CN112305991B - Electrical control device and control method of four-knife roll printing block cutting machine - Google Patents
Electrical control device and control method of four-knife roll printing block cutting machine Download PDFInfo
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
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- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D13/00—Making of soap or soap solutions in general; Apparatus therefor
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- 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
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Abstract
The invention provides an electric control device and a control method of a four-cutter roll printing block cutting machine, wherein the control device structurally comprises a main shaft position data input module, a parameter setting input module, a cam curve calculation module, a cam curve generation and storage module, a cam curve execution mechanism module and a driven shaft position output data module; the control method specifically comprises the following steps: 1) defining a main shaft and a driven shaft; 2) determining the period of the cam; 3) planning a cam curve; 4) drawing a cam curve; 5) processing PLC curve data; 6) the PLC executes a cam curve. The invention is designed aiming at the structural characteristics of the four-knife roll-printing block cutting machine, can ensure that the equipment runs continuously without obvious rapid acceleration, deceleration and stop, and has small impact on mechanical equipment; the knife edge and the soap bar are relatively static by synchronous application, so that the cutting surface of the product is smoother, the long-time continuous operation of equipment can be ensured, and the working efficiency is improved.
Description
Technical Field
The invention relates to an electrical control device and a control method of a four-cutter roll printing block cutting machine, belonging to the technical field of electronic equipment control.
Background
The soap is a daily product which is prepared by processing and forming fatty acid metal salt, surfactant and modifier as main raw materials, can be dissolved in water and has the functions of washing and decontamination. Because the soap is convenient to use, has a good decontamination effect, has the characteristics of low price, convenience in carrying and the like, the soap, the shampoo, the shower gel and the like are washing and nursing articles which are essential in daily life, and the industrial and life demands are huge, the soap production process gradually develops towards modernization and automation.
The soap roll printing and block cutting machine is used for continuously roll printing and block cutting the soap bars extruded by the soap bar discharging machine to form regular block-shaped soap products with printing, is convenient for subsequent packaging and transportation, and basically replaces the manual soap cutting and roll printing method. As shown in fig. 1, the mechanical structure of the four-blade roll-printing dicer is schematically shown, and the structure mainly comprises an encoder roller pressed on the surface of a toilet soap bar, a cutter wheel and a servo motor connected with the cutter wheel, wherein four cutters are uniformly distributed on the cutter wheel, and the cutters are always vertical to a material plane through a mechanical cam; the hob automatically follows the speed of the soap bar according to the feeding speed of the soap bar, and soap with a specified length is cut. However, toilet soaps used in daily life have a certain thickness, in order to solve the problem of slicing thick products, the common modes of electronic cam flying shears, chasing shears and the like of the existing slicing machine cannot meet the product requirements, and an efficient and accurate electrical control method needs to be provided aiming at the structural characteristics of a four-knife roll printing slicing machine so as to ensure that the cutting knife and the materials are relatively static when moving horizontally in the interval from the contact of the knife head of the cutting knife and the upper surface of the materials to the complete cutting of the materials, thereby realizing the smooth cut surface of the materials.
Disclosure of Invention
The invention aims to overcome the defects of the conventional soap block cutting equipment and the control method, and provides an electrical control device and a control method for a four-knife roll-printing block cutting machine, so that the high-efficiency operation of the four-knife roll-printing block cutting machine is stably controlled, and the soap production efficiency is improved.
The technical solution of the invention is as follows: the electric control device of the four-knife roll printing block cutting machine structurally comprises a main shaft position data input module, a parameter setting input module, a cam curve calculation module, a cam curve generation and storage module, a cam curve execution mechanism module and a driven shaft position output data module; the input end of the parameter setting input module is connected with an external input interface, the output end of the parameter setting input module is connected with the input end of the cam curve calculation module, the output end of the cam curve calculation module is connected with the input end of the cam curve generation and storage module, and the output end of the cam curve generation and storage module is connected with the first input end of the cam curve execution mechanism module; the input end of the main shaft position data input module is connected with a roller with an encoder at the position of a main shaft of the dicer, the output end of the main shaft position data input module is connected with the second input end of the cam curve actuating mechanism module, the output end of the cam curve actuating mechanism module is connected with the input end of the driven shaft position output data module, and the output end of the driven shaft position output data module is connected with a servo motor of the dicer.
The control method of the electrical control device of the four-knife roll-printing dicer specifically comprises the following steps:
1) defining a main shaft and a slave shaft: the position data of the horizontal movement of the material is specified as main shaft data, and the rotation angle of a cutter wheel driven by a servo motor is specified as driven shaft data;
2) determining the period of the cam: rotating the cutter wheel by 90 degrees to be used as the period of a cam;
3) planning a cam curve: dividing a cam curve between two cutters into a synchronous area and a withdrawing area, and defining a contact point between the cutter and the upper surface of the material as an initial point of the synchronous area according to different thicknesses of the material; when the cutter completely cuts off the material, the cutter reaches the lowest point of the whole disc, and the point is defined as the end point of the synchronous area; the synchronous area and the evacuation area are connected intervals, so that the starting point of the evacuation area is the end point of the synchronous area; determining the end point of the pull-out area: defining a point reached by rotating the cutter by 90 degrees after the cutter is determined from the starting point as an end point of the withdrawing area;
4) drawing a cam curve: the following variables are defined: the radius of the cutter disc is R, the length of the cut soap is L, the thickness of the soap is H, the synchronous angle of the synchronous area is theta, the material advancing moving distance is X, namely main shaft data, the rotation angle of the cutter disc is Y, namely driven shaft data, and the number of data records is n; dividing the data of the driven shaft into a plurality of parts, and calculating the relative movement data of the main shaft;
5) PLC curve data processing: calculating required points of the cam curve through the PLC, assigning the points to the cam table, selecting a cubic curve to optimize data through the cam function of the PLC, and connecting all the points in the cam table in series to form a smoother cam curve;
6) the PLC executes the cam curve: and starting a cam following function of the PLC, reading the position data of the main shaft, namely the feedback position data of the encoder pressed on the material, outputting the position data of the auxiliary shaft according to the calculated cam curve, and outputting the position data of the auxiliary shaft to a servo motor driving the cutter disc after proportional processing according to a speed reducer which is connected with the servo motor by an actual turntable.
The invention has the advantages that:
1) the structural characteristic design of the four-knife roll printing block cutting machine can ensure that equipment runs continuously without obvious rapid acceleration, deceleration and stop, has small impact on mechanical equipment and greatly protects the mechanical structure;
2) the knife edge and the soap bar are relatively static by synchronous application, so that the cutting surface of the product is smoother;
3) the long-time continuous operation of the equipment can be ensured, the working efficiency is improved, and the stable cutting speed of 300 blocks/min of the four-knife roll-printing block cutting machine can be realized.
Drawings
Figure 1 is a schematic diagram of the mechanical structure of a soap dicer.
FIG. 2 is a schematic structural diagram of an electric control device of the four-blade roll-printing dicer of the present invention.
Fig. 3 is a schematic diagram of a cam curve plan.
Fig. 4 is a cam curve variable value definition diagram.
Fig. 5 is a table of cam curve data results.
FIG. 6 is a cam curve position relationship diagram.
Detailed Description
The technical scheme of the invention is further explained by combining the attached drawings. 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.
According to the mechanical structure, an electronic cam function is required to be applied to realize synchronous following. In the interval that the cutter is completely cut off the material from the contact of the cutter head of the cutter and the upper surface of the material, the cutter and the material are relatively static when moving horizontally, so that the notch surface of the material is smooth.
The electric control device of the four-knife roll-printing block cutting machine shown in fig. 2 structurally comprises a main shaft position data input module, a parameter setting input module, a cam curve calculation module, a cam curve generation and storage module, a cam curve execution mechanism module and a driven shaft position output data module; the input end of the parameter setting input module is connected to an external input interface and is used for setting system parameters such as the radius of the cutter disc, the length of the cut soap, the thickness of the soap and the like; the output end of the parameter setting input module is connected with the input end of the cam curve calculation module, the cam curve calculation module calculates corresponding cam curve data according to the data of the parameter setting input module and sends the cam curve data to the input end of the cam curve generation and storage module from the output end, the cam curve generation and storage module generates the calculated cam curve data into a smooth cam curve and stores the smooth cam curve into the cam curve storage unit, and the output end of the cam curve generation and storage module is connected with the first input end of the cam curve execution mechanism module; the input end of the main shaft position data input module is connected with a roller with an encoder at the position of a main shaft of the dicer, and the position data of the main shaft is acquired through the encoder roller pressed on the surface of the material; the output end of the main shaft position data input module is connected with the second input end of the cam curve actuating mechanism module, the cam curve actuating mechanism module compares the main shaft position data acquired by the main shaft position data input module with a cam curve to obtain slave shaft position data, the output end of the cam curve actuating mechanism module is connected with the input end of the slave shaft position output data module, the output end of the slave shaft position output data module is connected with a servo motor of the dicer, and the slave shaft position data are output to the slave shaft actuating mechanism.
The control method of the electrical control device of the four-knife roll-printing dicer specifically comprises the following steps:
1) defining a main shaft and a secondary shaft
The cutter wheel of the four-cutter roll printing block cutting machine needs to adjust the position and the speed of the cutter wheel according to the advancing position and the speed of the material, so that the material is accurately cut. Pressing a follow-up rubber roller on the upper surface of the material, wherein the other end of the rubber roller drives an encoder so as to read the position and the speed of the horizontal movement of the material; and the position data of the horizontal movement of the material is specified as main shaft data, and the rotating angle of the cutter wheel driven by the servo motor is specified as slave shaft data.
2) Determining the period of the cam
Four cutters are uniformly distributed on a cutter wheel of the four-cutter roll printing block cutting machine, and once material cutting action can be completed as long as the cutter wheel rotates by 90 degrees, so that the cutter wheel rotates by 90 degrees to serve as the period of a cam.
3) Planning a cam curve
As shown in fig. 3, the cam curve between two cutters is divided into a synchronous area (a) and an evacuation area (B); the synchronous area is an area from the contact of the cutter head of the cutter and the upper surface of the material to the complete cutting of the material by the cutter, and in the area, the horizontal direction movement speed of the cutter is required to be completely consistent with the horizontal direction movement speed of the material, so that the cutter and the material are ensured to be relatively static when moving horizontally, and the flatness of the cut surface of the material is ensured; the withdrawing area is an interval from the time when the cutter completely cuts off the material to the time when the cutter head of the next cutter is contacted with the upper surface of the material, and in the interval, the horizontal moving speed of the cutter must be larger than or equal to the horizontal moving speed of the material. Such purpose has two, and the first prevents that the material is fast than cutter horizontal movement speed, and the motion of material can be stopped by the cutter, and the second cutter withdraws fast, can make next cutter get into next synchronization interval fast to realize cutting the material of different length. The planning of the cam curve specifically comprises the following steps:
(1) determining a start point of a synchronization area
According to different thicknesses of the materials, defining a contact point of the cutter and the upper surface of the materials as a starting point of a synchronous area;
(2) determining an end point of a synchronization zone
When the cutter completely cuts off the material, the cutter reaches the lowest point of the whole disc, and the point is defined as the end point of the synchronous area;
(3) determining a starting point of a pull-out region
The synchronous area and the evacuation area are connected intervals, so that the starting point of the evacuation area is the end point of the synchronous area;
(4) determining an end point of a pull-out region
The evacuation area end point is the end point of one cutter for completing the whole material cutting action, one disc is provided with four cutters which are divided into 90-degree equal parts, the disc acts for 90 degrees, and the working cutter moves from the synchronous area starting point to the evacuation area end point to complete one-time complete material cutting action. The point reached by the cutter rotating 90 ° after it has been determined from the starting point is therefore defined as the end point of the withdrawal zone.
4) Drawing cam curve
As shown in fig. 4, the following variables are defined: the radius of the cutter disc is R, the length of the cut soap is L, the thickness of the soap is H, the synchronous angle of the synchronous zone is theta, the advancing moving distance of the materials is X (main shaft data), the rotating angle of the cutter disc is Y (axial data), and the number of data records is n.
The existing cam curve calculation method is not suitable for a four-cutter roll printing block cutting machine because the main shaft data is the data of material movement, the cut materials are different in length according to needs, and the data calculation is complex. In order to solve the problem, the data of the driven shaft is divided into a plurality of parts, and then the data of the relative movement of the main shaft is calculated. The method comprises the following specific steps:
(1) calculating a synchronization angle of the synchronization region by a formula of theta ═ arccos ((R-H)/R), and rounding the data of theta by a further method;
(2) the synchronous area is divided into a plurality of parts, because the requirement on the relative position of the cutter and the material is higher in the synchronous area, the synchronous area is divided into theta parts evenly for more accurate cam curve, each data point has a difference of 1 degree, and thus the synchronous area is composed of theta +1 data points;
(3) the cutter and the material in the evacuation area have no special synchronous relation, and are directly processed by straight lines, and only the data of the end point of the evacuation area needs to be calculated, so that the whole curve can be composed of theta +2 data points. The function algorithm for each data point is as follows:
starting point of synchronization region:
secondly, each point in the synchronous area is operated by using a for-loop function: for i ═ 1to θ, i is an integer:
③ end point of synchronization zone (i.e. start point of pull-away zone): i ═ θ:
fourthly, the end point of the escape area:
5) PLC curve data processing
The required points of the cam curve are calculated through the PLC, then the points are assigned to the cam table, then the 'cubic curve' is selected to carry out optimization processing on data through the cam function of the PLC, and all the points in the cam table are connected in series to form a smooth cam curve.
6) Cam curve of PLC
And starting a cam following function of the PLC, reading the position data of the main shaft, namely the feedback position data of the encoder pressed on the material, outputting the position data of the auxiliary shaft according to the calculated cam curve, and outputting the position data of the auxiliary shaft to a servo motor driving the cutter disc after proportional processing according to a speed reducer which is connected with the servo motor by an actual turntable.
Examples
The radius R of the cutter disc is 80, the length L of the soap is 100, the thickness H of the soap is 20, θ is calculated according to the steps in the above control method as 0.723, the radian is converted into an angle, and the angle is rounded to 42 °.
Fig. 5 is a diagram showing 44 sets of calculated data, and fig. 6 is a diagram showing a cam curve position relationship drawn based on the 44 sets of calculated data. As can be seen from fig. 6, the curve formed by connecting the dense and dense jute points in the previous section is a curve of a synchronization interval, and the curve is more smooth by optimizing data through a 'cubic curve' of the PLC; the latter section of straight line is an evacuation area curve, and the evacuation area speed is obviously higher than the synchronous area speed, so that the cutter cannot block the movement of the material, and the working requirement of the four-cutter roll printing block cutting machine is met.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (4)
1. An electric control device of a four-cutter roll printing block cutting machine is characterized by comprising a main shaft position data input module, a parameter setting input module, a cam curve calculation module, a cam curve generation and storage module, a cam curve execution mechanism module and a driven shaft position output data module; the input end of the parameter setting input module is connected to an external input interface and is used for setting system parameters such as the radius of the cutter disc, the length of the cut soap, the thickness of the soap and the like; the output end of the parameter setting input module is connected with the input end of the cam curve calculation module, the cam curve calculation module calculates corresponding cam curve data according to the data of the parameter setting input module and sends the cam curve data to the input end of the cam curve generation and storage module from the output end, the cam curve generation and storage module generates the calculated cam curve data into a smooth cam curve and stores the smooth cam curve into the cam curve storage unit, and the output end of the cam curve generation and storage module is connected with the first input end of the cam curve execution mechanism module; the input end of the main shaft position data input module is connected with a roller with an encoder at the position of a main shaft of the dicer, and the position data of the main shaft is acquired through the encoder roller pressed on the surface of the material; the output end of the main shaft position data input module is connected with the second input end of the cam curve actuating mechanism module, the cam curve actuating mechanism module compares the main shaft position data acquired by the main shaft position data input module with a cam curve to obtain slave shaft position data, the output end of the cam curve actuating mechanism module is connected with the input end of the slave shaft position output data module, the output end of the slave shaft position output data module is connected with a servo motor of the dicer, and the slave shaft position data are output to the slave shaft actuating mechanism;
the method for calculating the cam curve data comprises the following steps:
the following variables are defined: the radius of the cutter disc is R, the length of the cut soap is L, the thickness of the soap is H, the synchronous angle of the synchronous area is theta, the material advancing moving distance is X, namely main shaft data, the rotation angle of the cutter disc is Y, namely driven shaft data, and the number of data records is n; dividing the data of the driven shaft into a plurality of parts, and calculating the relative movement data of the main shaft;
the specific steps for drawing the cam curve are as follows:
(1) calculating a synchronization angle of the synchronization region by a formula of theta ═ arccos ((R-H)/R), and rounding the data of theta by a further method;
(2) the synchronous area is divided into a plurality of parts, because the requirement on the relative position of the cutter and the material is higher in the synchronous area, the synchronous area is divided into theta parts evenly for more accurate cam curve, each data point has a difference of 1 degree, and thus the synchronous area is composed of theta +1 data points;
(3) the cutter and the material in the evacuation area have no special synchronous relation, and are directly processed by straight lines, and only the data of the end point of the evacuation area needs to be calculated, so that the whole curve can be composed of theta +2 data points.
2. The control method of the electrical control device of the four-blade roll-printing block cutting machine according to claim 1, characterized by comprising the following steps:
1) defining a main shaft and a slave shaft: pressing a follow-up rubber roller on the upper surface of the material, wherein the other end of the rubber roller drives an encoder so as to read the position and the speed of the horizontal movement of the material; the position data of the horizontal movement of the material is specified as main shaft data, and the rotation angle of a cutter wheel driven by a servo motor is specified as driven shaft data;
2) determining the period of the cam: rotating the cutter wheel by 90 degrees to be used as the period of a cam;
3) planning a cam curve: dividing the cam curve between two cutters into a synchronous area and an evacuation area: the synchronous area is an area from the contact of the cutter head of the cutter and the upper surface of the material to the complete cutting of the material by the cutter, and in the area, the horizontal direction movement speed of the cutter is required to be completely consistent with the horizontal direction movement speed of the material; the withdrawing area is an area from the time when the cutter completely cuts off the material to the time when the cutter head of the next cutter is contacted with the upper surface of the material, and in the area, the horizontal moving speed of the cutter is required to be larger than or equal to the horizontal moving speed of the material;
4) drawing a cam curve: the following variables are defined: the radius of the cutter disc is R, the length of the cut soap is L, the thickness of the soap is H, the synchronous angle of the synchronous area is theta, the material advancing moving distance is X, namely main shaft data, the rotation angle of the cutter disc is Y, namely driven shaft data, and the number of data records is n; dividing the data of the driven shaft into a plurality of parts, and calculating the relative movement data of the main shaft;
5) PLC curve data processing: calculating required points of the cam curve through the PLC, assigning the points to the cam table, selecting a cubic curve to optimize data through the cam function of the PLC, and connecting all the points in the cam table in series to form a smoother cam curve;
6) the PLC executes the cam curve: and starting a cam following function of the PLC, reading the position data of the main shaft, namely the feedback position data of the encoder pressed on the material, outputting the position data of the auxiliary shaft according to the calculated cam curve, and outputting the position data of the auxiliary shaft to a servo motor driving the cutter disc after proportional processing according to a speed reducer which is connected with the servo motor by an actual turntable.
3. The control method of the electrical control device of the four-blade roll-printing block cutting machine according to claim 2, wherein the step 3) of planning the cam curve specifically comprises the following steps:
(1) determining the starting point of the synchronization area: according to different thicknesses of the materials, defining a contact point of the cutter and the upper surface of the materials as a starting point of a synchronous area;
(2) determining the end point of the synchronization zone: when the cutter completely cuts off the material, the cutter reaches the lowest point of the whole disc, and the point is defined as the end point of the synchronous area;
(3) determining the starting point of the pull-out area: the synchronous area and the evacuation area are connected intervals, so that the starting point of the evacuation area is the end point of the synchronous area;
(4) determining the end point of the pull-out area: the point reached by the cutter rotating 90 ° after being determined from the starting point is defined as the end point of the withdrawal region.
4. The method as claimed in claim 2, wherein the function algorithm corresponding to each data point is as follows:
starting point of synchronization region:
secondly, each point in the synchronous area is operated by using a for-loop function: for i ═ 1to θ, i is an integer:
③ end point of synchronous area: i ═ θ:
fourthly, the end point of the escape area:
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