CN111930068A - Control system of vertical radial extrusion pipe making equipment - Google Patents
Control system of vertical radial extrusion pipe making equipment Download PDFInfo
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- CN111930068A CN111930068A CN202010843486.0A CN202010843486A CN111930068A CN 111930068 A CN111930068 A CN 111930068A CN 202010843486 A CN202010843486 A CN 202010843486A CN 111930068 A CN111930068 A CN 111930068A
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Abstract
The invention relates to a control system of vertical radial extrusion pipe-making equipment, which is characterized by comprising a positioning sensing module, a control module, an execution module, an intelligent human-computer interaction module and a network database; the positioning sensing module is connected with the input end of the control module to realize the input of signals; the control module is connected with the execution module to realize the output of control signals; the control module is in communication connection with the intelligent human-computer interaction module; the intelligent man-machine interaction module is connected with a network database through a serial server to realize data interaction of the system; the network database stores the current operation data, long-term operation data, historical fault data, conventional fault data and corresponding fault diagnosis results of the management equipment, so that the system can complete intelligent fault diagnosis of the management equipment. The system can effectively avoid that the rotation of the power head is blocked due to the excessively high material injection speed, so that the shaft control motor is overloaded, the system is abnormally stopped and damaged, and the continuous and safe production of the equipment is facilitated.
Description
Technical Field
The invention belongs to the technical field of industrial automatic control, and particularly relates to a control system of vertical radial extrusion pipe manufacturing equipment.
Background
The reinforced concrete drain pipe has the advantages of low manufacturing cost, relatively simple production process, high manufacturing speed, high hardness, high pressure bearing capacity, good sealing performance, vibration resistance, difficulty in blockage and the like, and is widely applied to the fields of urban drainage, agricultural irrigation, chemical industry, fuel gas conveying and the like. At present, a vertical radial extrusion forming process is mostly adopted for small-caliber reinforced concrete drain pipes with the diameter of less than 1200mm, but the process execution equipment is still in a semi-automatic state, the implementation of the process depends on manual intervention, and the process is extremely unfavorable for improving the production efficiency and the product quality.
In a vertical radial extrusion pipe making machine, in order to ensure that a shaft control motor drives a power head to stably operate, a closed-loop feedback control algorithm is generally adopted to regulate and control the material injection speed of a system. Due to the fact that parameters such as water content and average particle size of materials are different, a nonlinear relation exists between resistance torque generated by the materials and material injection speed, and the control model of the system is enabled to have large fluctuation. The classical PID control algorithm has fixed regulation and control parameters, and when the system model fluctuates greatly, the parameters of the PID control algorithm regulated according to experience are difficult to converge, so that the power head is still blocked in use.
The invention provides an automatic production system of a vertical radial extrusion pipe making machine and a use method thereof in a Chinese invention patent with the patent number of 201810355274.0, wherein the invention adopts a PLC as an automatic control core and comprises a sensor system, an execution system and an early warning system; the system can not display and collect the operation data of the pipe making machine, the early warning system is a safety early warning indicator lamp, only two display states of system operation fault and normal exist, fault diagnosis can not be carried out according to the operation data, and the intelligent degree is low; the lifting movement of the transmission device and the socket device of the system adopts a lifting slide block group in a lead screw slide block form, and the lifting slide block group has the defects of small transmission torque, large friction force, insufficient running stability and the like.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a control system of vertical radial extrusion pipe-making equipment; the control system realizes the automatic control of the vertical radial extrusion pipe making equipment, and improves the running stability, safety and reliability of the vertical radial extrusion pipe making equipment.
In order to solve the technical problems, the invention adopts the technical scheme that:
a control system of vertical radial extrusion pipe-making equipment is characterized by comprising a positioning sensing module, a control module, an execution module, an intelligent human-computer interaction module and a network database; the positioning sensing module is connected with the input end of the control module to realize the input of signals; the control module is connected with the execution module to realize the output of control signals; the control module is in communication connection with the intelligent human-computer interaction module; the intelligent man-machine interaction module is connected with a network database through a serial server to realize data interaction of the system; the network database stores the current operation data, the long-term operation data, the historical fault data and the conventional fault data of the management equipment and corresponding fault diagnosis results, so that the system can complete intelligent fault diagnosis of the management equipment;
the positioning sensing module comprises a limit switch, a current transformer and an oil temperature and oil pressure detector; the limit switches are used for positioning and detecting corresponding parts of the pipe manufacturing equipment; the current transformer is used for controlling the current detection of the module, so that the safety guarantee detection of the system is realized; the oil temperature and oil pressure detector is used for detecting the oil temperature and oil pressure of the pipe manufacturing equipment, so that the safe and stable operation of the system is guaranteed;
the intelligent human-computer interaction module comprises a key, an indicator light and a touch screen; the keys comprise a start key, an emergency stop key and a fault reset key, and all the keys are connected with the input end of the control module; the indicating lamps comprise a power-on indicating lamp and a fault indicating lamp, and the two indicating lamps are connected with the output end of the control module; the touch screen is in communication connection with the control module to complete data interaction between the touch screen and the control module.
The execution module comprises a die conveying frequency converter, a hydraulic bolt electromagnetic valve, a vibration motor frequency converter, a bottom steering frequency converter, a first socket manufacturing electromagnetic valve, a second socket manufacturing electromagnetic valve, a cylinder electromagnetic valve, a first shaft control motor frequency converter, a second shaft control motor frequency converter, a gas pump frequency converter, a hydraulic pump frequency converter, a transmission hydraulic cylinder electromagnetic valve, a stirring relay, a conveyor belt motor frequency converter, a material sweeping electromagnetic valve, a material sweeping tray electromagnetic valve and a socket tray electromagnetic valve, and the control module controls the pipe manufacturing equipment to complete related work through all parts of the execution module.
The fuzzy PID controller is adopted to realize the closed-loop control of the system, namely, the frequency converter of the conveyor belt motor is regulated and controlled by the fuzzy PID controller, the rotating speed of the conveyor belt motor of the pipe manufacturing equipment is regulated, and further the material injection speed of the conveyor belt of the pipe manufacturing equipment is regulated, so that the shaft control motor of the power head of the pipe manufacturing equipment is controlled to run at constant torque, and the phenomenon that the rotation of the power head of the pipe manufacturing equipment is blocked due to the overhigh material injection speed is prevented.
The fuzzy PID controller is implemented in the following steps:
1) establishing a control model: assuming that the working voltage and the running speed of a shaft control motor of the pipe manufacturing equipment are constant; near the rated working point of the system, the influence of different material humidity and material thickness on the resistance torque of the shaft control motor is constant, and the material injection speed of the conveyor belt of the pipe making equipment and the resistance torque T of the shaft control motor meet the formula (1):
T＝k·v+b (1)
in the formula, k and b are constants related to the humidity and the thickness of the material; v represents the injection speed of the conveyor belt;
based on the above assumptions, a control model of the system is established according to equation (2):
in the formula, n is the rated rotating speed of a shaft control motor of the pipe making equipment; u is the rated working voltage of a shaft control motor of the pipe making equipment; s is a complex variable of the laplace transform;
2) determining the input quantity and the output quantity of the controller: shaft control electricity of pipe manufacturing equipment acquired through positioning sensing moduleWorking current of the motor, and calculating the error e between the rated current of the shaft control motor and the working current at the current sampling moment; then, the error e of the current sampling moment is subtracted from the error of the last sampling moment to obtain the error ecTwo errors e, ecThe input quantity is the input quantity of the fuzzy PID controller;
proportional coefficient correction value delta K of fuzzy PID controllerpIntegral coefficient correction value DeltaKiAnd differential coefficient correction value DeltaKdAs the output of the fuzzy PID controller;
3) determining a fuzzy membership function: all input quantities e and ecOutput quantity DeltaKp、△KiAnd Δ KdCorresponding elements NB and PB in the fuzzy set respectively adopt Z-type membership functions and inverse Z-type membership functions, and the rest elements adopt triangular membership functions;
4) constructing a fuzzy relation: establishing fuzzy inference rules according to practical experience and basic requirements for controlling the pipe-making equipment to complete related work, and respectively calculating input quantities e and e by adopting an inference method of taking maximum and minimum valuescAnd output quantity DeltaKpInput quantities e and ecAnd output quantity DeltaKiInput quantities e and ecAnd output quantity DeltaKdFuzzy relation R ofp、RiAnd Rd；
5) Establishing a fuzzy inference machine: respectively establishing a proportional coefficient correction value delta K of the fuzzy PID controller according to the input quantity and the output quantity obtained in the step 2), the fuzzy membership function in the step 3) and the fuzzy relation in the step 4)pIntegral coefficient correction value DeltaKiAnd differential coefficient correction value DeltaKdFor the proportional coefficient K of the fuzzy PID controllerpIntegral coefficient KiAnd a differential coefficient KdAnd correcting to enable the fuzzy PID controller to control the shaft control motor frequency converter, further adjusting the material injection speed of the system and enabling the shaft control motor to operate at constant torque.
The fuzzy inference rule is as follows:
setting the threshold value of the error e to be m1 and m2, wherein the absolute value of m1 is larger than that of m 2; when the absolute value of e is larger than m1, indicating that the absolute value of e is large, and the output quantity of the controller is output according to the maximum or minimum, so that the absolute value of e is reduced at the maximum speed;
when e and ecIf the product of e is greater than or equal to m2, the absolute value of e is larger, and then a stronger control action is considered to be implemented, namely, the proportional coefficient of the controller is increased, the integral coefficient of the controller is reduced, the differential coefficient of the controller is kept unchanged, the absolute value of e is changed towards the direction of reduction, and the absolute value of e is rapidly reduced; if the absolute value of e is less than m2, it is stated that although the absolute value of e changes in the increasing direction, the absolute value of e itself is not very large, and then the control action of general strength is considered, that is, the proportional coefficient, the integral coefficient and the differential coefficient of the controller are not changed, so that the absolute value of e changes in the decreasing direction;
when e and ecProduct less than 0, ecAnd the last time ecWhen the product of the values of (a) is greater than 0 or e is equal to 0, the absolute value of e changes towards the direction of reduction, or the equilibrium state is reached, and the proportional coefficient and the differential coefficient of the controller are kept unchanged at the moment, so that the output quantity of the controller is unchanged;
when e and ecProduct less than 0 or ec and last ecWhen the product of the values of (a) is less than 0, indicating that e is in an extreme value state; if the absolute value of e is larger than m2, the absolute value of e is larger, and then the stronger control action is considered to be implemented, namely the proportional coefficient of the controller is increased, the integral coefficient of the controller is reduced, the differential coefficient of the controller is kept unchanged, and the absolute value of e is changed towards the reduction direction; if the absolute value of e is smaller than m2, the absolute value of e is smaller, and the weaker control action is considered to be implemented, namely the proportional coefficient of the controller is reduced, the integral coefficient of the controller is increased, the differential coefficient of the controller is kept unchanged, and the absolute value of e is changed towards the increasing direction;
when the absolute value of e is far smaller than m2, the absolute value of e is small, and the integral coefficient of the controller is increased, and the proportional coefficient and the differential coefficient of the controller are kept unchanged, so that the steady-state error of the whole system is reduced.
Compared with the prior art, the invention has the following beneficial effects:
1. the control system is provided with a network database, and the running data of the management equipment is stored in the network database, so that the information of operators, product information, equipment running parameters and conditions, production reports and the like can be conveniently inquired; the network database stores the current operation data, long-term operation data, historical fault data, conventional fault data and corresponding fault diagnosis results of the conventional fault data of the management equipment, the operation state of the management equipment can be obtained according to the data, the current fault data can be matched with the prestored fault data, the fault diagnosis result is obtained, and the intelligent fault diagnosis of the management equipment is completed.
2. The invention adopts the fuzzy PID algorithm to realize closed-loop control on the first shaft control motor and the second shaft control motor, constructs the fuzzy PID controller with certain self-adaptive capacity, can self-adaptively adjust the proportionality coefficient, the integral coefficient and the differential coefficient of the fuzzy PID controller according to different parameters of material water content, average particle size and the like, further adjusts the material injection speed of the system, ensures that the two shaft control motors run at constant torque, can effectively avoid the phenomenon that the power head rotates and is blocked because of the over-high material injection speed, causes the overload of the shaft control motors, causes abnormal shutdown and damage of the system, and is beneficial to the continuous and safe production of equipment.
3. The invention adopts the hydraulic cylinder to realize the control of the descending motion of the power head, so that the power head extends into the lower part of the die, and the descending process of the power head is subjected to variable speed control, thereby effectively avoiding abrasion and impact, prolonging the service life of the pipe-making equipment and simultaneously enabling the pipe-making equipment to run more stably.
Drawings
FIG. 1 is a schematic view of the overall connection structure of the present invention;
FIG. 2 is a diagram of the connection of an execution module of the present invention to a pipe making apparatus;
FIG. 3 is a schematic view showing the overall construction of a pipe-making apparatus controlled by the present invention;
in the figure: 1. a mold transfer device; 2. a socket making device; 3. a socket making device; 4. a body shaping device; 5. a material injection device; 6. a frame; 7. a work table; 8. a mold; 9. an execution module;
101. a hydraulic plug; 102. a transfer tray motor; 103. a transfer tray;
201. a bottom steering motor; 202. a first bottom vibration motor; 203. a second bottom vibration motor; 204. vibrating the cross beam; 205. a cross beam vibrating hydraulic cylinder; 206. a socket tray;
301. a first rotary hydraulic motor; 302. a second rotary hydraulic motor; 303. a grinding disc;
401. a transmission hydraulic cylinder; 402. the upper part is fixed with an air cylinder; 403. the lower part is fixed with an air cylinder; 404. a hydraulic pump; 405. a first shaft control motor; 406. a gas pump; 407. a second shaft control motor; 408. a power head; 409. a connecting shaft; 410. a power box;
501. sweeping the material tray; 502. a stirrer; 503. a sweeping hydraulic motor; 504. a conveyor belt motor; 505. a conveyor belt; 506. a hopper; 507. a hydraulic cylinder of the sweeping tray;
901. a mold conveying frequency converter; 902. a hydraulic hydrant solenoid valve; 903. a vibration motor frequency converter; 904. a steering motor frequency converter; 905. manufacturing an electromagnetic valve by a first socket; 906. manufacturing an electromagnetic valve by using a second socket; 907. an air cylinder electromagnetic valve; 908. a first shaft control motor frequency converter; 909. a second shaft control motor frequency converter; 910. a gas pump frequency converter; 911. a hydraulic pump frequency converter; 912. a hydraulic cylinder solenoid valve is driven; 913. a stirring relay; 914. a conveyor belt motor frequency converter; 915. a scavenging solenoid valve; 916. a sweeping disk electromagnetic valve; 917. bellmouth tray solenoid valve.
Detailed Description
Specific examples of the present invention are given below. The specific examples are only intended to illustrate the invention in detail and do not limit the scope of protection of the application.
The invention provides a control system (for short, see fig. 1-3) of vertical radial extrusion pipe-making equipment, which takes a PLC (programmable logic controller) as a control core and comprises a positioning sensing module, a control module, an execution module 9, an intelligent human-computer interaction module and a network database; the positioning sensing module is connected with the input end of the control module to realize the input of signals; the control module is connected with the execution module 9 to realize the output of control signals; the control module is in communication connection with the intelligent human-computer interaction module through an RS232 interface; the intelligent man-machine interaction module is connected with a network database through a serial server to realize data interaction of the system;
the positioning sensing module is mainly used for positioning the pipe manufacturing equipment and detecting the safety guarantee of the system in the pipe manufacturing process, realizing data acquisition and transmitting the acquired data to the control module; the control module analyzes and processes the data acquired by the positioning sensing module to generate a control signal so as to complete the task coordination of the system power supply configuration and the execution module 9; the execution module 9 performs corresponding work according to the control signal to complete the driving and speed regulation of each motor of the pipe making equipment, so that the pipe making equipment completes the die conveying, the socket making, the main body shaping and the material injection work; the intelligent man-machine interaction module mainly completes the input of system setting parameters and the display of system state parameters, and the network database mainly collects the operation data and fault data of the system and the corresponding fault diagnosis result thereof, thereby providing a data basis for intelligent fault diagnosis.
The system controlled pipe making equipment comprises a mould conveying device 1, a bell mouth making device 2, a spigot making device 3, a main body shaping device 4, an injection device 5, a rack 6, a workbench 7 and a mould 8; the frame 6 is fixed on the ground and is used for supporting each part of the pipe making equipment; the mould conveying device 1 is arranged at the lower part of the frame 6, the mould 8 is placed on the mould conveying device 1, and the mould conveying device 1 transfers the mould 8 to a working area; the socket making device 2 is positioned below the mould conveying device 1 and is used for making a socket of the cement pipe (the bottom of the cement pipe); the workbench 7 is arranged in the middle of the rack 6, is positioned above the socket manufacturing device 3 and is used for installing the material injection device 5 and the intelligent man-machine interaction module; the socket manufacturing device 3 is arranged on the material injection device 5 and is used for manufacturing a socket of the cement pipe; a part of the main body shaping device 4 is positioned at the upper part of the frame 6 and can move along the height direction of the frame 6, so that the main body shaping work of the cement pipe is mainly completed; the other part of the main body shaping device 4 is arranged at the lower part of the frame 6 and provides hydraulic power and pneumatic power for the whole pipe making equipment.
The mold conveying device 1 comprises a conveying disc motor 102, a conveying disc 103 and a hydraulic bolt 101; the conveying disc 103 is arranged at the lower part of the frame 6, the die 8 is placed on a die placing point of the conveying disc 103, and the conveying disc motor 102 is arranged at one end of the conveying disc 103 and used for driving the conveying disc 103 to rotate 180 degrees so as to move the die 8 to a station; the hydraulic bolt 101 is installed on the conveying disc 103, and the working end of the hydraulic bolt 101 can be inserted into a limiting hole in the corresponding position of the rack 6, so that the conveying disc 103 is locked after the mold 8 reaches the station.
The socket manufacturing device 2 comprises a first bottom vibration motor 202, a second bottom vibration motor 203, a bottom steering motor 201, a vibration cross beam 204, a vibration cross beam hydraulic cylinder 205 and a socket tray 206; a piston of the vibrating cross beam hydraulic cylinder 205 is fixed on the frame 6, a cylinder barrel of the vibrating cross beam hydraulic cylinder 205 is fixedly connected with the bellmouth tray 206, so that the bellmouth tray 206 is lifted, and the bellmouth manufacturing device 2 is adjusted to a proper position; the bottom steering motor 201, the first bottom vibration motor 202, the second bottom vibration motor 203 and the vibration cross beam 204 are all arranged on the bellmouth tray 206; when the bellmouth tray 206 rises to the upper stop position, the vibration cross beam 204 is in close contact with the inner bottom tray at the bottom of the die 8, and the first bottom vibration motor 202 and the second bottom vibration motor 203 can act on the vibration cross beam 204 to realize the vibration of the vibration cross beam 204, ensure the bellmouth quality and finish the bellmouth manufacturing; the bottom steering motor 201 is installed at the bottom of the vibration cross beam 204, so that the rotation of the vibration cross beam 204 is realized, the cement pipe is driven to rotate, and the material is prevented from being adhered to the mold 8.
The material injection device 5 comprises a material sweeping disc 501, a stirrer 502, a material sweeping hydraulic motor 503, a conveyor belt motor 504, a conveyor belt 505, a hopper 506 and a material sweeping disc hydraulic cylinder 507; the conveyer belt 505 is rotatably arranged on the workbench 7, the conveyer belt motor 504 and the hopper 506 are both arranged on the workbench 7, and the conveyer belt 505 is positioned at a discharge port of the hopper 506 and receives the materials output by the hopper 506; the conveyer belt motor 504 acts on the conveyer belt 505 to realize the rotation of the conveyer belt 505 and inject the material into the mold 8; the stirrer 502 is arranged in the hopper 506 and used for stirring materials; the material sweeping disc 501 is positioned above the die 8, a piston of a material sweeping disc hydraulic cylinder 507 is fixedly connected with the frame 6, a cylinder barrel of the material sweeping disc hydraulic cylinder 507 is fixedly connected with the material sweeping disc 501, the material sweeping disc 501 is lifted under the action of the material sweeping disc hydraulic cylinder 507, and the position adjustment of the material sweeping disc 501 is realized; the sweeping hydraulic motor 503 is installed on the sweeping tray 501, and the sweeping hydraulic motor 503 acts on the sweeping tray 501 to drive the sweeping tray 501 to rotate, so as to sweep the scattered materials into the mold 8.
The socket manufacturing device 3 comprises a first rotary hydraulic motor 301, a second rotary hydraulic motor 302 and a grinding disc 303; the first rotary hydraulic motor 301 and the second rotary hydraulic motor 302 are arranged at the bottom of the material sweeping disc 501, and the grinding disc 303 is fixed at the action ends of the two rotary hydraulic motors and drives the grinding disc 303 to rotate so as to finish the grinding process; the socket making device 3 can move up and down along with the grinding disc 303 under the action of the material sweeping disc hydraulic cylinder 507.
The main body shaping device 4 comprises a transmission hydraulic cylinder 401, an upper fixed air cylinder 402, a lower fixed air cylinder 403, a hydraulic pump 404, a first shaft control motor 405, an air pump 406, a second shaft control motor 407, a power head 408, a connecting shaft 409 and a power box 410; a cylinder piston of the transmission hydraulic cylinder 401 is fixedly connected with the frame 6, and a cylinder of the transmission hydraulic cylinder 401 is fixedly connected with the power box 410, so that the power box 410 is lifted; the first shaft control motor 405 and the second shaft control motor 407 are installed in the power box 410, output shafts of the two shaft control motors are fixedly connected with the upper end of a connecting shaft 409 through couplings respectively, a power head 408 is fixed at the lower end of the connecting shaft 409, the power head 408 extends into the die 8 and acts on materials, the power head 408 is driven to rotate through the two shaft control motors, the materials are extruded, and the main body shaping of the cement pipe is completed; the upper fixed air cylinder 402 and the lower fixed air cylinder 403 are arranged on the mold 8 and used for fixing a reinforcement cage in the mold 8; the hydraulic pump 404 and the gas pump 406 are both installed at the bottom of the frame 6, the hydraulic pump 404 is respectively connected with the hydraulic bolt 101, the vibration cross beam hydraulic cylinder 205, the sweeping hydraulic motor 503, the sweeping disc hydraulic cylinder 507, the first rotary hydraulic motor 301, the second rotary hydraulic motor 302 and the transmission hydraulic cylinder 401 of the pipe making equipment through oil pipes, and hydraulic power is provided for all the parts; the gas pump 406 is respectively connected with the upper fixed gas cylinder 402 and the lower fixed gas cylinder 403 through a gas supply seat on the sweeping tray 501 to provide pneumatic power.
The positioning sensing module comprises a plurality of limit switches, a current transformer and an oil temperature and oil pressure detector; the limit switches are respectively used for realizing the positioning of the conveying disc 103 when the mold 8 moves into the station, the positioning of the conveying disc 103 when the mold 8 moves out of the station, the positioning of the upper stop position of the power box 410, the positioning of the position of the power box 410 which changes from acceleration to uniform motion, the positioning of the position of the power box 410 which changes from uniform motion to deceleration motion, the positioning of the lower stop position of the power box 410, the positioning of the initial position of the sweeping disc 501, the positioning of the position when the sweeping disc 501 works, the positioning of the upper stop of the socket making device 2 and the positioning of the lower stop of the socket making device 2; the current transformers are respectively connected with the industrial three-phase power and used for controlling the current detection of the power distribution part of the module, preventing the problems of system overload, industrial power grid phase loss and the like and realizing the safety guarantee detection of the system; the oil temperature and oil pressure detector is installed in an oil cylinder of the hydraulic pump 404 and used for detecting the oil temperature and the oil pressure in the hydraulic pump 404 and transmitting acquired signals to the control module, so that the safety and the stable operation of the system are guaranteed.
The execution module comprises a mould transmission frequency converter 901, a hydraulic bolt electromagnetic valve 902, a vibration motor frequency converter 903, a bottom steering frequency converter 904, a first socket manufacturing electromagnetic valve 905, a second socket manufacturing electromagnetic valve 906, a cylinder electromagnetic valve 907, a first shaft control motor frequency converter 908, a second shaft control motor frequency converter 909, a gas pump frequency converter 910, a hydraulic pump frequency converter 911, a transmission hydraulic cylinder electromagnetic valve 912, a stirring relay 913, a conveyor belt motor frequency converter 914, a sweeping electromagnetic valve 915, a sweeping tray electromagnetic valve 916 and a socket tray electromagnetic valve 917;
the mold conveying frequency converter 901 is used for driving the conveying disc motor 102 to realize the rotation of the conveying disc 103; the hydraulic bolt solenoid valve 902 is used for controlling the hydraulic bolt 101 to complete the locking of the transfer plate 103; a bellmouth tray electromagnetic valve 917 drives the vibration cross beam hydraulic cylinder 205 to realize the lifting of the bellmouth tray 206; the vibration motor frequency converter 903 drives a first bottom vibration motor 202 and a second bottom vibration motor 203 respectively to realize vibration of the vibration cross beam 204; the bottom steering frequency converter 904 controls the bottom steering motor 201 to realize the rotation of the vibrating cross beam 204, drives the cement pipe to rotate, and prevents the materials from being adhered to the mold 8; the first socket manufacturing electromagnetic valve 905 and the second socket manufacturing electromagnetic valve 906 respectively control the first rotary hydraulic motor 301 and the second rotary hydraulic motor 302 to drive the grinding disc 303 to rotate, so that the grinding process is completed; an air cylinder electromagnetic valve 907 controls the upper fixed air cylinder 402 and the lower fixed air cylinder 403 to realize the fixation of the reinforcement cage in the mold 8; the first shaft control motor frequency converter 908 and the second shaft control motor frequency converter 909 respectively control the first shaft control motor 405 and the second shaft control motor 407, the first shaft control motor 405 and the second shaft control motor 407 are connected with the connecting shaft 409, and the rotary power is transmitted to the power head 408 for extrusion molding of the material in the mold 8; the gas pump inverter 910 is used to drive the gas pump 406; the hydraulic pump frequency converter 911 is used for driving the hydraulic pump 404; the transmission hydraulic cylinder electromagnetic valve 912 is used for controlling the transmission hydraulic cylinder 401 to realize the lifting motion of the power box 410, so that the first shaft control motor 405, the second shaft control motor 407, the power head 408 and the connecting shaft 409 move up and down together; the stirring relay 913 controls the stirrer 502 for material stirring; the conveyor belt motor frequency converter 914 controls the conveyor belt motor 504, so as to drive the conveyor belt 505 to rotate and inject the material into the mold 8; the sweeping electromagnetic valve 915 controls the sweeping hydraulic motor 503 to realize the rotary motion of the sweeping disc 501, and sweeps the scattered materials into the mold 8; the material sweeping disc electromagnetic valve 916 controls the material sweeping disc hydraulic cylinder 507 to realize the lifting of the material sweeping disc 501, so as to adjust the position of the material sweeping disc 501; the bellmouth tray solenoid valve 917 controls the cross beam vibrating hydraulic cylinder 205 to achieve the lifting motion of the bellmouth tray 206.
The control module comprises a power distribution part and a control part, wherein the control part is a control core of the system, specifically a PLC (programmable logic controller) and is used for completing process flow control and algorithm operation of the system.
The power distribution part is used for providing a driving power supply, the input end of the power distribution part is connected with an industrial three-phase power grid through current detection and isolation, and the output end of the power distribution part divides industrial three-phase power into three paths of three-phase alternating current after passing through three circuit breakers; the output ends of the two paths of three-phase alternating currents are respectively connected with a first shaft-controlled motor frequency converter 908 and a second shaft-controlled motor frequency converter 909; a third three-phase alternating current is connected with a mould transmission frequency converter 901, a vibration motor frequency converter 903, a steering motor frequency converter 904, a first shaft control motor frequency converter 908, a second shaft control motor frequency converter 909, a gas pump frequency converter 910, a hydraulic pump frequency converter 911, a conveyor belt motor frequency converter 914, a hydraulic electromagnetic valve 104, a first socket manufacturing electromagnetic valve 905, a second socket manufacturing electromagnetic valve 906, an air cylinder electromagnetic valve 907, a transmission hydraulic cylinder electromagnetic valve 912, a material sweeping electromagnetic valve 915, a material sweeping disc electromagnetic valve 916, a socket tray electromagnetic valve 917, a direct current switch power supply and a 220V power supply access end of a control part; the 24V power output end of the direct-current switching power supply is connected with the stirring relay 913 and the 24V power common end of the control part;
the intelligent human-computer interaction module comprises a key, an indicator light and a touch screen; the keys comprise a start key, an emergency stop key and a fault reset key, and all the keys are connected with the input end of the control part; the indicator lamps comprise an electrifying indicator lamp and a fault indicator lamp, and the two indicator lamps are connected with the output end of the control part; the touch screen is in communication connection with the control part through an RS232 interface to complete data interaction between the touch screen and the control module;
the network database is connected with the serial server through WIFI, and the serial server is connected with the touch screen through an RS485 interface at the same time, so that data transmission between the intelligent human-computer interaction module and the network database is realized; the network database stores the current operation data, long-term operation data, historical fault data, conventional fault data and corresponding fault diagnosis results of the conventional fault data of the management equipment, the operation state of the management equipment can be obtained according to the data, the current fault data can be matched with the prestored fault data to obtain the fault diagnosis result, and the intelligent fault diagnosis of the management equipment is completed; if the current fault data cannot be matched with the prestored fault data, the fault reason needs to be judged manually, and a fault diagnosis result is given.
In the control system, in order to prevent the situation that the power head 408 is blocked due to the excessively high material injection speed, overcurrent damage of the first shaft control motor 405 and the second shaft control motor 407 and system operation interruption are caused, the fuzzy PID controller is adopted to realize closed-loop control, namely, the fuzzy PID controller is designed to regulate and control the conveyor belt motor frequency converter 914, regulate the rotating speed of the conveyor belt motor 504 and further regulate the material injection speed of the conveyor belt 505 so that the two shaft control motors run at constant torque by detecting the feedback currents of the first shaft control motor frequency converter 908 and the second shaft control motor frequency converter 909 and indicating the output torques of the first shaft control motor 405 and the second shaft control motor 407;
the fuzzy PID controller is implemented in the following steps:
1) establishing a control model: assuming that the working voltage and the running speed of the shaft control motor are constant; near the rated working point of the system, the influence of factors such as different material humidity, thickness and the like on the resistance torque of the shaft control motor is constant, and the material injection speed of the conveyor belt and the resistance torque T of the shaft control motor meet the formula (1):
T＝k·v+b (1)
in the formula, k and b are constants related to factors such as material humidity and the like; v represents the injection speed of the conveyor belt;
based on the above assumptions, a control model of the system is established, as shown in equation (2):
in the formula, n is the rated rotating speed of the shaft control motor; u is the rated working voltage of the shaft control motor; s is a complex variable of the laplace transform;
2) determining the input quantity and the output quantity of the controller: collecting the working current of the shaft control motor through a positioning sensing module, and calculating the error e between the rated current of the shaft control motor (in the embodiment, a 45KW shaft control motor is adopted, and the rated current of the shaft control motor is 90A) and the working current at the current sampling moment; then, the error e of the current sampling moment is subtracted from the error of the last sampling moment to obtain the error ecTwo errors e, ecThe input quantity is the input quantity of the fuzzy PID controller;
in order to enable the control system to adaptively adjust the proportionality coefficient K of the fuzzy PID controller according to parameters such as water content, average particle size and the likepIntegral coefficient KiAnd a differential coefficient KdProportional coefficient correction value delta K using fuzzy PID controllerpAnd an accumulation of bloodFractional coefficient correction value delta KiAnd differential coefficient correction value DeltaKdAs the output of the fuzzy PID controller; the input/output values of the fuzzy PID controller are as follows:
expressing the numerical values in the fuzzy theory domain in the table as a fuzzy set { NB, NM, NS, ZO, PS, PM, PB }, wherein each element in the fuzzy set corresponds to negative large, negative middle, negative small, zero, positive small, positive middle and positive large respectively;
4) determining a fuzzy membership function: all input quantities e and ecOutput quantity DeltaKp、△KiAnd Δ KdCorresponding fuzzy concentrated elements NB and PB respectively select Z-type and inverse Z-type membership functions to form left and right boundaries so as to realize smooth transition; the middle five elements adopt a triangular membership function with higher sensitivity and are uniformly distributed;
4) constructing a fuzzy relation: according to actual experience and basic requirements for controlling the pipe-making equipment to complete related work, the fuzzy reasoning process follows the following rules:
setting the threshold value of the error e to be m1 and m2, wherein the absolute value of m1 is larger than that of m 2; when the absolute value of e is larger than m1, indicating that the absolute value of e is large, the output value of the controller is output at the maximum (or minimum) no matter the variation trend of e, so as to rapidly adjust e, and the absolute value of e is reduced at the maximum speed;
when e and ecIs greater than 0 or equal to ecIf the absolute value of e is greater than or equal to m2, the absolute value of e is greater, and a stronger control action is considered to be implemented, namely, the proportional coefficient of the controller is increased, the integral coefficient of the controller is decreased, the differential coefficient of the controller is kept unchanged, the absolute value of e is changed towards the decreasing direction, and the absolute value of e is rapidly decreased; if the absolute value of e is smaller than m2, it is shown that although the absolute value of e changes in the direction toward increase, the absolute value of e itself is not so large, whichThe control action of general intensity is considered, namely the absolute value of e is changed towards the decreasing direction without changing the proportional coefficient, the integral coefficient and the differential coefficient of the controller;
when e and ecProduct less than 0, ecAnd the last time ecWhen the product of the values of (a) is greater than 0 or e is equal to 0, the absolute value of e changes towards the direction of reduction, or the equilibrium state is reached, and the proportional coefficient and the differential coefficient of the controller are kept unchanged at the moment, so that the output quantity of the controller is unchanged;
when e and ecThe product being less than 0 or ecAnd the last time ecWhen the product of the values of (a) is less than 0, indicating that e is in an extreme value state; if the absolute value of e is larger than m2, the absolute value of e is larger, and then the stronger control action is considered to be implemented, namely the proportional coefficient of the controller is increased, the integral coefficient of the controller is reduced, the differential coefficient of the controller is kept unchanged, and the absolute value of e is changed towards the reduction direction; if the absolute value of e is smaller than m2, the absolute value of e is smaller, and the weaker control action is considered to be implemented, namely the proportional coefficient of the controller is reduced, the integral coefficient of the controller is increased, the differential coefficient of the controller is kept unchanged, and the absolute value of e is changed towards the increasing direction;
when the absolute value of e is far smaller than m2, the absolute value of e is small, and the integral coefficient of the controller is increased, and the proportional coefficient and the differential coefficient of the controller are kept unchanged, so that the steady-state error of the whole system is reduced.
According to the fuzzy inference rule, the input quantities e and e are respectively solved by adopting an inference method (Mamdani) for taking the maximum and minimum valuescAnd output quantity DeltaKpInput quantities e and ecAnd output quantity DeltaKiInput quantities e and ecAnd output quantity DeltaKdFuzzy relation R ofp、RiAnd Rd；
5) Establishing a fuzzy inference machine: respectively establishing a proportional coefficient correction value delta K of the fuzzy PID controller according to the input quantity and the output quantity of the step 2), the fuzzy membership function of the step 3) and the fuzzy relation of the step 4)pIntegral coefficient correction value DeltaKiAnd differential coefficient correction value DeltaKdFor the proportional coefficient K of the fuzzy PID controllerpIntegral coefficient KiAnd a differential coefficient KdAnd correcting, and adjusting the material injection speed of the system to enable the shaft control motor to operate at constant torque.
The fuzzy PID controller adopted by the invention has certain self-adaptive capacity, can self-adaptively adjust the proportional coefficient, the integral coefficient and the differential coefficient of the fuzzy PID controller according to parameters such as the water content of materials, the average particle size and the like, can effectively improve the material injection speed and the control precision of a control system, and can effectively overcome the problem of system control performance reduction caused by poor parameter setting of the traditional PID controller.
The working principle and the working process of the invention are as follows:
pressing a start key, enabling the system to enter a power-on self-inspection stage, wherein self-inspection items comprise industrial power grid phase loss detection, oil temperature and oil pressure detection of a hydraulic pump 404, initial position detection of a transmission hydraulic cylinder 401, initial position detection of a transmission disc 103, initial position detection of a socket manufacturing device and initial position detection of a sweeping disc 501;
when the self-checking project is normal, the system enters a normal working stage; placing the mold 8 on the conveying disc 103, driving the conveying disc 103 to rotate 180 degrees by the conveying disc motor 102, transferring the mold 8 to a station, detecting that the mold 8 reaches the station by a limit switch positioned by the conveying disc 103 when the mold 8 moves into the station, and driving the hydraulic bolt 101 to be inserted into a limit hole of the rack 6 by the hydraulic bolt electromagnetic valve 902 to realize the locking of the conveying disc 103; the material sweeping disc electromagnetic valve 916 controls the material sweeping disc hydraulic cylinder 507 to drive the lifting disc 508 to descend, so that the material sweeping disc 501 is in close contact with the upper part of the mold 8, meanwhile, a gas supply seat of the material sweeping disc 501 is sleeved into a gas receiving pile of the mold 8, gas is supplied to the upper fixed gas cylinder 402 and the lower fixed gas cylinder 403 through the gas cylinder electromagnetic valve 907, and a reinforcement cage in the mold 8 is fixed;
the transmission hydraulic cylinder electromagnetic valve 912 controls the transmission hydraulic cylinder 401, drives the power box 410 to descend to the lower stop position of the power box 410, and extends the power head 408 into the mold 8; in the descending process of the power box 410, the opening degree of the electromagnetic valve 912 of the transmission hydraulic cylinder is adjusted according to the state of each limit switch, so that the descending speed of the power box 410 is adjusted;
the bellmouth tray electromagnetic valve 917 controls the vibration cross beam hydraulic cylinder 205 to drive the bellmouth tray 206 to ascend, so that the contact ring of the vibration cross beam 204 is in close contact with the inner bottom tray at the bottom of the mold 8; the conveyor belt motor 504 is started through the conveyor belt motor frequency converter 914, the conveyor belt 505 is driven to rotate, and materials are injected into the mold 8; then the sweeping electromagnetic valve 915 controls the sweeping hydraulic motor 503 to rotate the sweeping tray 501, and the scattered materials are swept into the mold 8; when materials begin to be injected into the mold 8, a first bottom vibration motor 202, a second bottom vibration motor 203 and a bottom steering motor 201 are started, vibration and rotation motion are transmitted to the cement pipe through a vibration cross beam 204, the socket manufacturing at the bottom of the cement pipe is completed, the bottom steering motor 201 controls the vibration cross beam 204 to rotate for a certain angle at intervals, the cement pipe is driven to rotate, and the mold 8 is prevented from being adhered to the materials; after the bell mouth is manufactured, oil drainage of the vibration cross beam hydraulic cylinder 205 is controlled through a bell mouth tray electromagnetic valve 917, so that the bell mouth manufacturing device 2 is lowered to a lower stop position;
the transmission hydraulic cylinder electromagnetic valve 912 controls the transmission hydraulic cylinder 401 to make the power box 410 move up slowly; meanwhile, the first shaft control motor frequency converter 908 and the second shaft control motor frequency converter 909 respectively control the first shaft control motor 405 and the second shaft control motor 407, so that the power head 408 rotates to extrude materials, and the main body shaping work of the whole cement pipe is completed from bottom to top; after the body shaping work of the cement tube is started, the lower fixed air cylinder 403 is retracted, and as the power box 410 moves upward, when the power head 408 reaches the bottom of the upper fixed air cylinder 402, the upper fixed air cylinder 402 is retracted;
when the power head 408 rises to the socket making device 3, the conveyor belt 505 stops injecting the material; the first rotary hydraulic motor 301 and the second rotary hydraulic motor 302 are respectively controlled by a first socket manufacturing electromagnetic valve 905 and a second socket manufacturing electromagnetic valve 906 to drive the grinding disc 303 to rotate, so that grinding and capping of the cement pipe are completed; the power box 410 continues to rise to the initial position when the power box 410 descends, and the lifting disc 508 rises to the initial position, so that the whole pipe making process is completed;
finally, the conveying disc 103 transfers the cement pipe finished product and the mold 8 to a finished product area, and simultaneously transfers the mold 8 (the distance between the finished product area and the station is 180 degrees) of the finished product area to the station for next pipe making. When abnormality occurs, the system enters a failure mode, all parts of the system keep the current positions, the material injection device 5 stops injecting materials, the touch screen displays failure alarm, the system transmits current failure data to the network database, failure diagnosis is carried out according to historical failure data stored in the network database and conventional failure data pre-stored in advance, and the diagnosis result is transmitted back to the touch screen for display; under normal shutdown conditions, the components are restored to the original positions and the system enters a shutdown state.
Nothing in this specification is said to apply to the prior art.
Claims (5)
1. A control system of vertical radial extrusion pipe-making equipment is characterized by comprising a positioning sensing module, a control module, an execution module, an intelligent human-computer interaction module and a network database; the positioning sensing module is connected with the input end of the control module to realize the input of signals; the control module is connected with the execution module to realize the output of control signals; the control module is in communication connection with the intelligent human-computer interaction module; the intelligent man-machine interaction module is connected with a network database through a serial server to realize data interaction of the system; the network database stores the current operation data, the long-term operation data, the historical fault data and the conventional fault data of the management equipment and corresponding fault diagnosis results, so that the system can complete intelligent fault diagnosis of the management equipment;
the positioning sensing module comprises a limit switch, a current transformer and an oil temperature and oil pressure detector; the limit switches are used for positioning and detecting corresponding parts of the pipe manufacturing equipment; the current transformer is used for controlling the current detection of the module, so that the safety guarantee detection of the system is realized; the oil temperature and oil pressure detector is used for detecting the oil temperature and oil pressure of the pipe manufacturing equipment, so that the safe and stable operation of the system is guaranteed;
the intelligent human-computer interaction module comprises a key, an indicator light and a touch screen; the keys comprise a start key, an emergency stop key and a fault reset key, and all the keys are connected with the input end of the control module; the indicating lamps comprise a power-on indicating lamp and a fault indicating lamp, and the two indicating lamps are connected with the output end of the control module; the touch screen is in communication connection with the control module to complete data interaction between the touch screen and the control module.
2. The control system of vertical radial extrusion pipe making equipment according to claim 1, wherein the execution module comprises a die transmission frequency converter, a hydraulic bolt electromagnetic valve, a vibration motor frequency converter, a bottom steering frequency converter, a first socket manufacturing electromagnetic valve, a second socket manufacturing electromagnetic valve, a cylinder electromagnetic valve, a first shaft control motor frequency converter, a second shaft control motor frequency converter, a gas pump frequency converter, a hydraulic pump frequency converter, a transmission hydraulic cylinder electromagnetic valve, a stirring relay, a conveyor belt motor frequency converter, a sweeping electromagnetic valve, a sweeping tray electromagnetic valve and a socket tray electromagnetic valve, and the control module controls the pipe making equipment to complete related work through all parts of the execution module.
3. The control system of the vertical radial extrusion pipe-making equipment according to claim 2, wherein a fuzzy PID controller is adopted to realize closed-loop control of the system, namely a frequency converter of a conveyor belt motor is regulated and controlled by the fuzzy PID controller, the rotating speed of the conveyor belt motor of the pipe-making equipment is regulated, and further the material injection speed of the conveyor belt of the pipe-making equipment is regulated, so that a shaft control motor of a power head of the pipe-making equipment is controlled to run at constant torque, and the phenomenon that the rotation of the power head of the pipe-making equipment is blocked due to the overhigh material injection speed is prevented.
4. The control system of the vertical radial extrusion pipe-making equipment according to claim 3, wherein the fuzzy PID controller is implemented by the following steps:
1) establishing a control model: assuming that the working voltage and the running speed of a shaft control motor of the pipe manufacturing equipment are constant; near the rated working point of the system, the influence of different material humidity and material thickness on the resistance torque of the shaft control motor is constant, and the material injection speed of the conveyor belt of the pipe making equipment and the resistance torque T of the shaft control motor meet the formula (1):
T＝k·v+b (1)
in the formula, k and b are constants related to the humidity and the thickness of the material; v represents the injection speed of the conveyor belt;
based on the above assumptions, a control model of the system is established according to equation (2):
in the formula, n is the rated rotating speed of a shaft control motor of the pipe making equipment; u is the rated working voltage of a shaft control motor of the pipe making equipment; s is a complex variable of the laplace transform;
2) determining the input quantity and the output quantity of the controller: collecting the working current of a shaft control motor of the pipe manufacturing equipment through a positioning sensing module, and calculating the error e between the rated current of the shaft control motor and the working current at the current sampling moment; then, the error e of the current sampling moment is subtracted from the error of the last sampling moment to obtain the error ecTwo errors e, ecThe input quantity is the input quantity of the fuzzy PID controller;
proportional coefficient correction value delta K of fuzzy PID controllerpIntegral coefficient correction value DeltaKiAnd differential coefficient correction value DeltaKdAs the output of the fuzzy PID controller;
3) determining a fuzzy membership function: all input quantities e and ecOutput quantity DeltaKp、△KiAnd Δ KdCorresponding elements NB and PB in the fuzzy set respectively adopt Z-type membership functions and inverse Z-type membership functions, and the rest elements adopt triangular membership functions;
4) constructing a fuzzy relation: establishing fuzzy inference rules according to practical experience and basic requirements for controlling the pipe-making equipment to complete related work, and respectively calculating input quantities e and e by adopting an inference method of taking maximum and minimum valuescAnd output quantity DeltaKpInput quantities e and ecAnd output quantity DeltaKiInput quantities e and ecAnd output quantity DeltaKdFuzzy relation R ofp、RiAnd Rd；
5) Establishing a fuzzy inference machine: root of herbaceous plantRespectively establishing a proportional coefficient correction value delta K of the fuzzy PID controller according to the input quantity and the output quantity obtained in the step 2), the fuzzy membership function in the step 3) and the fuzzy relation in the step 4)pIntegral coefficient correction value DeltaKiAnd differential coefficient correction value DeltaKdFor the proportional coefficient K of the fuzzy PID controllerpIntegral coefficient KiAnd a differential coefficient KdAnd correcting to enable the fuzzy PID controller to control the shaft control motor frequency converter, further adjusting the material injection speed of the system and enabling the shaft control motor to operate at constant torque.
5. The control system of the vertical radial extrusion pipe making apparatus as set forth in claim 4, wherein the fuzzy inference rule is:
setting the threshold value of the error e to be m1 and m2, wherein the absolute value of m1 is larger than that of m 2; when the absolute value of e is larger than m1, indicating that the absolute value of e is large, and the output quantity of the controller is output according to the maximum or minimum, so that the absolute value of e is reduced at the maximum speed;
when e and ecIf the product of e is greater than or equal to m2, the absolute value of e is indicated to be larger, and then a stronger control action is considered to be implemented, namely, the proportional coefficient of the controller is increased, the integral coefficient of the controller is reduced, the differential coefficient of the controller is kept unchanged, the absolute value of e is changed towards the direction of reduction, and the absolute value of e is rapidly reduced; if the absolute value of e is less than m2, it is stated that although the absolute value of e changes in the increasing direction, the absolute value of e itself is not very large, and then the control action of general strength is considered, that is, the proportional coefficient, the integral coefficient and the differential coefficient of the controller are not changed, so that the absolute value of e changes in the decreasing direction;
when e and ecProduct less than 0, ecAnd the last time ecWhen the product of the values of (a) is more than 0 or e is equal to 0, the absolute value of e is changed towards the reduction direction, or the equilibrium state is reached, and the proportional coefficient and the differential coefficient of the controller are kept unchanged, so that the output quantity of the controller is enabled to be constantThe change is not changed;
when e and ecProduct less than 0 or ec and last ecWhen the product of the values of (a) is less than 0, indicating that e is in an extreme value state; if the absolute value of e is larger than m2, the absolute value of e is larger, and then the stronger control action is considered to be implemented, namely the proportional coefficient of the controller is increased, the integral coefficient of the controller is reduced, the differential coefficient of the controller is kept unchanged, and the absolute value of e is changed towards the reduction direction; if the absolute value of e is smaller than m2, the absolute value of e is smaller, and the weaker control action is considered to be implemented, namely the proportional coefficient of the controller is reduced, the integral coefficient of the controller is increased, the differential coefficient of the controller is kept unchanged, and the absolute value of e is changed towards the increasing direction;
when the absolute value of e is far smaller than m2, the absolute value of e is small, and the integral coefficient of the controller is increased, and the proportional coefficient and the differential coefficient of the controller are kept unchanged, so that the steady-state error of the whole system is reduced.
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