CN111983977B - Heat exchanger pipe penetrating equipment control system and method - Google Patents
Heat exchanger pipe penetrating equipment control system and method Download PDFInfo
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- CN111983977B CN111983977B CN202010835585.4A CN202010835585A CN111983977B CN 111983977 B CN111983977 B CN 111983977B CN 202010835585 A CN202010835585 A CN 202010835585A CN 111983977 B CN111983977 B CN 111983977B
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/414—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
- G05B19/4147—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller characterised by using a programmable interface controller [PIC]
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- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
- B23P19/02—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes for connecting objects by press fit or for detaching same
- B23P19/022—Extracting or inserting relatively long parts
- B23P19/024—Extracting or inserting relatively long parts tube bundles
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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Abstract
The invention discloses a heat exchanger pipe penetrating equipment control system and a method, wherein the control system comprises a gantry walking module, a main beam lifting module, a bracket translation module, a driving roller module, a manipulator feeding module and a workstation PLC (programmable logic controller); the gantry traveling module controls the movement of the base moving mechanism, the main beam lifting module controls the movement of the main beam lifting mechanism, the bracket translation module controls the movement of the bracket translation mechanism, and the active roller module controls the starting and stopping of the active roller group motor; the manipulator feeding module controls a manipulator feeding mechanism to be used for taking and feeding the heat exchange tube; the workstation PLC is used for storing and acquiring information, executing logical operation and sequence control instructions in software and controlling each module to realize process actions specified by the system. The control method is applied to the control system, the modules are sequentially controlled by the PLC according to a certain process flow, and the modules respectively control the action mechanisms of the pipe penetrating equipment to complete the pipe penetrating process of the heat exchanger.
Description
Technical Field
The invention relates to the technical field of automatic control, in particular to a system and a method for controlling a heat exchanger pipe penetrating device.
Background
The heat exchanger tube penetrating process is characterized in that heat exchange tubes are sequentially penetrated into tube plate holes of multiple layers of heat exchanger tube plates according to arrangement of the tube plate holes in a certain sequence, so that the heat exchange tubes and the tube plates structurally form a whole. The process before tightening is tube plate fixing, and the process after tightening is heat exchange tube welding and tube expansion. The pipe penetrating process is one of key processes of heat exchanger assembly operation, the pipe penetrating quality directly affects the product quality of the heat exchanger, and the pipe penetrating process is also one of processes with higher difficulty and higher labor intensity.
The existing heat exchanger tube penetrating process is generally completed by adopting a mode of manual work and auxiliary tools, the mode has low efficiency, the tube penetrating quality is greatly influenced by the proficiency of workers, and the labor intensity is high; the tube penetrating process of the heat exchanger adopts horizontal tube penetrating type automatic equipment, the process is only suitable for small tube plates and shorter heat exchange tubes, and for large tube plates and longer heat exchange tubes, the horizontal tube penetrating process is complex, the process of installing and dismantling a tube penetrating guide device needs to be added, and large-scale automation is not realized.
The invention relates to equipment based on the mode, wherein the equipment adopts automatic pipe penetrating equipment for vertical pipe penetrating, and all mechanism actions are controlled by automatic modules, so that the automatic pipe penetrating with less manual intervention is realized.
Disclosure of Invention
The invention aims to provide a heat exchanger pipe penetrating equipment control system and a heat exchanger pipe penetrating equipment control method which are suitable for vertical penetrating pipes and have high automation degree.
In order to achieve the purpose, the invention adopts the following technical scheme:
a heat exchanger pipe penetrating equipment control system comprises a gantry structure formed by two parallel bases and a main beam, wherein a bracket is arranged on the main beam;
the base moving mechanism drives the base to move along a first direction, and the first direction is a horizontal direction; the main beam lifting mechanism drives the main beam to move along a third direction, and the third direction is a vertical direction; the bracket translation mechanism drives the bracket to move on the main beam along a second direction, and the second direction is perpendicular to the first direction and is in the same horizontal plane with the first direction; the manipulator feeding mechanism is arranged on the main beam, and a trough for storing the heat exchange tubes is further arranged on the main beam; the guide mechanism is arranged on the bracket, a plurality of pipe penetrating guide channels surrounded by roller components are arranged on the guide mechanism, each roller component comprises a driving roller group, and the driving roller groups are driven by a motor;
the control system comprises a gantry walking module, a main beam lifting module, a bracket translation module, a driving roller module, a manipulator feeding module and a workstation PLC (programmable logic controller);
the gantry walking module controls the movement of the base moving mechanism, the main beam lifting module controls the movement of the main beam lifting mechanism, the bracket translation module controls the movement of the bracket translation mechanism, and the driving roller module controls the starting and stopping of a motor of the driving roller group; the manipulator feeding module controls the manipulator feeding mechanism to be used for taking and feeding the heat exchange tube; the workstation PLC is used for storing and acquiring information, executing logical operation and sequence control instructions in software and controlling each module to realize process actions specified by the system.
Furthermore, the pipe penetrating equipment further comprises a pressing and aligning mechanism, the pressing and aligning mechanism is arranged on the guide mechanism, the control system further comprises a pressing and aligning module, and the pressing and aligning module controls the pressing plate of the pressing and aligning mechanism to extend and retract.
Furthermore, two induction type limit switches are arranged on the bracket and are respectively arranged at the first position and the second position of the bracket; defining a first direction as a column, wherein the first position and the second position are set to correspond to the positions of the tube plate holes of the adjacent columns on the heat exchanger in the second direction; the bracket translation module adopts the inductive limit switch to realize the position feedback of the bracket on the two positions.
Furthermore, the gantry walking module adopts double servo motors for synchronous driving, and the speed and the position of the double servo motors are synchronized by utilizing the deviation comparison function of a servo driver and the gantry interlocking technology.
Furthermore, the main beam lifting module adopts a grating ruler to perform position feedback on the action of the hydraulic cylinder.
Furthermore, the manipulator feeding module adopts an external shaft function module of the manipulator to bring the pneumatic clamp control module into the manipulator control module to form linkage; and the offset instruction function in the manipulator control module is adopted, so that the multi-position continuous material taking and placing actions are realized.
Furthermore, the active roller module adopts an inductive switch to perform signal feedback on the position of the heat exchange pipe, and is matched with the PLC to complete corresponding process actions.
Furthermore, the workstation PLC adopts the PLC as a main control carrier and the operation screen as a man-machine interaction carrier, so that the sequential control of the modules is realized, and manual intervention is performed when needed.
A heat exchanger pipe penetrating equipment control method is applied to the control system, according to a certain process flow, a PLC is used for sequentially controlling all modules, and all the modules respectively control all action mechanisms of the pipe penetrating equipment to complete a heat exchanger pipe penetrating process.
Still further, the method comprises:
step 1: the workstation PLC calculates according to the heat exchanger data and the environment data to obtain the most reasonable third direction height data of the main beam on the pipe penetrating equipment and the most reasonable first direction coordinate data of the machine base, and respectively transmits the data to the main beam lifting module and the gantry traveling module to enable the main beam and the machine base to reach the height and the coordinate;
and 2, step: the workstation PLC is switched to a manual operation mode, the bracket translation mechanism is adjusted to a first position and locked, the base moving mechanism is adjusted to a corresponding position to determine the position coordinates of two adjacent tube plate holes in the first direction, and the workstation PLC records the coordinates of the two positions as a first coordinate and a second coordinate;
and step 3: the workstation PLC is switched to an automatic mode, and the gantry walking module controls the base moving mechanism to act so as to enable the pipe penetrating equipment to return to the first coordinate;
and 4, step 4: the workstation PLC transmits signals to the main beam lifting module, the gantry walking module, the driving roller module, the manipulator feeding module and the bracket translation module, the main beam lifting module controls the main beam lifting mechanism to be locked, the gantry traveling module controls the machine base moving mechanism to enable the machine base to move between a first coordinate and a second coordinate according to a set track, the active roller module controls the start and stop of the motor of the active roller group, an inductive switch on the active roller module feeds back the position of the heat exchange pipe, the manipulator feeding module controls the manipulator feeding mechanism to carry out heat exchange tube taking and feeding actions according to the set offset, and the bracket translation module controls the bracket translation mechanism to enable the bracket to move between a first position and a second position according to a set track, so that pipe penetration of all hole sites of the heat exchanger is completed.
Furthermore, the specific method for determining the positions of the first coordinate and the second coordinate in step 2 is as follows: and adjusting the base moving mechanism to enable the pipe penetrating equipment to move to the position where the pipe penetrating guide channel on the guide mechanism is superposed with the pipe plate hole on the heat exchanger, adjusting the base moving mechanism to enable the pipe penetrating equipment to move to the position where the pipe penetrating guide channel is superposed with the pipe plate hole on the heat exchanger in the same row and adjacent pipe plate holes, transmitting an operation signal to the gantry traveling module through the workstation PLC, and recording the coordinates of the two positions as a first coordinate and a second coordinate by the workstation PLC.
Furthermore, the specific control method for the tube penetration of the heat exchanger in the step 4 comprises the following steps:
after the pipe penetrating equipment returns to the first coordinate, the workstation PLC transmits signals to the main beam lifting module and the gantry walking module to lock corresponding mechanisms, transmits the signals to the driving roller module to start a motor of the driving roller group, and simultaneously transmits the signals to the manipulator feeding module to realize the heat exchange pipe taking and feeding processes; the induction switch in the active roller module feeds the position of the heat exchange tube back to the workstation PLC and transmits signals to the manipulator feeding module and the gantry traveling module, so that the manipulator feeding mechanism is reset and carries out the next material taking and feeding actions according to the set offset, the base reaches the second coordinate, and the tube penetrating process actions and control are repeated;
the workstation PLC transmits signals to the gantry walking module and the bracket translation module after all pipe penetrating actions of a first row of holes are finished, the corresponding mechanism is unlocked, the bracket is moved to a second position and locked, the machine base is moved to a position above a second row of holes according to a set distance, and the pipe penetrating process actions and control are repeated until the second row of holes finish the pipe penetrating work;
and performing the process action and the control analogize to cover the through pipes of all hole sites of the heat exchanger.
Furthermore, after all the tubes are penetrated, the workstation PLC respectively transmits starting signals to the gantry walking module and the pressing and aligning module, defines the second direction as a row, moves the machine base to the position above the first row of holes, starts the pressing and aligning mechanism to press and align the heat exchange tube heads, moves the machine base to the position above the second row of holes, starts the pressing and aligning mechanism to press and align the heat exchange tube heads, and so on, and finishes the pressing and aligning of all the heat exchange tube heads.
The invention has the beneficial effects that: the system and the method for controlling the tube penetrating equipment of the heat exchanger are suitable for automatic tube penetrating operation of the tube heat exchanger with a large tube plate (the diameter is 4-5 m) and a long heat exchange tube (the length is 5-8 m), the process is simple, manual intervention is reduced, the automation degree is high, the labor intensity of the tube penetrating operation is greatly reduced, the operation efficiency is improved, the phenomenon that the heat exchange tube collides with the hole of the tube plate in the operation is avoided, and the operation quality is ensured.
Drawings
FIG. 1 is a schematic structural diagram of one embodiment of a heat exchanger tube penetrating device applying the control system of the invention;
FIG. 2 is a rear view of the apparatus of FIG. 1;
FIG. 3 is a bottom view of the guide mechanism of FIG. 1;
FIG. 4 is a cross-sectional view of the guide mechanism of FIG. 1;
FIG. 5 is a block schematic diagram of the control system of the present invention;
FIG. 6 is a block schematic view of the gantry walking module of FIG. 5;
FIG. 7 is a block schematic diagram of the main beam lift module of FIG. 5;
FIG. 8 is a block schematic diagram of the carriage translation module of FIG. 5;
FIG. 9 is a block diagram of the active roller module of FIG. 5;
FIG. 10 is a block schematic diagram of the leveling module of FIG. 5;
figure 11 is a block schematic diagram of the robot loading module of figure 5.
Wherein: 1-workstation PLC; 2-a control cabinet; 3-operating a screen; 4-a power cable; 5-a control cable; 10-gantry walking module; 11-a servo driver; 12-a servo motor; 13-a band-type brake cable; 14-an encoder cable; 15-limit switch; 20-a main beam lifting module; 21-a hydraulic system; 22-servo hydraulic cylinder; 23-a grating ruler; 30-a carriage translation module; 31-a hydraulic cylinder; 32-inductive limit switches; 40-active roller module; 41-inductive switch; 42-a frequency converter; 43-speed regulating motor; 50-pressing and aligning the module; 51-relief valve; 60-a manipulator feeding module; 61-a robot control module; 62-remote control demonstrator; 63-a pneumatic clamp control module; 100-a base moving mechanism; 101-a stand; 200-a main beam lifting mechanism; 201-main beam; 300-a carriage translation mechanism; 301-a bracket; 400-a guide mechanism; 401-driving roller group; 402-passive roller group; 403-a guide sleeve; 500-pressing and aligning mechanism; 600-a manipulator feeding mechanism; 700-material groove; 800-heat exchanger; 801-Heat exchange tube.
Detailed Description
To better illustrate the objects, aspects and advantages of the present invention, the present invention will be further described with reference to specific embodiments. This invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concept of the invention to those skilled in the art, and the present invention will only be defined by the appended claims.
The heat exchanger tube-penetrating equipment control system is applied to a heat exchanger tube-penetrating process in heat exchanger assembly operation, and heat exchange tubes are sequentially penetrated into tube plate holes according to certain sequence according to the arrangement of the tube plate holes, so that the heat exchange tubes and the tube plates are structurally integrated. Fig. 1-4 show one preferred embodiment of a heat exchanger tube threading device to which the control system of the present invention is applied.
As shown in fig. 1, the pipe penetrating device includes a gantry structure formed by two parallel bases 101 and a main beam 201, a bracket 301 is disposed on the main beam 201, and the pipe penetrating device further includes a base moving mechanism 100, a main beam lifting mechanism 200, a bracket translation mechanism 300, a guide mechanism 400, a pressing and aligning mechanism 500, and a manipulator feeding mechanism 600.
The base moving mechanism 100 drives the base 101 to move along a first direction (X axis), which is a horizontal direction.
The main beam lifting mechanism 200 drives the main beam 201 to move along a third direction (Z axis), which is a vertical direction.
The carriage translation mechanism 300 drives the carriage 301 to move on the main beam 201 along a second direction (Y-axis) perpendicular to and in the same horizontal plane as the first direction (X-axis).
The manipulator feeding mechanism 600 is arranged on the main beam 201, and a trough 700 for storing heat exchange tubes is also arranged on the main beam 201; the guide mechanism 400 is arranged on the bracket 301, a plurality of pipe penetrating guide channels surrounded by roller components are arranged on the guide mechanism 400, each roller component comprises a driving roller group 401, and the driving roller groups 401 are driven by a motor; the pressing and aligning mechanism 500 is provided on the guide mechanism 400.
Fig. 5 is a block schematic diagram of the control system of the present invention, which includes a gantry traveling module 10, a main beam lifting module 20, a carriage translation module 30, a driving roller module 40, a leveling module 50, a robot loading module 60, and a workstation PLC 1. Each module controls each action mechanism of the pipe penetrating equipment.
The workstation PLC1 is used for storing and collecting information, executing instructions such as logic operation and sequence control in software, and controlling each module to realize the process action specified by the system.
Further, the workstation PLC1 includes: PLC, switch board 2, operation panel 3, power cable 4 and control cable 5. The workstation PLC1 adopts the PLC as the main control carrier and the operation screen 3 as the man-machine interaction carrier, realizes the sequential control of each module and carries out manual intervention when needed. The control cabinet 2 is a manual operation and monitoring platform, and a complete set of electric control elements are arranged inside the control cabinet. The operation screen 3 is arranged on the control cabinet 2, and for the human-computer interaction equipment, system operation related parameters can be set in the operation screen 3 unit. And the power cable 4 supplies power to the control cabinet 2 and the operation screen 3. The control cable 5 is used for transmitting control signals between the PLC and the modules.
As shown in fig. 6, which is a block schematic view of the gantry traveling module 10, the gantry traveling module 10 is used for controlling the machine base moving mechanism 100 to move along a first direction (X axis), and the first direction (X axis) is a horizontal direction.
As an example, as shown in fig. 1, two guide rail bases are arranged in parallel, two bases 101 are respectively arranged above the two guide rail bases, and the two bases 101 are movable on the two guide rail bases along a guide rail direction (first direction/X axis). One main beam 201 is horizontally arranged between the two bases 101, and the two bases 101 and the main beam 201 form a gantry structure together. The base moving mechanism 100 realizes the synchronous linear movement of the two bases 101 on the two guide rail bases by adopting a conventional linear slide rail + slide block + speed reduction motor driving mode.
The equipment action mechanism corresponding to the gantry walking module 10 is a gantry walking mechanism 100/machine base 101, and the gantry walking module 10 needs to be matched with the pipe penetrating process action to realize the forward and backward movement and real-time position feedback of the pipe penetrating equipment.
The gantry walking module 10 adopts synchronous driving of double servo motors, and the speed and the position of the double servo motors are synchronized by utilizing the deviation comparison function of a servo driver and the gantry interlocking technology.
Further, the gantry walking module 10 further includes: servo motor 12, servo driver 11, limit switch 15, power cable 4, encoder cable 14, band-type brake cable 13.
The servo system composed of the servo driver 11 and the servo motor 12 can realize accurate positioning and quick start and stop, and realize dual-motor synchronization. And the limit switches 15 are respectively arranged at the limit positions at the two ends of the guide rail, so that the equipment is prevented from moving in the process. The power cable 4 provides power for the servo motor 12. The encoder cable 14 implements position signal feedback. The band-type brake cable 13 is used for motor band-type brake signal feedback.
As shown in fig. 7, which is a block schematic diagram of the main beam lifting module 20, the main beam lifting module 20 is configured to control the main beam lifting mechanism 200 to move along a third direction (Z axis), where the third direction (Z axis) is a vertical direction, so as to realize the lifting and lowering of the main beam 201.
As one embodiment, as shown in fig. 1, the number of the main beam lifting mechanisms 200 is 2, and the main beam lifting mechanisms 200 are respectively disposed at two ends of the main beam 201, the main beam lifting mechanisms 200 realize the lifting and lowering of the main beam 201 between the bases 101, and the lifting of the main beam 201 between the bases 101 adopts a conventional driving mode of a linear slide rail, a slider and a hydraulic cylinder.
The main beam lifting module 20 utilizes the grating ruler 23 to perform real-time position feedback, and the corresponding equipment action mechanism is the main beam lifting mechanism 200. The main beam lifting module 20 does not need to be matched with the pipe penetrating process action, and only needs to adjust the height of the main beam 201 of the equipment according to the length of the heat exchange pipe 801 before the pipe penetrating operation, so that the preparation is made for realizing vertical pipe penetrating.
Further, the main beam lifting module 20 further includes: servo hydraulic cylinder 22, hydraulic system 21, power cable 4 and control cable 5.
The servo hydraulic cylinder 22 and the hydraulic system 21 form a hydraulic servo system, and the action of the servo hydraulic cylinder 22 is accurately controlled through the combination of various valve groups and hydraulic elements, so that accurate positioning and double-cylinder synchronization can be realized. The servo hydraulic cylinder 22 feeds back position signals from the strip grating ruler 23. The power cable 4 provides power for the hydraulic system 21. The control cable 5 is used for transmitting control signals between the hydraulic system 21 and the servo hydraulic cylinder 22.
As shown in fig. 8, which is a block diagram of the carriage translation module 30, the carriage translation module 30 is used to control the carriage translation mechanism 300/carriage 301 to move along a second direction (Y-axis) which is perpendicular to and level with the first direction (X-axis).
As one embodiment, as shown in fig. 1, the number of the carriage translation mechanisms 300 is 1, and horizontal sliding of the carriage 301 on the main beam 201 is realized, and the carriage 301 slides on the main beam 201 by adopting a conventional driving mode of a guide shaft + a guide shaft sleeve + a hydraulic cylinder.
The carriage translation module 30 is configured to control the carriage translation mechanism 300 of the device to move along the second direction (Y-axis), and the corresponding device action mechanism is the carriage translation mechanism 300. Further, the carriage translation module 30 further includes: hydraulic cylinder 31, hydraulic system 21, inductive limit switch 32, power cable 4 and control cable 5.
The hydraulic cylinder 31 and the hydraulic system 21 are of conventional configuration. The two inductive limit switches 32 are respectively arranged at a first position ("1") and a second position ("2") of the bracket, and the first position ("1") and the second position ("2") are set to correspond to the positions of the tube plate holes of the adjacent columns on the heat exchanger 800 (the first direction is defined as a column, for example, the first column of tube plate holes and the second column of tube plate holes) in the second direction; the inductive limit switch 32 realizes accurate positioning and feedback of the position of the bracket 301 at the two positions. The power cable 4 provides a power source for the hydraulic system 21. The control cable 5 transmits control signals between the hydraulic system 21 and the hydraulic cylinder 31.
The carriage translation module 30 is required to coordinate with the poling process action to effect indexing of the carriage 301 in both the first ("1") and second ("2") positions and to provide position feedback.
Fig. 9 is a block diagram of the active roller module 40, and the active roller module 40 is used for controlling the start and stop of the governor motor 43 of the active roller set 401 in the guiding mechanism 400.
The active roller module 40 adopts the inductive switch 41 to perform signal feedback on the position of the heat exchange pipe 801, and completes corresponding process actions in cooperation with the PLC.
As one embodiment, as shown in fig. 1, 3 and 4, a tube-through guide chamber is provided in the guide mechanism 400, three rows of roller assemblies are provided in the chamber, a guide sleeve 403 is vertically provided between each row of roller assemblies, and the guide sleeve 403 is composed of a plurality of guide tubes which are through from top to bottom; each row of roller components consists of two roller groups which are arranged oppositely, each roller group is divided into a driving roller group 401 and a driven roller group 402, each of the upper row and the middle row of roller components consists of 2 driven roller groups 402, and each of the lower row of roller components consists of 1 driving roller group 401 and 1 driven roller group 402. The driving roller set 401 is formed by a plurality of driving rollers in parallel, is connected with the speed regulating motor 43 and is driven by the speed regulating motor 43, and the driven roller set 402 is formed by a plurality of driven rollers in parallel. The outer circumference of the roller is inwards sunken to form an arc-shaped groove, a roller channel hole is formed between the arc-shaped grooves of the two opposite rollers, and the roller channel hole and the guide pipe in the same vertical plane jointly form a pipe penetrating guide channel.
Further, the active roller module 40 further includes: a speed regulating motor 43 (provided with a frequency converter 42), an inductive switch 41, a power cable 4 and a control cable 5. The speed regulating motor 43 provides power for all the driving rollers of the driving roller group 401, and the equipped frequency converter 42 is used for regulating the speed of the speed regulating motor 43. The inductive switch 41 is mainly used for cooperating with the PLC to perform process control and transmitting some specific signals to the PLC. The power cable 4 provides power for the speed regulating motor 43. The control cable 5 is used for transmitting control signals between the speed regulating motor 43 and the frequency converter 42.
The active roller module 40 is used for controlling the start and stop of the speed regulating motor 43 of the active roller set 401 in the guiding mechanism 400, and the corresponding equipment action mechanism is the active roller set 401 of the guiding mechanism 400. The active roller module 40 need not be coordinated with the pipe threading process action, and need only be started and stopped at designated process steps.
Referring now to FIG. 10, there is shown a block diagram of a press-alignment module 50, which is used to control the extension and retraction of the platens of a press-alignment mechanism 500, of the press-alignment module 50.
As an embodiment, as shown in fig. 1, the leveling mechanism 500 is driven by a conventional pressing plate and a hydraulic cylinder, and the leveling mechanism 500 is composed of a pressing frame, a pressing plate, a guide rod, a guide sleeve and a hydraulic cylinder; the pressing frame is arranged on the bracket; the guide rod is arranged on the pressure plate; the guide sleeve is arranged on the pressing frame; the guide rod is matched with the guide sleeve for guiding; the pneumatic cylinder is installed on compressing tightly the frame, and the clamp plate is connected to the rod end of pneumatic cylinder, for the reciprocating of clamp plate provides power.
The press-alignment module 50 is used to control the extension and retraction of the press plates of the press-alignment mechanism 500, and the corresponding device action mechanism is the press-alignment mechanism 500/press plate. The tube head pressing and aligning process is realized by matching with the gantry walking module 10 without matching with the tube penetrating process action, and the process does not belong to the tube penetrating process and is mainly used for preparing the subsequent tube plate welding process.
Further, the flush module 50 further includes: hydraulic cylinder 31, hydraulic system 21 (with relief valve 51), power cable 4 and control cable 5. The hydraulic cylinder 31 and the hydraulic system 21 need to realize synchronization of 3 hydraulic cylinders 31 through combination of hydraulic valves and hydraulic elements, and realize overflow after the pressure of the hydraulic cylinder 31 reaches a specified value. The power cable 4 powers the hydraulic system 21. The control cable 5 transmits control signals between the hydraulic system 21 and the hydraulic cylinder 31.
As shown in fig. 11, which is a block diagram of the robot loading module 60, the robot loading module 60 controls the robot loading mechanism 600 for taking and loading the heat exchange tube 801.
As one embodiment, as shown in fig. 2, a manipulator feeding mechanism 600 is installed on the main beam 201, the manipulator feeding mechanism 600 uses a manipulator to carry a pneumatic fixture, 2 troughs 700 are also installed on the main beam 201, and the manipulator feeding mechanism 600 is responsible for grabbing the heat exchange tube 801 from the trough 700 and moving the heat exchange tube 801 to a position above the tube penetrating guide channel of the guide mechanism 400, so as to realize taking and feeding of the heat exchange tube 801.
Further, the manipulator feeding module 60 further includes: a robot control module 61 (including a robot unit), a pneumatic clamp control module 63, a remote control teach pendant 62, a power cable 4, and a control cable 5. The manipulator control module 61 and the pneumatic clamp control module 63 both adopt mature technologies in the market; the pneumatic clamp is used as an external shaft of the manipulator for control, and the pneumatic clamp control module 63 and the manipulator and manipulator control module 61 jointly form a manipulator system. The power cable 4 provides power for the manipulator system. The control cable 5 is used for transmitting control signals between the manipulator control module 61 and the pneumatic clamp control module 63.
The manipulator feeding module 60 adopts an external shaft function module of the manipulator to bring the pneumatic clamp control module 63 into the manipulator control module 61, so as to form linkage; and the offset instruction function in the manipulator control module 61 is adopted to realize multi-position continuous material taking and placing actions.
The manipulator feeding module 60 controls the manipulator feeding mechanism 600 to take and feed the heat exchange tube 801, and the corresponding device action mechanism is the manipulator feeding mechanism 600. The manipulator feeding module 60 needs to cooperate with the pipe threading process to realize the taking and feeding of the heat exchange pipe 801 by the manipulator feeding mechanism 600.
A control method of heat exchanger tube penetrating equipment is applied to the control system, and sequentially controls all modules by using a PLC according to a certain process flow, and the modules respectively control all action mechanisms of the tube penetrating equipment to complete a tube penetrating process of a heat exchanger 800. The specific control method of the PLC for each module and each action mechanism is as follows:
the workstation PLC1 performs calculation according to the heat exchanger 800 data and the environmental data (pit depth), obtains the most reasonable operation height data of the main beam 201 on the pipe penetrating equipment, and transmits the height data to the main beam lifting module 20, and the main beam lifting module 20 controls the main beam lifting mechanism 200 to move, so that the main beam 201 reaches the height.
The workstation PLC1 calculates according to the heat exchanger 800 data and the environmental data (pit position), obtains the first direction coordinate of the best operation of the pipe penetrating equipment, transmits the coordinate data to the gantry traveling module 10, and the gantry traveling module 10 controls the movement of the machine base moving mechanism 100 to make the pipe penetrating equipment reach the coordinate.
The workstation PLC1 switches to a manual operation mode, the manual operation handheld operation box performs immediate operation on the tube penetrating device, adjusts the bracket translation mechanism 300 to a first position ("1") and locks the bracket translation mechanism 300, adjusts the base moving mechanism 100 to move the tube penetrating device to a position where the tube penetrating guide channel on the guide mechanism 400 coincides with a tube plate hole (for example, a first row and a first column of tube plate holes) on the heat exchanger 800, adjusts the base moving mechanism 100 to move the tube penetrating device to a position where the tube penetrating guide channel coincides with a tube plate hole (for example, a third row and a first column of tube plate holes) on the heat exchanger 800, which is in the same column and adjacent to the tube plate hole, an operation signal is transmitted to the gantry traveling module 10 through the workstation PLC1, and the workstation PLC1 records the coordinates of the two positions as a first coordinate (first point) and a second coordinate (second point).
The workstation PLC1 switches to the automatic mode, and the gantry traveling module 10 controls the base moving mechanism 100 to move, so that the pipe penetrating device returns to the first coordinate (firstpoint).
The work station PLC1 transmits the action locking command signal to the main beam lifting module 20 and the gantry traveling module 10 to lock the corresponding mechanism; meanwhile, the start signal is transmitted to the active roller module 40, so that the active roller of the active roller group 401 rotates at a set speed.
The workstation PLC1 transmits a start signal to the manipulator loading module 60, so that the manipulator loading mechanism 600 performs a series of actions according to a set path and program, thereby implementing the material taking and loading process.
When the induction switch 41 in the driving roller module 40 induces the heat exchange pipe 801 to enter, the signal is transmitted to the workstation PLC1, and the workstation PLC1 transmits a command signal to the manipulator feeding module 60, so that the manipulator feeding mechanism 600 is reset and the next taking and feeding actions are performed according to the set offset.
When the inductive switch 41 in the active roller module 40 senses that the heat exchange tube 801 leaves, a signal is transmitted to the workstation PLC1, the workstation PLC1 transmits an operation signal to the gantry walking module 10 to control the base moving mechanism 100 to move, so that the tube penetrating equipment reaches a second coordinate (second point), and the tube penetrating process movement and control are repeated.
After all the pipe penetrating actions of the first row (the first direction is defined as a row) of holes are completed, the PLC1 transmits command signals to the gantry walking module 10 and the bracket translation module 30, the corresponding mechanisms are unlocked, the bracket 301 is moved to the second position (2) and locked, and the machine base 101 is moved to the corresponding position above the second row of holes according to a set distance and locked.
The workstation PLC1 transmits a command signal to the manipulator feeding module 60, so that the manipulator feeding mechanism 600 performs secondary hole arrangement feeding according to a predetermined path and program, the subsequent tube penetrating process actions and control are similar to those of the primary hole arrangement, and the manipulator feeding mechanism 600 performs cyclic material taking and feeding actions according to a fixed offset until the secondary hole arrangement completes the tube penetrating operation.
The process actions and control analogizes to cover the through pipes of all hole sites of the heat exchanger 800.
After all the tubes are penetrated, the workstation PLC1 transmits a starting signal to the gantry walking module 10 and the pressing and aligning module 50 respectively, a second direction is defined as a row, the machine base 101 is moved to the position above the first row of holes, the pressing and aligning mechanism 500 is started to press and align the tube heads of the heat exchange tubes 801, then the machine base 101 is moved to the position above the second row of holes, the pressing and aligning mechanism 500 is started to press and align the tube heads of the heat exchange tubes 801, and the like, so that the pressing and aligning of the tube heads of all the heat exchange tubes 801 are completed.
As one example, the following provides a complete process flow of a specific process, and the following process flow applies the heat exchanger tube-penetrating equipment control system and the control method of the invention.
STEP01 production preparation
1. The PLC determines the specification of a heat exchange tube 801 according to a production plan;
2. resetting all actions of the device;
3. manually placing the heat exchange tubes 801 meeting the specification into the trough 700;
4. the heat exchanger 800 is manually placed in the pit and adjusted to a prescribed attitude.
STEP02 bit-seeking
1. The PLC determines the working height of the equipment according to the height of the heat exchanger 800 and the depth of the pit, and starts the main beam lifting mechanism 200 to enable the main beam 201 of the equipment to reach the working height of the equipment;
2. the PLC determines the horizontal coordinate of the equipment according to the diameter of the heat exchanger 800 and the position in the pit, and the PLC starts the equipment base moving mechanism 100 to enable the equipment to reach the horizontal coordinate;
3. manually judging the posture of the heat exchanger 800, starting the bracket translation mechanism 300, and locking the bracket 301 after being positioned at the position of '1';
4. the manual fine-tuning device enables the device-assigned pipe-penetrating guide channel to coincide with a first pipe plate hole (a first direction is defined as a row, a second direction is defined as a row, for example, a first row and a first column of pipe plate holes) assigned by the heat exchanger 800, and a coordinate of the first pipe plate hole assigned by the heat exchanger 800 is recorded as a first coordinate (first point);
5. the manual fine-tuning device enables the device-specified tube-penetrating guide channel to coincide with a second tube plate hole (for example, a third row of first column tube plate holes) specified by the heat exchanger 800, and records the coordinate of the second tube plate hole specified by the heat exchanger 800 as a second coordinate (second point);
6. the device automatically returns to the first coordinate (first point).
STEP03 first row first through pipe
1. The equipment locks the main beam lifting mechanism 200 and the bracket translation mechanism 300 at a first coordinate (first point), and starts a motor of a driving roller train 401;
2. the manipulator carries a pneumatic clamp and moves to the first vacant position of the material groove 700 to take materials;
3. the manipulator moves above the pipe penetrating guide channel, so that the bottom of the heat exchange pipe 801 is opposite to the pipe penetrating guide channel;
4. the pneumatic clamp is opened by 0.5mm, so that the heat exchange tube 801 enters the upper row roller assemblies in the tube penetrating guide channel due to the dead weight, the manipulator and the pneumatic clamp keep the existing postures at the moment, and the heat exchange tube 801 continues to move downwards;
5. when the heat exchange tube 801 enters the lower row of roller assemblies in the tube penetrating guide channel due to self weight, the inductive switch 41 at the position transmits a signal to the PLC, and the pneumatic clamp is completely opened and reset;
6. the heat exchange tube 801 continues to pass through the heat exchanger 800 downwards due to the clamping and self-weight mixing action of the driving roller set 401, and when the heat exchange tube 801 is separated from the inductive switch 41, the inductive switch 41 transmits a signal to the equipment PLC.
STEP04 first row second poling
1. Starting the base moving mechanism 100 to move the device to a second coordinate (second point) and lock the device, and starting the motor of the driving roller train 401;
2. the manipulator carries a pneumatic clamp and moves to the second vacant position of the material groove 700 to take materials;
3. the manipulator automatically moves to the position above the pipe penetrating guide channel, so that the bottom of the heat exchange pipe 801 is opposite to the pipe penetrating guide channel;
4. starting the clamp to open by 0.5mm, so that the heat exchange tube 801 enters the upper row roller assembly in the tube penetrating guide channel due to self weight, the manipulator and the pneumatic clamp keep the existing postures at the moment, and the heat exchange tube 801 continues to move downwards;
5. when the heat exchange tube 801 enters the lower row of roller assemblies in the tube penetrating guide channel due to self weight, the inductive switch 41 at the position transmits a signal to the PLC, and the pneumatic clamp is completely opened and reset;
6. the heat exchange tube 801 continues to pass through the heat exchanger 800 downwards due to the clamping and self-weight mixing action of the driving roller set 401, and when the heat exchange tube 801 is separated from the inductive switch 41, the inductive switch 41 transmits a signal to the equipment PLC.
STEP05 first row other through tubes
1. The rest penetrating pipes in the first row are sequentially processed according to STEPs 03 and 04;
2. after the rest of the first row of tubes are penetrated, the locking of the bracket translation mechanism 300 is released, the mechanical arm and the pneumatic clamp are reset, and the rest of the action positions are unchanged.
STEP06 first poling pipe of inferior row
1. Starting the bracket translation mechanism 300 to enable the bracket 301 to be locked after being located at the position 2;
2. starting the base moving mechanism 100 to move the equipment to the corresponding position;
3. the manipulator carries a pneumatic clamp and moves to the Nth vacancy of the trough 700 (in sequence, recursion) to take materials;
4. the rest actions are the same as STEP 03/04/05;
5. the columns operate as above.
STEP07 press flush
1. After all the actions are finished, all the induction switches 41 can not detect the heat exchange tubes 801, and then the locking of the base moving mechanism 100 is released;
2. the equipment moves to the position of the first row of heat exchange tubes 801, and a hydraulic cylinder of the pressing and aligning mechanism 500 is started to enable the whole pressing plate to press and align the heat exchange tubes 801;
3. the line-pressing alignment action is the same as above.
STEP08 reset
1. Resetting all actions of the equipment;
2. the PLC stores the operation data;
3. the PLC is ready to enter the next job heat exchanger 800 data.
In the embodiments provided by the present invention, it should be understood that the disclosed system and method can be implemented in other ways. The system and method embodiments described above are illustrative only, and the flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of apparatus, methods and computer program products according to embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems which perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
In addition, each functional module in the embodiments of the present invention may be integrated together to form an independent part, or each module may exist separately, or two or more modules may be integrated to form an independent part. The functions, if implemented in the form of software functional modules and sold or used as a stand-alone product, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present invention or a part thereof, which essentially contributes to the prior art, can be embodied in the form of a software product, which is stored in a storage medium and includes several instructions for causing a computer device (which may be a personal computer, an electronic device, or a network device) to execute all or part of the steps of the method described in the embodiments of the present disclosure. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk or an optical disk, and other various media capable of storing program codes.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element. Furthermore, the terms "first location," "second location," "first coordinate," "second coordinate," "1," "2," "first point," "second point," and the like are used solely to distinguish one from another, and are not to be construed as indicating or implying relative importance.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications therefrom are within the scope of the invention.
Claims (9)
1. The utility model provides a heat exchanger poling equipment control system which characterized in that:
the pipe penetrating equipment comprises a gantry structure formed by two parallel bases and a main beam, wherein a bracket is arranged on the main beam, and the pipe penetrating equipment also comprises a base moving mechanism, a main beam lifting mechanism, a bracket translation mechanism, a guide mechanism and a manipulator feeding mechanism;
the base moving mechanism drives the base to move along a first direction, and the first direction is a horizontal direction; the main beam lifting mechanism drives the main beam to move along a third direction, and the third direction is a vertical direction; the bracket translation mechanism drives the bracket to move on the main beam along a second direction, and the second direction is perpendicular to the first direction and is in the same horizontal plane with the first direction; the manipulator feeding mechanism is arranged on the main beam, and a trough for storing the heat exchange tubes is further arranged on the main beam; the guide mechanism is arranged on the bracket, a plurality of pipe penetrating guide channels surrounded by roller components are arranged on the guide mechanism, each roller component comprises a driving roller group, and the driving roller groups are driven by a motor;
the control system comprises a gantry walking module, a main beam lifting module, a bracket translation module, a driving roller module, a manipulator feeding module and a workstation PLC (programmable logic controller);
the gantry traveling module controls the movement of the base moving mechanism, the main beam lifting module controls the movement of the main beam lifting mechanism, the bracket translation module controls the movement of the bracket translation mechanism, and the active roller module controls the starting and stopping of the active roller group motor; the manipulator feeding module controls the manipulator feeding mechanism to be used for taking and feeding the heat exchange tube; the workstation PLC is used for storing and acquiring information, executing logical operation and sequence control instructions in software and controlling each module to realize process actions specified by the system; the pipe penetrating equipment further comprises a pressing and aligning mechanism, the pressing and aligning mechanism is arranged on the guide mechanism, the control system further comprises a pressing and aligning module, and the pressing and aligning module controls the pressing plate of the pressing and aligning mechanism to extend and retract.
2. The heat exchanger poling equipment control system of claim 1, characterized in that: the bracket is provided with two induction type limit switches which are respectively arranged at a first position and a second position of the bracket; defining a first direction as a column, wherein the first position and the second position are set to correspond to the positions of the tube plate holes of the adjacent columns on the heat exchanger in the second direction; the bracket translation module adopts the inductive limit switch to realize the position feedback of the bracket on the two positions.
3. The heat exchanger poling equipment control system of claim 1, characterized in that: the active roller module adopts an inductive switch to perform signal feedback on the position of the heat exchange pipe and is matched with the PLC to complete corresponding process actions.
4. The heat exchanger poling equipment control system of claim 1, characterized in that: the workstation PLC adopts the PLC as a main control carrier and the operation screen as a man-machine interaction carrier, realizes sequential control of all modules and performs manual intervention when needed.
5. A control method of heat exchanger tube penetrating equipment is characterized by comprising the following steps: the control system applied to any one of claims 1 to 4, wherein the modules are sequentially controlled by using a PLC according to a certain process flow, and the modules respectively control the action mechanisms of the tube penetrating equipment to complete the tube penetrating process of the heat exchanger.
6. The heat exchanger pipe penetrating equipment control method according to claim 5, characterized in that: the method comprises the following steps:
step 1: the workstation PLC calculates according to the heat exchanger data and the environment data to obtain the most reasonable third direction height data of the main beam on the pipe penetrating equipment and the most reasonable first direction coordinate data of the machine base, and respectively transmits the data to the main beam lifting module and the gantry traveling module to enable the main beam and the machine base to reach the height and the coordinate;
step 2: the workstation PLC is switched to a manual operation mode, the bracket translation mechanism is adjusted to a first position and locked, the base moving mechanism is adjusted to a corresponding position to determine the position coordinates of two adjacent tube plate holes in the first direction, and the two determined position coordinates are recorded as a first coordinate and a second coordinate by the workstation PLC;
and step 3: the workstation PLC is switched to an automatic mode, and the gantry walking module controls the base moving mechanism to act so that the pipe penetrating equipment returns to the first coordinate;
and 4, step 4: the workstation PLC transmits signals to the main beam lifting module, the gantry walking module, the driving roller module, the manipulator feeding module and the bracket translation module, the main beam lifting module controls the main beam lifting mechanism to be locked, the gantry traveling module controls the machine base moving mechanism to enable the machine base to move between a first coordinate and a second coordinate according to a set track, the active roller module controls the start and stop of the motor of the active roller group, an inductive switch on the active roller module feeds back the position of the heat exchange pipe, the manipulator feeding module controls the manipulator feeding mechanism to carry out heat exchange tube taking and feeding actions according to the set offset, and the bracket translation module controls the bracket translation mechanism to enable the bracket to move between the first position and the second position according to a set track, so that pipe penetration of all hole sites of the heat exchanger is completed.
7. The heat exchanger pipe penetrating equipment control method according to claim 6, characterized in that: the specific method for determining the positions of the first coordinate and the second coordinate in the step 2 is as follows: and adjusting the base moving mechanism to enable the pipe penetrating equipment to move to the position where the pipe penetrating guide channel on the guide mechanism is superposed with the pipe plate hole on the heat exchanger, adjusting the base moving mechanism to enable the pipe penetrating equipment to move to the position where the pipe penetrating guide channel is superposed with the pipe plate hole on the heat exchanger in the same row and adjacent pipe plate holes, transmitting an operation signal to the gantry traveling module through the workstation PLC, and recording the coordinates of the two positions as a first coordinate and a second coordinate by the workstation PLC.
8. The method for controlling the tube penetrating equipment of the heat exchanger as claimed in claim 6, wherein: the specific control method for the heat exchanger tube penetration in the step 4 comprises the following steps:
after the pipe penetrating equipment returns to the first coordinate, the workstation PLC transmits signals to the main beam lifting module and the gantry walking module to lock corresponding mechanisms, transmits the signals to the driving roller module to start a motor of the driving roller group, and simultaneously transmits the signals to the manipulator feeding module to realize the heat exchange pipe taking and feeding processes; the induction switch in the active roller module feeds the position of the heat exchange tube back to the workstation PLC and transmits signals to the manipulator feeding module and the gantry traveling module, so that the manipulator feeding mechanism is reset and carries out the next material taking and feeding actions according to the set offset, the base reaches the second coordinate, and the tube penetrating process actions and control are repeated;
the workstation PLC transmits signals to the gantry walking module and the bracket translation module after all pipe penetrating actions of a first row of holes are finished, the corresponding mechanism is unlocked, the bracket is moved to a second position and locked, the machine base is moved to a position above a second row of holes according to a set distance, and the pipe penetrating process actions and control are repeated until the second row of holes finish the pipe penetrating work;
and performing the process action and the control analogize to cover the through pipes of all hole sites of the heat exchanger.
9. The method for controlling the tube penetrating equipment of the heat exchanger as claimed in claim 6, wherein: after all the tubes are penetrated, the workstation PLC respectively transmits starting signals to the gantry walking module and the pressing and aligning module, defines a second direction as a row, moves the machine base to the position above the first row hole, starts the pressing and aligning mechanism to press and align the heat exchange tube heads, then moves the machine base to the position above the second row hole, starts the pressing and aligning mechanism to press and align the heat exchange tube heads, and the like, so that the pressing and aligning of all the heat exchange tube heads are completed.
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Effective date of registration: 20230815 Address after: 168 Fazhan Avenue, Sanshui Demonstration Zone, Xishui County, Huanggang, Hubei Province, 438200 Patentee after: Hubei Kaibisi Intelligent Equipment Co.,Ltd. Address before: Room 02, 4th floor, building 1, phase III, international enterprise center, special 1, Guanggu Avenue, Donghu New Technology Development Zone, Wuhan City, Hubei Province, 430000 Patentee before: WUHAN KEMPINSH POWER EQUIPMENT CO.,LTD. |