: installing the core-spun layer raw material (201) at a corresponding position on a reduction gear box (203) of the core-spun layer feeding and forming mechanism (2);
step 2: after confirming that no foreign matter exists on a feeding roller (101) of the core layer feeding mechanism (1), placing the core layer raw material (103) above, and drawing a stub bar of the core layer raw material (103) to penetrate through a material guide pipe (207) of the core layer feeding and forming mechanism (2) and winding the stub bar on a product winding barrel (306) of the winding mechanism (3), so that subsequent finished products can be smoothly received;
and step 3: setting production process parameters on a touch screen (402) of an intelligent control mechanism (4), and turning on a switch (406) to start production after the process is confirmed to be correct;
and 4, step 4: after the core-spun layer is started to be produced, under the control of the intelligent control mechanism (4), the core layer feeding mechanism (1) and a first driving motor (104) and a third driving motor (302) corresponding to the winding mechanism (3) start to operate to adjust the tension of the core layer raw material (103), and when the tension of the core layer raw material (103) stably reaches a preset value, a second driving motor (202) of the core-spun layer feeding and forming mechanism (2) starts to be produced according to the operation of preset parameters;
and 5: in the manufacturing process, the real-time shape of the finished product acquired by the high-speed camera (206) and the acquisition value of each mechanism encoder are transmitted to the intelligent control mechanism (4) for automatic regulation and control, so that the quality of the product and the safety of personnel and equipment are guaranteed when external interference or internal failure occurs;
step 6: if a mechanical failure or other human accident occurs during the machining process, the machine can be stopped emergently by pressing the emergency stop button (403).
9. The method for processing spiral core-spun products based on single-board machine control according to claim 8, characterized in that in step 2, the feeding manner of the core layer feeding mechanism (1) is driven to complete feeding by means of friction force generated by direct contact of the core layer raw material (103) with the first feeding roller (101) and the second feeding roller (102), the three are in direct contact, and the rotating linear speed is the same.
10. The single board computer control-based spiral core-spun product processing method according to claim 8, wherein in step 4, the control algorithm of the intelligent control mechanism (4) is implemented by using a cascade PID controller, the process parameter is used as the input value of the outer ring, the real-time process parameter obtained by the image recognition algorithm is used as the feedback value of the outer ring, the output value of the outer ring PID controller is used as the input value of the inner ring PID controller, the real-time rotating speed of the motor returned by the encoder is used as the feedback value, and finally the processing of the preset process parameter is completed by controlling the rotating speed of the motor in real time.
11. The method for processing the spiral core-spun product based on the single board computer control of claim 8, wherein in step 5, the real-time form of the finished product collected by the high-speed camera (206) is captured as a picture according to a video frame rate, and then the image recognition of the finished product is performed, so as to calculate real-time product process parameters, and a control algorithm programmed in the single board computer system compares the real-time process parameters with preset parameters to obtain real-time adjustment instructions to adjust the real-time rotation speeds of the first driving motor (104), the second driving motor (202) and the third driving motor (302), wherein the image recognition is mainly realized by the following three steps: firstly, binarization processing is carried out on an intercepted picture, then filtering is carried out on the image after binarization so as to remove noise points, and finally, each process parameter of the core-spun finished product is obtained in an edge identification mode and is output to a control algorithm unit for control.
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| CN112776316A (en) * | 2021-04-09 | 2021-05-11 | 山东国维复合材料科技有限公司 | Method for manufacturing spring plate of heavy truck by using thermoplastic composite material |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112776316A (en) * | 2021-04-09 | 2021-05-11 | 山东国维复合材料科技有限公司 | Method for manufacturing spring plate of heavy truck by using thermoplastic composite material |
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