CN112286129B - PLC-based optical fiber screening machine control model design method - Google Patents
PLC-based optical fiber screening machine control model design method Download PDFInfo
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- CN112286129B CN112286129B CN202011028716.4A CN202011028716A CN112286129B CN 112286129 B CN112286129 B CN 112286129B CN 202011028716 A CN202011028716 A CN 202011028716A CN 112286129 B CN112286129 B CN 112286129B
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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
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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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
- G05B2219/10—Plc systems
- G05B2219/11—Plc I-O input output
- G05B2219/1103—Special, intelligent I-O processor, also plc can only access via processor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a method for designing an optical fiber screening machine control model based on a PLC (programmable logic controller), which comprises the steps that a module for configuring an application is accessed into a PLC controller, and signals of the optical fiber screening machine are defined through the PLC controller; and designing an internal model of the PLC. The invention innovatively applies 1200 series of PLC products as a main controller in the optical fiber screening machine industry, simultaneously designs an internal model of the PLC controller to replace 500 series of PLCs commonly used in the optical fiber industry, solves the problem that the 500 series of PLCs are not provided with subsequent PLC products which can be compatibly replaced after being updated, and has high cost performance of the 1200 series of PLC products.
Description
Technical Field
The invention relates to the technical field of optimization of control systems of optical fiber production equipment, in particular to a PLC-based design method of an optical fiber screening machine control model.
Background
With the continuous development of the communication industry, the optical fiber production cost of mainstream optical fiber cable production enterprises is continuously increased, which is more than 30-40 yuan/core kilometer, so that the living space of the enterprises is already compressed to the limit, and the production cost has to be reduced and new technologies have to be developed to reduce the cost.
An important optical fiber process applied to optical fiber screening machines is tension screening of optical fibers, which are produced from a drawing tower and are generally wound on a large optical fiber reel. The optical fiber length of a large optical fiber plate is different from 30-400KM, the optical fibers must be rewound to a standard small optical fiber plate in a commercial length required by a customer before being shipped out of a factory, on the other hand, the mechanical strength of the optical fibers is strictly checked while the optical fibers are rewound, and the optical fibers which can bear the tension which is more than 9.8N and less than 9.8N are generally required to be scrapped, namely screening. Most of optical fiber screening machines used in the current market are OFC32 optical fiber screening machines, a control system of the optical fiber screening machine adopts an SLC5 series PLC module, except the high cost, the technology is not updated for more than 10 years, the higher and higher labor cost is faced, the operation speed cannot improve the upper limit, the production efficiency of an enterprise is low, the production cost is high, great pressure is brought to the enterprise, and the products are more faced with the crisis of production stoppage, so that the problem that subsequent PLC products which can be replaced by compatibility are not available is directly caused. Therefore, how to get rid of the dilemma becomes a problem to be solved urgently in the industry.
Disclosure of Invention
In order to solve the existing problems, the invention provides a method for designing a control model of an optical fiber screening machine based on a PLC, which comprises the following steps:
the module for configuring the application is accessed to a PLC controller, and the signal of the optical fiber screening machine is defined through the PLC controller;
and designing an internal model of the PLC.
According to the technical scheme, the internal model of the PLC comprises a tension control model, the tension control model calculates the tension variation according to a tension set value set by the PLC and a fed-back tension actual value, the calculation is further carried out according to the proportional relation between the speed variation and the tension variation, and finally the rotating speed of the take-up main traction motor is calculated.
By adopting the technical scheme, the tension control model is as follows:
ΔT＝TS-TS0 (1)
ΔV＝VT-V0 (2)
ΔV＝-KT*ΔT (3)
VT＝ΔV+V0 (4)
VT＝V0-KT*ΔT (5)
wherein T isSIs the actual value of the tension, TS0Set value for tension, VTFor taking up the main traction line speed, V0For paying-off main traction line speed, KTIs the tension proportionality coefficient.
By adopting the technical scheme, the internal model of the PLC comprises a paying-off rotating model, after the paying-off rotating model is started, whether the feedback value of the dancing wheel is equal to the set value of the dancing wheel is judged, and if yes, the process is finished; and if not, adding or subtracting the multiple of the offset of the paying-off dancing wheel by the rotating speed of the paying-off rotating motor until the difference value between the feedback value of the dancing wheel and the set value is equal to 0, and re-entering the cycle judgment after the operation is finished.
By adopting the technical scheme, if the difference value between the feedback value of the dancing wheel and the set value of the dancing wheel is greater than 0, the rotating speed of the paying-off rotating motor is multiplied by the offset of the paying-off dancing wheel and output to the motor;
and if the difference value between the feedback value of the dancing wheel and the set value of the dancing wheel is less than 0, reducing the rotation speed of the paying-off rotating motor by the multiple of the offset of the paying-off dancing wheel and outputting the multiple to the motor.
By adopting the technical scheme, the internal model of the PLC comprises an extra length calculation model, and the extra length calculation model comprises the following steps:
calculating the length L of the n-th layern：
Calculating the residual length delta L: Δ L ═ L- (L)1+L2+L3+Ln) (2)
Calculating the number of the extra length layers C:
wherein phitIs the inner diameter of the optical fiber reel, fΦN is the number of layers for the fiber diameter.
By adopting the technical scheme, the number of the extra-long layers is less than or equal to that of the first layer, wherein the number of the first layer
Wherein
To ensure the spacing of each half-pass for a layer to be filled, LtThe width of the fiber optic disc.
According to the technical scheme, the internal model of the PLC comprises a take-up rotation speed model which is as follows:
calculating the speed and rotation speed omega of the n-th layern：
Calculating the residual layer speed and rotation speed omegan+1：
Wherein v is0For paying-off main traction drive speed, phitIs the diameter of the take-up drum, fΦFor the diameter of the fiber, K' is the dancing wheel proportionality coefficient, Δ PtIs the difference in voltage of the dancing wheel.
By adopting the technical scheme, the internal model of the PLC comprises a tension calibration model which is as follows:
calculating a coefficient K:
calculating the tension T, T ═ T0+K(V-V0) (2)
Wherein T is0Calibrating tension for zero point, TsFor a 1kg weight, the tension, V0Calibrating tension voltage value, V, for zerosFor a 1kg weight calibration tensionAnd V is a set tension voltage value.
The invention has the beneficial effects that: the invention innovatively applies 1200 series of PLC products as a main controller in the optical fiber screening machine industry, simultaneously designs an internal model of the PLC controller to replace 500 series of PLCs commonly used in the optical fiber industry, solves the problem that the 500 series of PLCs are not provided with subsequent PLC products which can be compatibly replaced after being updated, and has high cost performance of the 1200 series of PLC products.
Drawings
FIG. 1 is a flow chart of the steps of the PLC-based fiber screening machine control model design method of the present invention.
FIG. 2 is a flow chart of step 1 of the PLC-based fiber screening machine control model design method of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.
Examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.
Referring to fig. 1 and 2, an embodiment of the present invention provides a method for designing a fiber screening machine control model based on a PLC, including the following steps:
firstly, step S1 is performed, where the module configured and applied in step S1 is connected to the PLC controller, and the PLC controller defines the signal of the optical fiber screening machine, which includes three small steps: s1-1, screening out modules to be applied according to actual requirements, S1-2, arranging the screened out modules on a rack of the PLC, and S1-3, correspondingly connecting the PLC with hardware equipment of the optical fiber screening machine; next is step S2
In step S2, an internal model of the PLC controller is designed, where the internal model of the PLC controller includes a tension control model, a pay-off rotation model, an excess length calculation model, a take-up rotation speed model, and a tension calibration model, and by designing these internal models, it is most basic to make the PLC controller compatible with the optical fiber screening machine, and at the same time, to control the stability of the system, so that it can operate stably at high speed.
Based on the present embodiment, in step S1-1, one optional PM1207 power module, one optional 1214C CPU, three optional SM1221 digital input modules, two optional SM1222 digital output modules, two optional SM1232 analog output modules, and one optional SM1231 analog input module are configured according to actual requirements; then in step S1-2, the above modules are arranged in position on the rack of the PLC controller, preferably, one optional 1214C CPU is located in slot No. 0 of the PLC system, one optional SM1221 digital quantity input module is located in slot No. 1 of the PLC system, one optional SM1221 digital quantity input module is located in slot No. 2 of the PLC system, one optional SM1222 digital quantity output module is located in slot No. 3 of the PLC system, one optional SM1222 digital quantity output module is located in slot No. 4 of the PLC system, one optional SM1221 digital quantity input module is located in slot No. 5 of the PLC system, one optional SM1232 analog quantity output module is located in slot No. 6 of the PLC system, one optional SM1232 analog quantity output module is located in slot No. 7 of the PLC system, and one optional SM1231 analog quantity input module is located in slot No. 8 of the PLC system; finally, in step S1-3, the PLC controller is correspondingly connected to the hardware device of the optical fiber screening machine, that is, the input/output point of the PLC controller is connected to the hardware device of the optical fiber screening machine, and the input/output signal of the optical fiber screening machine is redefined.
Based on this embodiment, in step S2, the tension control model calculates the tension variation according to the tension set value set by the PLC controller and the fed-back tension actual value, further calculates the tension variation according to the proportional relationship between the speed variation and the tension variation, and finally calculates the rotation speed of the take-up main traction motor, specifically, the tension control model is as follows:
ΔT＝TS-TS0 (1)
ΔV＝VT-V0 (2)
ΔV＝-KT*ΔT (3)
VT＝ΔV+V0 (4)
VT＝V0-KT*ΔT (5)
wherein T isSIs the actual value of tension, TS0Set value for tension, VTIs the main line speed of the take-up traction, V0For paying-off main traction line speed, KTIs the tension proportionality coefficient;
before the system is operated, the tension set value set by the system is TS0The actual tension value fed back by the system in the running process is TSWhen there is a difference Δ T between them; step (2) is deduced according to the proportional relation between the speed variation and the tension variation, and then the rotation speed of the take-up main traction motor is calculated through step (3), so that the tension is kept constant, for example, the running speed set by the system is 2000 m/min, the set tension is 9N, the feedback value of the tension sensor is 10N, the speed difference is 5 m/min when the delta V is-5 x (10-9) is 5, and then the V ist＝2000-5＝1996m/min。
Based on the situation of the embodiment, in step S2, the paying-off rotation model mainly controls the speed of the paying-off rotation motor according to the voltage signal of the paying-off dancing wheel, after the paying-off rotation model is started, it is determined whether the feedback value of the dancing wheel is equal to the set value of the dancing wheel, and if so, the process is ended; if the difference value between the feedback value of the dancing wheel and the set value of the dancing wheel is not equal to 0, judging the relationship between the difference value between the feedback value of the dancing wheel and the set value of the dancing wheel and 0 again, if the difference value between the feedback value of the dancing wheel and the set value of the dancing wheel is less than 0, reducing the rotating speed of the paying-off rotating motor by the multiple of the offset of the paying-off dancing wheel and outputting the multiple to the motor until the difference value between the feedback value of the dancing wheel and the set value is equal to 0; and if the difference value between the feedback value of the dancing wheel and the set value of the dancing wheel is less than 0, reducing the rotation speed of the paying-off rotating motor by the multiple of the offset of the paying-off dancing wheel and outputting the multiple to the motor until the difference value between the feedback value of the dancing wheel and the set value is equal to 0, and re-entering the cycle judgment after the operation is finished.
Based on the situation of this embodiment, in step S2, the system needs to perform screening according to the length set by the customer, and needs to know the number of layers being screened and the length already screened, and then determines whether the extra length meets the requirement of one layer by calculating the difference between the set length and the length already screened, if the extra length is less than one layer, the system performs a deceleration shutdown on the extra length, and the extra length calculation model is as follows:
calculating the length L of the n-th layern：
Calculating the residual length Δ L: Δ L ═ L- (L)1+L2+L3+Ln) (2)
Calculating the number of the extra length layers C:
wherein phitIs the inner diameter of the optical fiber reel, fΦIs the diameter of the optical fiber, n is the number of layers, C1Is the number of first layers, wherein the number of first layers
Wherein
To ensure a full layer spacing per half-pass, LtThe width of the fiber optic disc is, for example,
number of first layers C1：
Length L of the first layer1：
Number of second layers C2：C2＝C1(ii) a Length L of the second layer2：
Number of layers C of the third layer3：C3＝C1(ii) a Length L of the third layer3：
Assuming that the length to be screened is 50km, the screening length of each layer can be calculated based on the known set fiber diameter and fiber gap, and when screening N layers, where the screened length is 49.5km, by calculating the difference between the set length and the screened length to be 0.5km, when the difference is less than the length L of the N +1 layern+1It means that the remaining length is less than one layer, and at this time, the system is decelerated and stopped.
Based on the situation of this embodiment, in step S2, the take-up reel is accumulated along with the number of layers of the optical fiber, the radius of the optical fiber reel is continuously increased along with the layer height, and for increasing the radius, in order to ensure that the linear velocity is constant, the take-up rotation model needs to be introduced, and the take-up rotation model is as follows:
calculating the speed and rotation speed omega of the n-th layern：
Calculating the residual layer speed and rotation speed omegan+1：
Wherein v is0For paying-off main traction drive speed, phitIs the diameter of the take-up drum, fΦFor the diameter of the fiber, K' is the dancing wheel proportionality coefficient, Δ PtFor example, the difference in voltage for the dancing wheel:
first layer speed rotation speed omega1：
Second layer velocity rotation speed omega2：
Third layer speed rotation speed omega3：
When the user sets the running speed to be 2500m/min, the radius of the optical fiber to be 0.251mm and the radius of the take-up rotating disc to be 178mm, the corresponding first layer rotating speed is 2500/(3.14 × 0.178) ≈ 4472r/min according to the formula; the radius of rotation of the second layer is (178+0.251) mm, the rotating speed is 2500/(3.14 × 0.178251) ≈ 4466r/min, and so on, when the rotating speed of the radius compensation is not enough to maintain the stability of the dancing wheel, the voltage variation (K' delta P) passing through the dancing wheelt) Automatically adjust until the stability of the system is maintained.
Based on the present embodiment, in step S2, since the tension sensor itself has gravity, in order to better reflect the actual force applied to the optical fiber, a tension calibration model is introduced, which is as follows:
calculating a coefficient K:
calculating the tension T, T ═ T0+K(V-V0) (2)
Wherein T is0Calibrating tension for zero point, TsFor a 1kg weight, the tension, V0Calibrating tension voltage value, V, for zerosThe tension voltage value is calibrated for a 1kg weight, and V is the set tension voltage value.
The invention has the beneficial effects that: the invention innovatively applies 1200 series of PLC products as a main controller in the optical fiber screening machine industry, simultaneously designs an internal model of the PLC controller to replace 500 series of PLCs commonly used in the optical fiber industry, solves the problem that the 500 series of PLCs are not provided with subsequent PLC products which can be compatibly replaced after being updated, and has high cost performance of the 1200 series of PLC products.
The above-mentioned embodiments are merely preferred embodiments for fully illustrating the present invention, and the scope of the present invention is not limited thereto. The equivalent substitution or change made by the technical personnel in the technical field on the basis of the invention is all within the protection scope of the invention. The protection scope of the invention is subject to the claims.
Claims (5)
1. A method for designing an optical fiber screening machine control model based on a PLC is characterized by comprising the following steps:
the module for configuring the application is accessed to a PLC controller, and the signal of the optical fiber screening machine is defined through the PLC controller;
designing an internal model of the PLC; the internal model of the PLC comprises a tension control model, the tension control model calculates the tension variation according to a tension set value set by the PLC and a fed-back tension actual value, the calculation is further carried out according to the proportional relation between the speed variation and the tension variation, and finally the rotating speed of the take-up main traction motor is calculated; the tension control model is as follows:
ΔT＝TS-TS0 (1)
ΔV＝VT-V0 (2)
ΔV＝-KT*ΔT (3)
VT＝ΔV+V0 (4)
VT＝V0-KT*ΔT (5)
wherein T isSIs the actual value of tension, TS0Set value for tension, VTFor taking up the main traction line speed, V0For paying-off the main traction line speed, KTIs the tension proportionality coefficient;
the internal model of the PLC controller comprises a take-up rotation speed model which is as follows:
calculating the speed and rotation speed omega of the n-th layern：
Calculating the residual layer speed and rotation speed omegan+1：
Wherein v is0For paying-off main traction drive speed, phitIs the diameter of the take-up drum, fΦFor the diameter of the fiber, K' is the dancing wheel proportionality coefficient, Δ PtIs the voltage difference of the dancing wheel;
the internal model of the PLC controller comprises a tension calibration model which is as follows:
calculating a coefficient K:
calculating the tension T, T ═ T0+K(V-V0) (2)
Wherein T is0Calibrating tension for zero point, TsFor a 1kg weight, the tension, V0Calibrating tension voltage value, V, for zerosThe tension voltage value is calibrated for a 1kg weight, and V is the set tension voltage value.
2. The PLC-based optical fiber screening machine control model design method according to claim 1, wherein: the internal model of the PLC controller comprises a paying-off rotating model, and after the paying-off rotating model is started, whether the feedback value of the dancing wheel is equal to the set value of the dancing wheel is judged, and if the feedback value of the dancing wheel is equal to the set value of the dancing wheel, the process is finished; and if not, adding or subtracting the multiple of the offset of the paying-off dancing wheel by the rotating speed of the paying-off rotating motor until the difference value between the feedback value of the dancing wheel and the set value is equal to 0, and re-entering the cycle judgment after the operation is finished.
3. The PLC-based optical fiber screening machine control model design method according to claim 2, wherein: if the difference value between the feedback value of the dancing wheel and the set value of the dancing wheel is greater than 0, the rotating speed of the paying-off rotating motor is multiplied by the offset of the paying-off dancing wheel and output to the motor;
and if the difference value between the feedback value of the dancing wheel and the set value of the dancing wheel is less than 0, reducing the rotation speed of the paying-off rotating motor by the multiple of the offset of the paying-off dancing wheel and outputting the multiple to the motor.
4. The PLC-based optical fiber screening machine control model designing method of claim 1, wherein: the internal model of the PLC controller comprises an extra length calculation model, and the extra length calculation model comprises the following steps:
calculating the length L of the n-th layern：
Calculating the residual length delta L: Δ L ═ L- (L)1+L2+L3+Ln) (2)
Calculating the number of the extra length layers C:
wherein phitIs the inner diameter of the optical fiber reel, fΦN is the number of layers for the fiber diameter.
5. The PLC-based fiber screening machine control model design method of claim 4, wherein: the number of the extra long layers is less than or equal to that of the first layer, wherein the number of the first layer
Wherein
To ensure the spacing of each half-pass for a layer to be filled, LtThe width of the optical fiber disc.
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| CN114137824B (en) * | 2021-11-29 | 2024-01-16 | 长飞光纤光缆股份有限公司 | Method and system for controlling high-speed paying-off stability of small-pitch ADSS optical cable |
| CN115824264B (en) * | 2023-02-23 | 2023-05-09 | 中国船舶集团有限公司第七〇七研究所 | Method for evaluating and improving process reliability of hollow microstructure fiber-optic gyroscope |
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