CN112025965B - Embedded control system and method for vertical radial extrusion pipe manufacturing equipment - Google Patents

Embedded control system and method for vertical radial extrusion pipe manufacturing equipment Download PDF

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Publication number
CN112025965B
CN112025965B CN202010842673.7A CN202010842673A CN112025965B CN 112025965 B CN112025965 B CN 112025965B CN 202010842673 A CN202010842673 A CN 202010842673A CN 112025965 B CN112025965 B CN 112025965B
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module
unit
position sensor
detection
control
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CN112025965A (en
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肖艳军
李泽玉
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Jiangsu Keruide Intelligent Control Automation Technology Co ltd
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Jiangsu Keruide Intelligent Control Automation Technology Co ltd
Hebei University of Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B21/00—Methods or machines specially adapted for the production of tubular articles
    • B28B21/52—Methods or machines specially adapted for the production of tubular articles by extruding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B28B17/0063—Control arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B28B17/0063—Control arrangements
    • B28B17/0081—Process control

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Automation & Control Theory (AREA)
  • Control Of Conveyors (AREA)

Abstract

The invention relates to an embedded control system of vertical radial extrusion pipe manufacturing equipment, which adopts a microprocessor as a main control chip in the system structure, adopts the field bus technology of the microprocessor to connect a main control subsystem, a man-machine interaction subsystem and a fault diagnosis subsystem, adopts respective control systems as hardware supports, adopts the wireless communication technology to send data acquired by the hardware system to a cloud platform, and can log in the cloud platform at a client side for remote real-time monitoring. The embedded technology is adopted to take the microcontroller system as a control system, for example, the single chip microcomputer STM32 is taken as a main control chip, so that the automation of the production process is realized, the production efficiency is improved, and the control precision is improved. The newly added modules and the control system of the system can be directly subjected to data communication, the reconstruction, upgrading and reconstruction of the control system are facilitated, and the unnecessary functional modules can be removed without influencing the operation control of the main control subsystem.

Description

Embedded control system and method for vertical radial extrusion pipe manufacturing equipment
Technical Field
The invention belongs to the technical field of automatic production of vertical radial extrusion pipe-making equipment, and particularly relates to an embedded control system and method of vertical radial extrusion pipe-making equipment.
Background
With increasingly accelerated urbanization development in China, underground water channels in urban construction are also increasingly emphasized, the market demand of cement pipes is increasing, and high-efficiency pipe manufacturing equipment and process flow become more and more important. At present, a domestic independently-researched vertical radial extrusion cement pipe making machine starts late and is low in automation level. Along with the intelligent manufacturing of China, the vertical radial extrusion cement pipe making machine also needs an intelligent production control system, and the automation level of the pipe making machine is improved.
The invention provides an automatic production system of a vertical radial extrusion pipe making machine and a use method thereof, which are disclosed in the Chinese invention patent with the patent number of 201810355274.0. The paper vertical type radial extrusion type cement pipe production real-time monitoring system is designed by taking a PLC as a control core, realizing connection between a data sending end and a data receiving end by using an industrial router, and performing real-time monitoring by logging in the router. However, the cost of the PLC in the method and the control system is high, the early warning system is simple to set, and the real-time monitoring of the data transmission of each device needs to be realized through one computer, so that partial function and cost waste is caused.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides an embedded control system and method of vertical radial extrusion pipe-making equipment, which take an embedded control technology as a core, simultaneously combine the interface and the information processing technology of the current embedded system, integrate various functional modules of a cement pipe into a whole, can meet the control requirements of the vertical radial extrusion pipe-making equipment, and have the characteristics of high control precision, strong flexibility, high intelligence and the like.
In order to achieve the above object, the invention adopts the technical scheme that: an embedded control system of vertical radial extrusion pipe manufacturing equipment is characterized in that a microprocessor is adopted as a main control chip in the system structure, a main control subsystem, a man-machine interaction subsystem and a fault diagnosis subsystem are connected by adopting the field bus technology of the microprocessor, the respective control systems are used as hardware supports, the wireless communication technology is adopted, data acquired by the hardware systems are sent to a cloud platform, and meanwhile, a client can log in the cloud platform for remote real-time monitoring; in particular, the amount of the solvent to be used,
the main control subsystem comprises a self-detection module, an embedded control module, a sensor module and an execution module, wherein the sensor module is mainly used for carrying out real-time positioning detection, equipment operation parameter acquisition and system safety parameter acquisition on control execution equipment in the process of a pipe manufacturing process; the embedded control module mainly completes the motor control, hydraulic control and manufacturing process flow of system operation equipment and communication with other subsystems; the execution module mainly completes the driving and speed regulation of each mechanical device;
the fault detection subsystem comprises a storage module, a fault diagnosis module and a wireless communication module; the fault diagnosis module finishes fault diagnosis by a neural network algorithm according to the acquired data information, the storage module stores the data information and fault information acquired by the fault diagnosis module, and the wireless communication module wirelessly and remotely transmits the data information and fault information acquired by the fault diagnosis module; the human-computer interaction subsystem comprises a human-computer interaction module, a field touch screen and a wireless communication module;
the embedded control module acquires data of the sensor module and the self-detection module, and simultaneously outputs a control instruction to the execution module; the embedded control module is in two-way communication with the fault diagnosis module and the human-computer interaction module, the storage module is in two-way communication with the fault diagnosis module, the fault diagnosis module and the human-computer interaction module are in communication with the cloud platform through corresponding wireless communication modules, the cloud platform is in communication with the client side at the same time, real-time data of the fault diagnosis module and working data of each process parameter and corresponding devices of the vertical radial extrusion pipe manufacturing equipment can be displayed through the client side, the cloud platform can store data information transmitted by each subsystem, and the human-computer interaction module is in mutual communication with the field touch screen at the same time.
The embedded control module comprises a downloading unit, a power supply unit, a minimum system unit, a field bus unit, a detection input unit, a loading output unit, an unloading output unit, a socket output unit, a straight section output unit and a socket output unit; a workbench position sensor, a power box initial position sensor, a power box working position sensor, a feeding device initial position sensor, a feeding device working position sensor and a feeding belt conveyor current detection in the sensor module are all connected with a detection input unit in the embedded control module; the download unit, the power supply unit and the detection input unit are connected with the minimum system unit; the minimum system unit is electrically connected with the loading output unit, the unloading output unit, the socket output unit, the straight section output unit and the socket output unit; the field bus unit is bidirectionally connected with the minimum system unit and is bidirectionally connected with the self-detection unit in the self-detection module; the loading output unit is connected with a workbench, a power box device and a feeding device in the execution module and is used for loading the cement pipe to a working position; the bell mouth output unit is connected with a feeding belt machine, a vibration device and a feeding device in the execution module and is used for manufacturing a bell mouth of the cement pipe; the straight section output unit is connected with a feeding belt conveyor, a power box device, an outer mould air receiving pile and a forming head in the execution module and is used for manufacturing a straight section of the cement pipe; the socket output unit is connected with a grinding disc in a feeding device in the execution module and is used for manufacturing a socket of a cement pipe; the unloading output unit is connected with a workbench, a power box device and a feeding device in the execution module and is used for removing the cement pipe from a working position;
the power supply unit is used for supplying power to the system, takes external 24V direct current voltage as input and can output 12V, 5V and 3.3V voltage; the minimum system unit comprises a clock circuit, a reset circuit and a control chip, wherein the control chip takes an STM32F4 chip as a core; the field bus unit comprises various communication interfaces including a CAN bus, a 485 bus, a 232 bus, an SPI bus and WIFI, so that the field bus unit CAN be conveniently communicated with other functional modules; the detection input unit is used for detecting the working state of a sensor in the sensor module and comprises switching value input and analog value input; the loading output unit, the unloading output unit, the socket output unit, the straight section output unit and the socket output unit all comprise a plurality of output circuits, the output circuits are identical in structure, and the output circuits are connected with corresponding peripheral devices, so that the minimum system unit controls and drives the execution module.
One output circuit of the loading output unit mainly comprises an optocoupler TLP2301, a PMOS tube and a peripheral circuit, is used for driving peripheral devices, and supports 24V pulse output with the maximum of 100 KHz; specifically, an Anode end of the optocoupler TLP2301 is directly connected to VCC3.3V, a Cathode of the optocoupler TLP2301 is connected to a resistor R1, a resistor R1 is connected to an I/O port of a control chip in the minimum system unit and is marked as GPIOx, an output terminal Collector of the optocoupler TLP2301 is connected to AGND, another output terminal Emitter of the optocoupler TLP2301 is connected to two resistors R2 and R3 which are connected in series, the resistor R2 is connected to 24V voltage, the resistor R3 is connected to a G pole of a PMOS tube, an S pole of the PMOS tube is connected to a 24V power supply, and a D pole of the PMOS tube is marked as an output terminal, is Yout, and is connected to GND through a current limiting resistor R4 and an output indicator light LED.
The self-detection module is mainly used for detecting the execution mechanism before the system starts to operate, so that errors in the operation of equipment are prevented; the self-detection module comprises a hydraulic oil position sensor, a hydraulic oil temperature sensor, a current detection unit, a self-detection unit, a hydraulic indicator lamp, a constant temperature device and a current indicator lamp; the hydraulic pressure is mainly applied to driving the power box device; the hydraulic oil level sensor is arranged in a standard port inner cylinder position sensor pin mode of a hydraulic cylinder for driving the power box device to work and is used for detecting the position of a hydraulic oil level and ensuring that an oil pump supplies oil normally; the hydraulic oil temperature sensor is arranged in the hydraulic oil tank and used for detecting the temperature of hydraulic pressure, so that the influence on normal use and the reduction of service life caused by overhigh temperature is prevented; the current detection is arranged on a power supply circuit unit in the embedded control module and is used for detecting the power supply condition; the self-detection unit is used for collecting sensor data and comparing the sensor data with sensor data set by a system to make a next step instruction; the self-detection unit is STM32F4 series; the self-detection module and the embedded control module carry out data transmission through a CAN bus and a field bus unit; the hydraulic indicator light is used for displaying whether the hydraulic oil level is normal or not and is directly connected with the self-detection unit; the constant temperature device is arranged on the hydraulic transmission pipeline and comprises a heating machine and a cold oil machine, and is used for ensuring the normal temperature of hydraulic oil and ensuring the oil supply efficiency.
The fault diagnosis module comprises a fault diagnosis control unit, an acquisition unit and a bus unit and is used for carrying out data analysis, operation record and fault information transmission on the operation equipment; the acquisition unit is connected with the fault diagnosis control unit; the fault diagnosis control unit is connected with the bus unit and is electrically connected with the embedded control module through the bus unit; the acquisition unit comprises starting time, shutdown time, motor current detection, belt conveyor rotating speed detection, a power box initial position sensor, a feeding device initial position sensor, a workbench position sensor, a power box working position sensor, a feeding device working position sensor, hydraulic pressure detection and forming head vibration detection; the fault diagnosis control unit adopts a DSP chip to execute a fault diagnosis neural network algorithm; the bus unit comprises a 232 bus interface, a wireless communication interface, a CAN bus interface, a 485 bus interface and an SPI bus interface and is used for conveniently connecting other embedded systems for communication; the fault diagnosis control unit is connected with the storage module and the wireless communication module.
An embedded control method of vertical radial extrusion pipe manufacturing equipment uses the control system, and comprises the following specific processes:
1) when a start button is pressed, a self-detection module in the main control subsystem starts to detect the position of hydraulic oil, the temperature of the hydraulic oil and the current, so that the oil supply of an oil pump is normal, the oil temperature is between 20 and 60 ℃, and the power supply is normal; meanwhile, each rolling wheel of the mechanical power head is flexibly rotated by manual inspection, and other moving parts are free from loosening and have no stagnation; if no abnormity exists, the self-detection module communicates with the embedded control module through the CAN bus to start preparation work; meanwhile, the main control subsystem detects whether the fault detection subsystem is connected or not, and if not, the partial function brake shielding is carried out; the main control subsystem detects whether the human-computer interaction subsystem is connected, if not, the function of the main control subsystem is braked and shielded, and if so, various signals can be displayed on a field touch screen in the human-computer interaction subsystem;
2) when the self-detection module detects that the data is normal, the embedded control module in the main control subsystem starts to work; the embedded control module starts to detect the position states of the power box initial position sensor, the feeding device initial position sensor, the workbench position sensor, the power box working position sensor and the feeding device working position sensor through the detection input unit; when the project is normal, the minimum system unit in the embedded control module starts to control the workbench, the power box device and the feeding device through the loading output unit; preparing to start tube making;
3) after loading is finished, the system carries out socket part manufacturing on the cement pipe; the minimum system in the embedded control module starts to control the feeding belt conveyor, the feeding device and the vibrating device through the bellmouth output unit;
4) after the socket part is manufactured, the system enters the straight section part of the cement pipe for manufacturing; the minimum system in the embedded control module starts to control the feeding belt conveyor, the power box device, the outer mould air-receiving pile and the forming head through the straight-section output unit;
5) after the straight section part is manufactured, the system enters the socket part of the cement pipe for manufacturing; the minimum system in the embedded control module starts to detect a working position sensor of the feeding device through the detection input unit, if the detection is normal, the minimum system unit controls a grinding port disc in the feeding device through the socket output unit, and the socket of the grinding port disc is smoothed and capped;
6) after the socket part is manufactured, the system enters an unloading process; the embedded control module starts to detect the position states of the power box initial position sensor, the feeding device initial position sensor, the workbench position sensor, the power box working position sensor and the feeding device working position sensor through the detection input unit; when the project is normal, the minimum system unit in the embedded control module starts to control the workbench, the power box device and the feeding device through the unloading output unit, and the cement pipe is placed at a designated position;
7) when an abnormality occurs, the system enters a fault mode, all execution modules of the system keep current positions, the feeding belt conveyor stops feeding, if the main control subsystem is connected with the man-machine interaction subsystem, a field touch screen gives an alarm when the fault occurs, and current system data are transmitted to the cloud platform through the wireless communication module, so that remote real-time alarm is realized; if the main control subsystem is connected with the fault detection module, the fault detection subsystem acquires start-up time, shut-down time, motor current detection, belt conveyor rotating speed detection, a power box initial position sensor, a feeding device initial position sensor, a workbench position sensor, a power box working position sensor, a feeding device working position sensor, hydraulic pressure detection and forming head vibration detection information in real time, if a fault occurs, the fault detection subsystem is communicated with the main control subsystem and the man-machine interaction subsystem through a CAN bus, simultaneously stores the states and fault time of all collected data, judges fault information and transmits the fault information to the cloud platform through the wireless communication module, and data of the cloud platform is displayed in real time in a client side to realize remote fault monitoring; and under the condition that the system is normally stopped, each execution module is recovered to the initial position, and the system enters a stopped state.
The invention has the following beneficial effects:
1. the invention adopts the embedded technology to take the microcontroller system as a control system, for example, the single chip microcomputer STM32 as a main control chip, realizes the automation of the production process, improves the production efficiency and improves the control precision.
2. The invention carries out unitized decomposition on the manufacturing process of the cement pipe, thereby more conveniently controlling the manufacturing process of the pipe and improving the production quality.
3. According to the invention, the current detection of the feeding belt conveyor is added in the sensor module as the input in the PID control, the closed-loop control of the feeding belt conveyor is realized by adopting a fuzzy PID algorithm, the proportional coefficient, the integral coefficient and the differential coefficient of a fuzzy PID controller can be adjusted in a self-adaptive manner according to different parameters such as the water content and the average particle size of materials, the material injection speed of the feeding belt conveyor is further adjusted, and the blocking of the rotation of a feeding device caused by the overhigh material injection speed can be effectively avoided.
4. The intelligent human-computer interaction system is provided with the intelligent human-computer interaction subsystem, the touch screen and the wireless communication module, so that the operation condition of the equipment can be observed on site in real time, the data can be transmitted and stored remotely through the wireless communication module, and the safety early warning can be performed on the operating equipment more intelligently.
5. The invention is provided with the self-detection module, can carry out self-detection, detects the oil supply and power supply current of each part before the equipment runs, and prevents the fault when the equipment is started.
6. The invention is designed with an output circuit, so that the microcontroller can control the large voltage (24V) required by the execution equipment through the small voltage, the control efficiency of the system is improved, and the possibility is provided for embedded control.
7. The system is provided with a fault diagnosis subsystem, acquires and analyzes fault acquisition parameters, sends fault information to a cloud platform through a wireless communication module to realize remote fault diagnosis, uses a neural network algorithm as a fault diagnosis algorithm, and communicates with a main control subsystem and a human-computer interaction subsystem by using an embedded CAN interface.
8. The invention is provided with various embedded interfaces, such as a CAN bus, a 485 bus, a 232 bus and an SPI bus, CAN directly carry out data communication on a module newly added to the system and a control system, is beneficial to reconstruction, upgrade and reconstruction of the control system, CAN remove unnecessary functional modules (such as a fault diagnosis subsystem or other functional modules added by external upgrade and reconstruction) and does not influence the operation control of a main control subsystem, and has the advantage of embodying the embedded cuttability and reconfigurability.
Drawings
FIG. 1 is a block diagram of the control system of the present invention;
FIG. 2 is a mechanical structural illustration of the system of the present invention;
FIG. 3 is a block diagram of the main control subsystem of the present invention;
FIG. 4 is a block diagram of the fault diagnosis system of the present invention;
FIG. 5 is a diagram of an output circuit of an output unit according to the present invention
In the figure, 1 is a main control subsystem, 2 is a fault detection subsystem, 3 is a human-computer interaction subsystem, and 4 is a data storage terminal; 5-workbench position sensor, 6-workbench, 7-die, 8-feeding device, 9-feeding lifting device, 10-feeding device working position sensor, 11-forming head, 12-feeding device initial position sensor, 13-feeding belt machine, 14-funnel, 15-power box working position sensor, 16-bracket, 17-power box lifting device, 18-power box device, 19-power box initial position sensor, 20-outer die air-receiving pile, 21-vibration device and 22-transmission device; 23-self-detection module, 24-sensor module, 25-embedded control module, 26-execution module, 27-acquisition unit, 28-fault diagnosis control unit, 29-bus unit; 30-minimum system unit, 31-field bus unit, 32-detection input unit, 33-loading output unit, 34-unloading output unit, 35-socket output unit, 36-straight section output unit, 37-socket output unit, 38-downloading unit and 39-power supply unit;
Detailed Description
The invention is further described below with reference to the figures and examples.
Referring to fig. 1, which shows a general structural block diagram of an automated production control system according to an embodiment of the present invention, a control method for an embedded technical vertical radial extrusion pipe-making device includes a main control subsystem 1, a fault detection subsystem 2, a human-computer interaction subsystem 3, and a data storage terminal 4.
The main control subsystem 1 comprises a self-detection module, an embedded control module, a sensor module and an execution module, wherein the sensor module mainly has the functions of carrying out real-time positioning detection, equipment operation parameter acquisition, system safety parameter acquisition and the like on control execution equipment in the process of a pipe manufacturing process; the embedded control module completes the motor control, hydraulic control and manufacturing process flow of system operation equipment and communication with other subsystems; the execution module mainly completes the driving and speed regulation of each mechanical device;
the fault detection subsystem 2 comprises a storage module, a fault diagnosis module and a wireless communication module, the man-machine interaction subsystem 3 comprises a man-machine interaction module, a field touch screen and a wireless communication module, and the data storage terminal 4 comprises a cloud platform and a client (such as a remote PC (personal computer) terminal or an intelligent terminal such as an intelligent mobile phone client and a tablet personal computer); the embedded control module acquires data of the sensor module and the self-detection module, and simultaneously outputs a control instruction to the execution module; the embedded control module is in two-way communication with the fault diagnosis module and the human-computer interaction module, the storage module is in two-way communication with the fault diagnosis module, the fault diagnosis module and the human-computer interaction module are in communication with the cloud platform through corresponding wireless communication modules, meanwhile, the cloud platform is in communication with the remote PC end, real-time data of the fault diagnosis module and working data of each process parameter and corresponding devices of the vertical radial extrusion pipe manufacturing equipment can be displayed through the remote PC end, the cloud platform can store data information transmitted by each subsystem, and the human-computer interaction module is in mutual communication with the field touch screen.
The fault diagnosis module finishes fault diagnosis by a neural network algorithm according to the acquired data information, the storage module stores the data information and the fault information acquired by the fault diagnosis module, and the wireless communication module carries out wireless remote transmission according to the data information and the fault information acquired by the fault diagnosis module. The neural network algorithm is a neural network and a deep learning algorithm.
FIG. 2 is a block diagram of an embodiment of a vertical radial extrusion pipe making apparatus of the present invention; FIG. 3 is a block diagram showing the structure of the main control subsystem of the present invention; the execution module comprises a workbench 6, an outer mold air receiving pile 24, a power box device 18, a feeding belt conveyor 13, a forming head 11, a feeding device 8 and a vibrating device 21, is used for executing control instructions and is connected with the embedded control module. The support 16 is vertically fixed on the ground and supports all parts of the vertical radial extrusion pipe making machine; the workbench 6 is arranged below the bracket 16, and a cement pipe die 7 is arranged on the workbench 6 and used for fixing and restraining cement materials; the outer mould air receiving pile 20 consists of eight three-position five-way cylinders which are divided into an upper group and a lower group and are arranged on the mould 7 and used for fixing the reinforcement cage. The feeding device 8 comprises a grinding disc, a material sweeping disc and a stirrer, and the mechanism is arranged on the workbench 6 to complete the material injection and material sweeping work; the ground disc is used for manufacturing the shape and the accurate size of the position of the cement pipe socket. The feeding belt conveyor 13 stably feeds the concrete into the feeding device 8 through a hopper 14; the power box device 18 is mounted on the support 16, is driven by a hydraulic motor of an external hydraulic system, and is used for controlling the power box device 18 and the forming head 11 to lift. The vibrating device 21 comprises a vibrating motor and an inner low tray, and the vibrating device 21 is arranged at the socket part of the cement pipe to complete the manufacturing process of the bottom socket and the required driving. The power box lifting device 17 is connected with the bracket 16 in a sliding way, the power box device 18 is fixedly connected with the power box lifting device 17, the power box device 18 is lifted through the power box lifting device 17, and the transmission device 22 is used for transmitting power to drive the forming head 11; the forming head 11 is connected with the transmission device 22 and used for extrusion forming of cement materials, and the forming head 11 can move up and down under the action of the transmission device 22; the hopper 14 is connected with the bracket 16 and is used for leaking cement into the feeding device 8; the feeding belt conveyor 13 is connected with the bracket 16 and is used for uniformly conveying cement materials; the feeding lifting device 9 is connected with the bracket 16 in a sliding way, and the feeding lifting device 9 is fixedly connected with the feeding device 8 and used for lifting the feeding device 8;
the sensor module comprises a power box initial position sensor, a power box working position sensor, a feeding device initial position sensor, a feeding device working position sensor, a workbench position sensor and a feeding belt conveyor current detection device. The workbench position sensor is positioned below the whole support and used for detecting whether the workbench is in a working range or not, two limit switches are arranged at a distance of 180 degrees and used for positioning the workbench and moving the die into or out of a station. The power box initial position sensor 19 and the power box working position sensor 15 are arranged in the ascending and descending range of the power box, are arranged on the bracket, are particularly arranged on the bracket 16 and are used for limiting the working range of the power box; the shown initial position sensor 12 and working position sensor 10 of the feeding device are arranged on the bracket in the lifting range of the feeding device 8, and the initial position sensor of the feeding device is arranged right above the working position sensor of the feeding device and is used for detecting the position of the feeding device. The current detection device of the feeding belt conveyor is arranged on a power supply circuit of the feeding belt conveyor and is used for detecting the current of the feeding belt conveyor during working and finishing PID algorithm control.
Furthermore, the power box initial position sensor and the power box working position sensor are composed of two infrared sensors, are connected with the bracket and are used for detecting the position of the power box device; the feeding device initial position sensor and the feeding device working position sensor consist of two infrared sensors, are connected with the bracket and are used for detecting the position of the feeding device; the worktable position sensor consists of an infrared sensor, is connected with the bracket and is used for detecting the position of the worktable.
The embedded control module comprises a downloading unit 38, a power supply unit 39, a minimum system unit 30, a field bus unit 31, a detection input unit 32, a loading output unit 33, an unloading output unit 34, a socket output unit 35, a straight section output unit 36 and a socket output unit 37; the workbench position sensor, the power box initial position sensor, the power box working position sensor, the feeding device initial position sensor, the feeding device working position sensor and the feeding belt conveyor current detection in the sensor module 24 are all connected with the detection input unit 32 in the embedded control module 25; the downloading unit 38, the power supply unit 39 and the detection input unit 32 are connected with the minimum system unit 30; the minimum system unit 30 is connected with the loading output unit 33, the unloading output unit 34, the socket output unit 35, the straight section output unit 36 and the socket output unit 37; the field bus unit 31 is bidirectionally connected with the minimum system unit 30 and is bidirectionally connected with the self-detection unit in the self-detection module 23; the loading output unit 33 is connected with a workbench, a power box device and a feeding device in the execution module 26 and is used for loading the cement pipe to a working position; the bell mouth output unit 35 is connected with the feeding belt machine, the vibration device and the feeding device in the execution module 26 and is used for manufacturing a bell mouth of the cement pipe; the straight section output unit 36 is connected with a feeding belt conveyor, a power box device, an outer mould air receiving pile and a forming head in the execution module 26 and is used for manufacturing a straight section of the cement pipe; the socket output unit 37 is connected with a grinding disc in a feeding device in the execution module 26 and is used for manufacturing a socket of a cement pipe; the unloading output unit 34 is connected with a workbench, a power box device and a feeding device in the execution module 26 and is used for removing the cement pipe from a working position;
the downloading unit 38 is used for burning the written program for controlling the operation of the vertical radial extrusion pipe making equipment into a single chip machine, and comprises two downloading modes of JTAG and CH 340; the power supply unit 39 is used for supplying power to the system, takes an external 24V direct current voltage as an input, and can output 12V, 5V and 3.3V; the minimum system unit 30 comprises a clock circuit, a reset circuit and a control chip, wherein the control chip takes an STM32F4 chip as a core, the clock circuit improves the logic time for the chip, the PCF8563 clock chip is taken as the core, the crystal oscillator input end of the control chip is connected with a capacitor from 5pF to 20pF, and the reset circuit realizes the reset of the system; the field bus unit 31 comprises various communication interfaces such as a CAN bus, a 485 bus, a 232 bus, an SPI bus, WIFI and the like, so that the field bus unit is convenient to communicate with other functional modules, and CAN also communicate with a system which is not extracted but is provided with one of the field buses; the detection input unit 32 detects the working state of the sensor in the sensor module 24, and comprises a switching value input and an analog value input, and mainly comprises an AD7705 chip and a peripheral conditioning circuit; the loading output unit 33, the unloading output unit 34, the socket output unit 35, the straight-section output unit 36 and the socket output unit 37 all include a plurality of output circuits, the structures of the plurality of output circuits are the same, and the plurality of output circuits are connected with corresponding peripheral devices, so that the control and the driving of the minimum system unit 30 on the execution module are realized; because there are many output circuits, the following description will be given by taking one output circuit in the loading output unit 33 as an example:
fig. 5 is a schematic circuit connection diagram of an output circuit of the load output unit, which is mainly composed of an optocoupler TLP2301, a PMOS transistor IRF9540 and a peripheral circuit, and is used for driving peripheral devices such as a relay, a driver, a switch valve and the like, and the maximum 24V pulse output of 100KHz is supported. Specifically, an Anode end of the optocoupler TLP2301 is directly connected to VCC3.3V, a Cathode of the optocoupler TLP2301 is connected to a resistor R1, a resistor R1 is connected to a certain I/O port of a main control chip STM32F4 in the minimum system unit 30, which is designated as GPIOx, an output terminal Collector of the optocoupler TLP2301 is connected to AGND, another output terminal Emitter of the optocoupler TLP2301 is connected to two resistors R2 and R3 connected in series, the resistor R2 is connected to 24V voltage, the resistor R3 is connected to a G pole of a PMOS tube IRF9540, an S pole of the PMOS tube IRF9540 is connected to a 24V power supply, and a D pole of the PMOS tube IRF9540 is an output terminal, which is designated as Yout, and is connected to an output indicator light LED through a current limiting resistor R4. Each output unit is provided with the plurality of output circuits, and each corresponding peripheral device realizes driving control through the matching of the corresponding number of output circuits; and then the embedded control module can drive and control the whole pipe-making equipment.
The self-detection module is mainly used for detecting the execution mechanism before the system starts to operate, so that errors in the operation of equipment are prevented; the self-detection module comprises a hydraulic oil position sensor, a hydraulic oil temperature sensor, a current detection unit, a self-detection unit, a hydraulic indicator lamp, a constant temperature device and a current indicator lamp. The hydraulic pressure is mainly applied to driving the power box device 18; the hydraulic oil position sensor is arranged in a standard port inner cylinder position sensor pin mode of a hydraulic cylinder for driving the power box device to work, and is used for detecting the position of a hydraulic oil level and ensuring that an oil pump supplies oil normally; the hydraulic oil temperature sensor is arranged in the hydraulic oil tank and is used for detecting the temperature of hydraulic pressure, so that the influence on normal use and the reduction of service life caused by overhigh temperature is prevented; the current detection is installed on a power supply circuit unit 39 in the embedded control module 25 and is used for detecting the power supply condition; the self-detection unit is used for comparing the collected sensor data with the sensor data set by the system to make a next step instruction; the self-detection unit is STM32F4 series; the self-detection module and the embedded control module carry out data transmission through the CAN bus and the field bus unit 31; the hydraulic indicator light is used for displaying whether the hydraulic oil level is normal or not and is directly connected with the self-detection unit; the current indicator light is used for displaying whether the power supply circuit is normal or not and is directly connected with the self-detection unit; the constant temperature device is arranged on the hydraulic transmission pipeline and comprises a heating machine and a cold oil machine, and is used for ensuring the normal temperature of hydraulic oil and ensuring the oil supply efficiency.
The human-computer interaction subsystem 3 is used for displaying data of the sensor module 24 in the main control subsystem 1 in real time and designing different parameters of the cement pipe in the pipe manufacturing process, and comprises a human-computer interaction module, a field touch screen and a wireless communication module; the human-computer interaction module is STM32F 4; the field touch screen is a Kunlun general state MCGS touch screen; the wireless communication module is WIFIESP 8266; the human-computer interaction module is connected with the embedded control module through a CAN bus; the field touch screen is connected with the human-computer interaction module through a CAN bus to complete data interaction between the touch screen and the human-computer interaction module; the human-computer interaction module is connected with a network database on the cloud platform through the wireless communication module, and performs data interaction with the network database; the cloud platform is used for sending, receiving and storing remote data, and real-time data are operated through the remote display equipment at the remote PC end.
The fault diagnosis module in the fault detection subsystem 2 comprises a fault diagnosis control unit 28, an acquisition unit 27 and a bus unit 29, and is used for performing data analysis, operation record and fault information transmission on operating equipment; the acquisition unit is connected with the fault diagnosis control unit; the fault diagnosis control unit is connected with the bus unit and is electrically connected with the embedded control module through the bus unit; the acquisition unit comprises starting time, shutdown time, motor current detection, belt conveyor rotating speed detection, a power box initial position sensor, a feeding device initial position sensor, a workbench position sensor, a power box working position sensor, a feeding device working position sensor, hydraulic pressure detection and forming head vibration detection; the fault diagnosis control unit is TSM320F28335 used for executing a fault diagnosis neural network algorithm, such as a BP neural network; the bus unit 29 comprises a 232 bus interface, a wireless communication interface, a CAN bus interface, a 485 bus interface and an SPI bus interface, and is used for conveniently connecting other embedded systems for communication. The wireless communication module in the fault detection subsystem 2 is a WIFI module, and more specifically, an ESP8266 wireless module. The storage module in the fault detection subsystem 2 is a FLASH storage chip W25Q 64; the fault diagnosis control unit is connected with the storage module and the wireless communication module.
Furthermore, the fuzzy PID controller is adopted to realize closed-loop control of the feeding belt conveyor, namely, the motor of the feeding belt conveyor is regulated and controlled by the fuzzy PID controller, the rotating speed of the feeding belt conveyor is adjusted, the feeding speed of the belt conveyor is further adjusted, and the phenomenon that the feeding device is blocked due to the fact that the material injection speed is too high can be effectively avoided.
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 motor of the feeding belt conveyor 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 motor in the feeding device is constant, and the injection speed of the feeding belt machine of the pipe making equipment and the resistance torque T of the motor of the feeding device 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):
Figure BDA0002642006210000101
in the formula, n is the rated rotating speed of a motor of a feeding belt conveyor of the pipe making equipment; u is the rated working voltage of the motor of the feeding belt conveyor 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 feeding belt conveyor of a pipe manufacturing device through the current detection of the feeding belt conveyor in the sensor module, and calculating the error e between the rated current of the feeding belt conveyor 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 KdThe corresponding elements NB and PB in the fuzzy set respectively select Z-type and inverse Z-type membership functionsThe other elements adopt a triangular membership function;
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 a motor frequency converter of the feeding belt conveyor, so as to adjust the material injection speed of the system and enable the motor of the feeding belt conveyor to operate at constant torque.
The embedded control system of the vertical radial extrusion pipe-making equipment has the working process as follows:
1) when the start button is pressed, the self-detection module 23 in the main control subsystem 1 starts to detect the position of hydraulic oil, the temperature of the hydraulic oil and the current, so that the oil supply of an oil pump is normal, the oil temperature is between 20 and 60 ℃, and the power supply is normal. Meanwhile, the rolling wheels of the mechanical power head are manually checked to flexibly rotate, and other moving parts are free from loosening and have no stagnation. If there is no abnormality, the self-detection module 23 communicates with the embedded control module 25 through the CAN bus to start preparation. Meanwhile, the main control subsystem 1 detects whether the fault detection subsystem 2 is connected or not, and if not, the partial function brake shielding is carried out; the main control subsystem 1 detects whether the human-computer interaction subsystem 3 is connected or not, if not, the function of the part is braked and shielded, and if so, various signals can be displayed on a field touch screen in the human-computer interaction subsystem 3.
2) When the self-detection module detects that the data is normal, the embedded control module in the main control subsystem starts to work; the embedded control module 25 starts to detect the respective position states of the power box initial position sensor 19, the feeding device initial position sensor 12, the table position sensor 5, the power box working position sensor 15 and the feeding device working position sensor 10 through the detection input unit 32. When the project is normal, the minimum system unit 30 in the embedded control module 25 starts to control the workbench 6, the power box device 18 and the feeding device 9 through the loading output unit 33; specifically, when the mold is placed on a designated preparation area, the mold is rotated by 180 ° by the table and transferred to the working area. After the workbench position sensor detects that the mold is in place, the hydraulic bolt on the power box device is locked, the power box device is opened, the whole power box device descends rapidly, and the whole power box device is close to a descending point and slowly descends to a descending point, so that the mold is in close contact with an inner bottom tray in the vibrating device. Ready to begin tubing.
3) After loading is complete, the system proceeds to make the socket portion of the cement pipe. The minimum system 30 in the embedded control module 25 starts to control the feeding belt conveyor 13, the feeding device 9 and the vibrating device 21 through the bellmouth output unit 35; specifically, the system controls to start the feeding belt conveyor, so that concrete is stably fed into the feeding device through the hopper, and meanwhile, the sweeping tray in the feeding device starts to work and feeds the concrete scattered on the periphery into the round holes of the feeding tray. After a proper amount of concrete is accumulated on an inner bottom tray in the vibrating device, a vibrating motor in the vibrating device is started, and the concrete pipe is vibrated for a plurality of seconds according to a set program to carry out pouring operation of a concrete pipe socket.
4) And after the socket part is manufactured, the system enters the straight section part of the cement pipe for manufacturing. The minimum system 30 in the embedded control module 25 starts to control the feeding belt conveyor 13, the power box device 18, the outer mold air receiving pile 20 and the forming head 11 through the straight section output unit 36; specifically, the power box device 18 moves downwards in a designated mode, the feeding belt conveyor 13 continuously injects materials into the feeding device 8 through the hopper 14, simultaneously, the forming head 11 uniformly pours the materials onto a steel reinforcement framework on the inner side of the mould by adopting a centrifugal casting method, and the power box device 18 is controlled by an external hydraulic system to move upwards slowly to finish the main body pouring work of the whole cement pipe from bottom to top. When the forming head 11 starts to work, the four lower cylinders in the outer die air receiving pile 20 work simultaneously, and when the casting work reaches the position of the upper cylinder along with the upward movement of the forming head 11, the four upper cylinders start to work simultaneously.
5) And when the straight section part is manufactured, the system enters the socket part of the cement pipe for manufacturing. The minimum system unit 30 in the embedded control module 25 starts to detect the working position sensor 10 of the feeding device through the detection input unit 32, if the detection is normal, the minimum system unit 30 controls the grinding disc in the feeding device 8 through the socket output unit 37, and the socket of the grinding disc is smoothed and capped.
6) And when the socket part is manufactured, the system enters an unloading process. The embedded control module 25 starts to detect the respective position states of the power box initial position sensor 19, the feeding device initial position sensor 12, the table position sensor 5, the power box working position sensor 15 and the feeding device working position sensor 10 through the detection input unit 32. When the project is normal, the minimum system unit 30 in the embedded control module starts to control the workbench 6, the power box device 18 and the feeding device 9 through the unloading output unit 34; specifically, when the mold is detected to be placed in the designated preparation area, the mold is rotated by 180 ° by the table and is transferred out of the work area. Waiting for the cement pipe to be placed in the designated position.
7) When an abnormality occurs, the system enters a fault mode, all execution modules of the system keep the current positions, the feeding belt conveyor stops feeding, if the main control subsystem 1 is connected with the man-machine interaction subsystem 3, a field touch screen gives an alarm when a fault occurs, and current system data are transmitted to the cloud platform through the wireless communication module, so that remote real-time alarm is realized. If the main control subsystem 1 is connected with the fault detection module 2, the fault diagnosis control unit 28 carries out real-time acquisition on the start-up time, the shutdown time, the motor current detection, the belt conveyor rotating speed detection, a power box initial position sensor, a feeding device initial position sensor, a workbench position sensor, a power box working position sensor, a feeding device working position sensor, hydraulic pressure detection, forming head vibration detection and the like of the acquisition unit 27, if a fault occurs, the fault detection subsystem 2 is communicated with the main control subsystem 1 and the man-machine interaction subsystem 3 through a CAN bus, parameters such as the state of each acquired data, the fault time and the like are stored at the same time, the fault information is judged through a neural network algorithm and is transmitted to a cloud platform through a wireless communication module, the data of the cloud platform is displayed in real time in a remote PC terminal, and remote fault monitoring is realized, when a fault occurs, fault maintenance is performed. And under the condition that the system is normally stopped, each execution module is recovered to the initial position, and the system enters a stopped state.
Nothing in this specification is said to apply to the prior art.

Claims (7)

1. An embedded control system of vertical radial extrusion pipe manufacturing equipment is characterized in that a microprocessor is adopted as a main control chip in the system structure, a main control subsystem, a man-machine interaction subsystem and a fault diagnosis subsystem are connected by adopting the field bus technology of the microprocessor, the respective control systems are used as hardware supports, the wireless communication technology is adopted, data acquired by the hardware systems are sent to a cloud platform, and meanwhile, a client can log in the cloud platform for remote real-time monitoring; in particular, the amount of the solvent to be used,
the main control subsystem comprises a self-detection module, an embedded control module, a sensor module and an execution module, wherein the sensor module is mainly used for carrying out real-time positioning detection, equipment operation parameter acquisition and system safety parameter acquisition on control execution equipment in the process of a pipe manufacturing process; the embedded control module mainly completes the motor control, hydraulic control and manufacturing process flow of system operation equipment and communication with other subsystems; the execution module mainly completes the driving and speed regulation of each mechanical device;
the fault detection subsystem comprises a storage module, a fault diagnosis module and a wireless communication module; the fault diagnosis module finishes fault diagnosis by a neural network algorithm according to the acquired data information, the storage module stores the data information and the fault information acquired by the fault diagnosis module, and the wireless communication module wirelessly and remotely transmits the data information and the fault information acquired by the fault diagnosis module; the human-computer interaction subsystem comprises a human-computer interaction module, a field touch screen and a wireless communication module;
the embedded control module acquires data of the sensor module and the self-detection module, and simultaneously outputs a control instruction to the execution module; the embedded control module is in two-way communication with the fault diagnosis module and the human-computer interaction module, the storage module is in two-way communication with the fault diagnosis module, the fault diagnosis module and the human-computer interaction module are in communication with the cloud platform through corresponding wireless communication modules, meanwhile, the cloud platform is in communication with the client, real-time data of the fault diagnosis module and process parameters of the vertical radial extrusion pipe manufacturing equipment and working data of corresponding devices can be displayed through the client, the cloud platform can store data information transmitted by subsystems, and the human-computer interaction module is in mutual communication with the field touch screen;
the embedded control module comprises a downloading unit, a power supply unit, a minimum system unit, a field bus unit, a detection input unit, a loading output unit, an unloading output unit, a socket output unit, a straight section output unit and a socket output unit; a workbench position sensor, a power box initial position sensor, a power box working position sensor, a feeding device initial position sensor, a feeding device working position sensor and a feeding belt conveyor current detection in the sensor module are all connected with a detection input unit in the embedded control module; the download unit, the power supply unit and the detection input unit are connected with the minimum system unit; the minimum system unit is electrically connected with the loading output unit, the unloading output unit, the socket output unit, the straight section output unit and the socket output unit; the field bus unit is bidirectionally connected with the minimum system unit and is bidirectionally connected with the self-detection unit in the self-detection module; the loading output unit is connected with a workbench, a power box device and a feeding device in the execution module and is used for loading the cement pipe to a working position; the bell mouth output unit is connected with a feeding belt conveyor, a vibration device and a feeding device in the execution module and is used for manufacturing a bell mouth of the cement pipe; the straight section output unit is connected with a feeding belt conveyor, a power box device, an outer mould air receiving pile and a forming head in the execution module and is used for manufacturing a straight section of the cement pipe; the socket output unit is connected with a grinding disc in a feeding device in the execution module and is used for manufacturing a socket of the cement pipe; the unloading output unit is connected with a workbench, a power box device and a feeding device in the execution module and is used for removing the cement pipe from a working position;
the power supply unit is used for supplying power to the system, takes external 24V direct current voltage as input and can output 12V, 5V and 3.3V voltage; the minimum system unit comprises a clock circuit, a reset circuit and a control chip, wherein the control chip takes an STM32F4 chip as a core; the field bus unit comprises various communication interfaces including a CAN bus, a 485 bus, a 232 bus, an SPI bus and WIFI, so that the field bus unit CAN be conveniently communicated with other functional modules; the detection input unit is used for detecting the working state of a sensor in the sensor module and comprises switching value input and analog value input; the loading output unit, the unloading output unit, the socket output unit, the straight section output unit and the socket output unit all comprise a plurality of output circuits, the structures of the output circuits are the same, and the output circuits are connected with corresponding peripheral devices to realize the control and the driving of the minimum system unit on the execution module.
2. The control system of claim 1, wherein the sensor module comprises a power box initial position sensor, a power box working position sensor, a feeding device initial position sensor, a feeding device working position sensor, a workbench position sensor and a feeding belt conveyor current detection; the workbench position sensor is used for detecting whether the workbench is in a working range or not, two limit switches which are spaced by 180 degrees are used for positioning the workbench and moving the die into or out of a station; the power box initial position sensor and the power box working position sensor are arranged in the ascending and descending range of the power box and used for limiting the working range of the power box; the feeding device initial position sensor and the feeding device working position sensor are arranged on the bracket in the lifting range of the feeding device, and the feeding device initial position sensor is arranged right above the feeding device working position sensor and used for detecting the position of the feeding device; the current detection device of the feeding belt conveyor is arranged on a power supply circuit of the feeding belt conveyor and is used for detecting the current of the feeding belt conveyor during working.
3. The control system according to claim 1, wherein one output circuit of the loading output unit mainly comprises an optocoupler TLP2301, a PMOS transistor and a peripheral circuit, is used for driving peripheral devices, and supports 24V pulse output of up to 100 KHz; specifically, an Anode end of the optocoupler TLP2301 is directly connected to VCC3.3V, a Cathode of the optocoupler TLP2301 is connected to a resistor R1, a resistor R1 is connected to an I/O port of a control chip in the minimum system unit, which is denoted as GPIOx, an output terminal Collector of the optocoupler TLP2301 is connected to AGND, another output terminal Emitter of the optocoupler TLP2301 is connected to two resistors R2 and R3 connected in series, the resistor R2 is connected to 24V voltage, the resistor R3 is connected to a G pole of a PMOS tube, an S pole of the PMOS tube is connected to a 24V power supply, and a D pole of the PMOS tube is denoted as Yout, and is connected to GND through a current limiting resistor R4 and an output indicator light LED.
4. The control system of claim 1, wherein the self-detection module mainly detects an actuating mechanism before the system starts to operate, so as to prevent errors in the operation of equipment; the self-detection module comprises a hydraulic oil position sensor, a hydraulic oil temperature sensor, a current detection unit, a self-detection unit, a hydraulic indicator lamp, a constant temperature device and a current indicator lamp; the hydraulic pressure is mainly applied to driving the power box device; the hydraulic oil position sensor is arranged in a standard port inner cylinder position sensor pin mode of a hydraulic cylinder for driving the power box device to work and is used for detecting the position of the hydraulic oil level and ensuring that the oil supply of the oil pump is normal; the hydraulic oil temperature sensor is arranged in the hydraulic oil tank and used for detecting the hydraulic temperature, so that the influence on normal use and the reduction of service life caused by overhigh temperature is prevented; the current detection is arranged on a power supply circuit unit in the embedded control module and is used for detecting the power supply condition; the self-detection unit is used for acquiring sensor data and comparing the sensor data with sensor data set by the system to make a next step instruction; the self-detection unit is STM32F4 series; the self-detection module and the embedded control module carry out data transmission through a CAN bus and a field bus unit; the hydraulic indicator light is used for displaying whether the hydraulic oil level is normal or not and is directly connected with the self-detection unit; the constant temperature device is arranged on the hydraulic transmission pipeline and comprises a heating machine and a cold oil machine, and is used for ensuring the normal temperature of hydraulic oil and ensuring the oil supply efficiency.
5. The control system of claim 1, wherein the fault diagnosis module comprises a fault diagnosis control unit, a collection unit and a bus unit, and is used for performing data analysis, operation recording and fault information transmission on operating equipment; the acquisition unit is connected with the fault diagnosis control unit; the fault diagnosis control unit is connected with the bus unit and is electrically connected with the embedded control module through the bus unit; the acquisition unit comprises starting time, shutdown time, motor current detection, belt conveyor rotating speed detection, a power box initial position sensor, a feeding device initial position sensor, a workbench position sensor, a power box working position sensor, a feeding device working position sensor, hydraulic pressure detection and forming head vibration detection; the fault diagnosis control unit adopts a DSP chip to execute a fault diagnosis neural network algorithm; the bus unit comprises a 232 bus interface, a wireless communication interface, a CAN bus interface, a 485 bus interface and an SPI bus interface and is used for conveniently connecting other embedded systems for communication; the fault diagnosis control unit is connected with the storage module and the wireless communication module.
6. The control system of claim 1, wherein a fuzzy PID control algorithm for controlling the feeding speed of the feeding belt conveyor is loaded in the embedded control module, the algorithm adopts a fuzzy PID controller to realize closed-loop control of the feeding belt conveyor,
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 motor of the feeding belt conveyor 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 motor in the feeding device is constant, and the injection speed of the feeding belt conveyor of the pipe making equipment and the resistance torque T of the motor of the feeding device 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 g(s) of the system is established according to equation (2):
Figure FDA0002933829620000041
in the formula, n is the rated rotating speed of a motor of a feeding belt conveyor of the pipe making equipment; u is the rated working voltage of the motor of the feeding belt conveyor 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 feeding belt conveyor of the pipe manufacturing equipment through the current detection of the feeding belt conveyor in the sensor module, and calculating the error e between the rated current of the feeding belt conveyor 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) structure of the organizationModeling a fuzzy relation: establishing fuzzy inference rules according to practical experience and 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 a motor frequency converter of the feeding belt conveyor, so as to adjust the material injection speed of the system and enable the motor of the feeding belt conveyor to operate at constant torque.
7. An embedded control method of vertical radial extrusion pipe-making equipment, which is characterized in that the method uses the control system of claim 1, and the specific process is as follows:
1) when a start button is pressed, a self-detection module in the main control subsystem starts to detect the position of hydraulic oil, the temperature of the hydraulic oil and the current, so that the oil supply of an oil pump is normal, the oil temperature is between 20 and 60 ℃, and the power supply is normal; meanwhile, the rolling wheels of the mechanical power head are manually checked to flexibly rotate, and other moving parts are free from loosening and have no stagnation; if no abnormity exists, the self-detection module communicates with the embedded control module through the CAN bus to start preparation work; meanwhile, the main control subsystem detects whether the fault detection subsystem is connected or not, and if not, the partial function brake shielding is carried out; the main control subsystem detects whether the human-computer interaction subsystem is connected, if not, the function of the main control subsystem is braked and shielded, and if so, various signals can be displayed on a field touch screen in the human-computer interaction subsystem;
2) when the self-detection module detects that the data is normal, the embedded control module in the main control subsystem starts to work; the embedded control module starts to detect the position states of the power box initial position sensor, the feeding device initial position sensor, the workbench position sensor, the power box working position sensor and the feeding device working position sensor through the detection input unit; when the project is normal, the minimum system unit in the embedded control module starts to control the workbench, the power box device and the feeding device through the loading output unit; preparing to start tube making;
3) after loading is finished, the system carries out socket part manufacturing on the cement pipe; the minimum system in the embedded control module starts to control the feeding belt conveyor, the feeding device and the vibrating device through the bellmouth output unit;
4) after the socket part is manufactured, the system enters the straight section part of the cement pipe for manufacturing; the minimum system in the embedded control module starts to control the feeding belt conveyor, the power box device, the outer mould air-receiving pile and the forming head through the straight-section output unit;
5) after the straight section part is manufactured, the system enters the socket part of the cement pipe for manufacturing; the minimum system in the embedded control module starts to detect the working position sensor of the feeding device through the detection input unit, if the detection is normal, the minimum system unit controls a grinding port disc in the feeding device through the socket output unit, and the socket of the grinding port disc is smoothed and capped;
6) after the socket part is manufactured, the system enters an unloading process; the embedded control module starts to detect the position states of the power box initial position sensor, the feeding device initial position sensor, the workbench position sensor, the power box working position sensor and the feeding device working position sensor through the detection input unit; when the project is normal, the minimum system unit in the embedded control module starts to control the workbench, the power box device and the feeding device through the unloading output unit, and the cement pipe is placed at a designated position;
7) when an abnormality occurs, the system enters a fault mode, all execution modules of the system keep current positions, the feeding belt conveyor stops feeding, if the main control subsystem is connected with the man-machine interaction subsystem, a field touch screen gives an alarm when the fault occurs, and current system data are transmitted to the cloud platform through the wireless communication module, so that remote real-time alarm is realized; if the main control subsystem is connected with the fault detection module, the fault detection subsystem acquires start-up time, shut-down time, motor current detection, belt conveyor rotating speed detection, a power box initial position sensor, a feeding device initial position sensor, a workbench position sensor, a power box working position sensor, a feeding device working position sensor, hydraulic pressure detection and forming head vibration detection information in real time; and under the condition that the system is normally stopped, each execution module is recovered to the initial position, and the system enters a stopped state.
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