CN112317608A - Self-resistance electric heating incremental forming temperature real-time control system and method - Google Patents
Self-resistance electric heating incremental forming temperature real-time control system and method Download PDFInfo
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- CN112317608A CN112317608A CN202011259576.1A CN202011259576A CN112317608A CN 112317608 A CN112317608 A CN 112317608A CN 202011259576 A CN202011259576 A CN 202011259576A CN 112317608 A CN112317608 A CN 112317608A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D31/00—Other methods for working sheet metal, metal tubes, metal profiles
- B21D31/005—Incremental shaping or bending, e.g. stepwise moving a shaping tool along the surface of the workpiece
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D23/00—Control of temperature
- G05D23/19—Control of temperature characterised by the use of electric means
- G05D23/27—Control of temperature characterised by the use of electric means with sensing element responsive to radiation
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- Automation & Control Theory (AREA)
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Abstract
The invention provides a self-resistance electric heating incremental forming temperature real-time control system and a method thereof, wherein the control system comprises: the device comprises an upper computer, a temperature control unit, a forming unit and a direct-current power supply; the upper computer is connected with the temperature control unit; the temperature control unit and the forming unit are connected with a direct current power supply in sequence. The control method comprises the following steps: the upper computer sets an initial temperature and calculates an effective current based on a temperature prediction model; the upper computer issues a power-on command and controls the temperature control unit to acquire the forming temperature of the forming unit; the temperature control unit performs signal conversion on the temperature value of the forming area; and the upper computer compares the temperature value of the forming area with the preset temperature to obtain a temperature adjustment amount, controls the temperature control unit, adjusts the current and controls the temperature on line. The invention can eliminate the adverse effects of unstable, overhigh and overlow temperature on the product quality, realize online rapid temperature adjustment and control, and avoid the defect of overlong adjustment time of the traditional control system.
Description
Technical Field
The invention relates to the technical field of sheet plastic forming, in particular to a system and a method for controlling self-resistance electric heating incremental forming temperature in real time.
Background
The self-resistance electric heating incremental forming technology has the advantages of rapid forming, dieless forming, rapid temperature rise, simple heating device and the like, has the characteristics of high flexibility, short development period, low cost and the like in a small-batch and multi-variety production mode, and can meet the requirement of the aviation field for rapid forming of high-performance light alloy material individualized structural members. The technology adopts a self-resistance electric heating mode which instantly generates a large amount of Joule heat when large current is applied to the plate to process the material on the basis of the original incremental forming technology, promotes the development of the incremental forming technology, and has great significance for forming and manufacturing the light alloy with poor plasticity at normal temperature in the field of aerospace.
At present, the commonly used single-point electric auxiliary heating incremental forming method has the problems of unstable temperature control, easy cracking, easy oxidation and the like, and in view of the current research situation, the method aims at the problems of incomplete temperature control of a forming area, overlong adjusting time, inflexible temperature adjustment and the like. The specific process is as follows: when the forming is started, the circuit is switched on, the preset temperature value determined in advance is compared with the temperature of the forming area, and the control is carried out through a programmable logic controller. The initial adjustment time of the temperature control method is too long, and the temperature preset value cannot be adjusted flexibly and rapidly by people in the forming process. For the deficiency, no scholars at home and abroad propose corresponding solutions. Therefore, it is necessary to provide an on-line temperature control system which can effectively solve the problems of unstable temperature control, overlong temperature adjusting time and the like in the self-resistance heating incremental forming process.
Disclosure of Invention
The invention aims to design a self-resistance electric heating incremental forming temperature real-time control system and a self-resistance electric heating incremental forming temperature real-time control method aiming at online monitoring and adjustment of the temperature of a forming area so as to eliminate adverse effects of unstable, overhigh and overlow temperature on product quality.
In order to achieve the purpose, the invention provides the following scheme: the invention provides a self-resistance electric heating incremental forming temperature real-time control system, which is characterized by comprising the following components: the device comprises an upper computer, a temperature control unit, a forming unit and a direct-current power supply;
the upper computer is connected with the temperature control unit;
the temperature control unit and the forming unit are sequentially connected with the direct-current power supply;
the upper computer is used for setting an initial temperature, calculating an effective current based on a temperature prediction model and adjusting the forming temperature of the forming unit in real time;
the temperature control unit is used for monitoring and adjusting the forming temperature of the forming unit in real time;
the forming unit is used for performing progressive forming on the material to be processed.
Preferably, a temperature prediction model is included in the upper computer;
the construction process of the temperature prediction model comprises the following steps: calculating the resistance of the deformation area of the material to be processed according to the relation between the reference resistance and the resistance of the deformation area of the material to be processed, and obtaining the heat value of the deformation area to be processed according to the effective current and the resistance value of the deformation area of the material to be processed; obtaining mass flow according to the density of the material to be processed, the feeding speed of the forming unit during forming and the cross section area of a contact area during incremental forming, and obtaining a set heat value of a deformation area to be processed according to the mass flow, the set initial temperature and the temperature of the plate to be processed; and obtaining a temperature prediction model according to the relation between the heat value of the deformation area to be processed and the set heat value of the deformation area to be processed.
Preferably, the temperature control unit comprises an infrared thermometer, a transmitter, a programmable logic controller and a relay which are connected in sequence;
the infrared thermometer is used for acquiring forming temperature data of the forming unit;
the transmitter is used for receiving the forming temperature data collected by the infrared thermometer and performing data signal conversion;
the programmable logic controller is connected with the upper computer and used for receiving the forming temperature data after data signal conversion and transmitting the forming temperature data to the upper computer;
and the relay is connected with the direct current power supply and used for controlling the output current of the direct current power supply according to the temperature adjustment quantity output by the upper computer and carrying out online temperature control.
Preferably, the forming unit comprises a forming tool, a first metal electrode, a second metal electrode and a plate material to be processed;
the forming tool is used for carrying out incremental forming on the plate to be processed and is connected with the infrared thermometer;
the first metal electrode is arranged on the forming tool and is connected with the direct current power supply;
one end of the second metal electrode is connected with the processing plate, and the other end of the second metal electrode is connected with the relay.
Preferably, the upper computer can adjust the preset temperature in real time.
The invention also provides a real-time control method for the self-resistance electric heating incremental forming temperature, which is characterized by comprising the following steps of:
s1, setting an initial temperature through the upper computer, calculating an effective current based on a temperature prediction model, issuing a power-on command, and controlling the temperature control unit to acquire the forming temperature of the forming unit to obtain a forming temperature value;
s2, performing signal conversion on the collected forming area temperature value through the temperature control unit, and transmitting the converted forming area temperature value to the upper computer;
and S3, comparing the temperature value of the forming area with the preset temperature through the upper computer to obtain a corresponding temperature adjustment amount, controlling the temperature control unit according to the temperature adjustment amount, adjusting the current and carrying out online temperature control.
The invention discloses the following technical effects: the real-time control system for the self-resistance electric heating incremental forming temperature can eliminate the adverse effects of unstable, overhigh and overlow temperature on the product quality; meanwhile, the upper computer can realize online rapid temperature adjustment and control, the defect of overlong adjustment time of the traditional control system is avoided, the page of the upper computer is good in intuition and strong in operability, and the upper computer plays a good auxiliary role in the self-resistance electric heating incremental forming process.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a schematic structural diagram of an on-line temperature control system based on self-resistance heating according to the present invention;
FIG. 2 is a schematic flow chart of an on-line temperature control method based on self-resistance heating according to 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. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
As shown in fig. 1, the present invention provides a self-resistance electric heating incremental forming temperature real-time control system, which comprises an upper computer 1, a temperature control unit 3, a forming unit 6 and a dc power supply 12;
the upper computer 1 is connected with a temperature control unit 3;
the temperature control unit 3 and the forming unit 6 are connected with the direct current power supply 12 in sequence;
the upper computer 1 is used for setting initial temperature and adjusting the temperature, a temperature prediction model is included in the upper computer 1, effective current is calculated based on the temperature prediction model by using the initial temperature, and then a power-on command is issued, so that the temperature of the plate can be quickly adjusted to be close to the set temperature;
the temperature prediction model is mainly constructed based on Joule's law, a heat calculation formula and an energy conservation formula, and the specific process is as follows:
calculating the heat value of the deformation region of the material to be processed according to the effective current and the resistance value of the deformation region of the material to be processed:
wherein:
is the electric heat equivalent as heat input; i is the effective current; r is the resistance value of the deformation area of the material to be processed and is calculated by the formula (2).
Wherein: rrefThe resistivity of the reference resistor is obtained by performing reference test on the same material; delta is the resistivity of the material to be processed; t is the thickness of the deformation zone of the material to be processed, and t is t by using the cosine theorem0Is calculated as cos α, where t0Is the initial thickness, α is the forming angle; srefA contact area that is a reference resistance; deltarefIs the resistivity of the reference resistance; t is trefThe thickness of the plate material which is a reference resistor; and S is the contact area.
Calculating the set heat value of the deformation area of the material to be processed:
wherein:
the heat value required for raising the temperature of the deformation zone is heat transmissionDischarging; c. CpIs the specific heat capacity; t is a set initial temperature value; t is0Is the initial temperature of the material to be processed;
the mass flow rate is calculated from equation (4).
Wherein rho is the density of the material to be processed; v is the forming unit feed speed; a is the contact area cross-sectional area calculated from equation (5).
Wherein: r isUWIs the cutter diameter of the forming unit.
Finally, equation (6) is obtained based on the energy conservation equation by combining equations (1) and (3), and a temperature prediction model is derived from equation (6) and represented by equation (7).
The temperature control unit 3 is used for monitoring and adjusting the temperature of the forming unit 6 in real time, and the temperature control unit 3 comprises an infrared thermometer 4, a transmitter 2, a programmable logic controller 8 and a relay 11 which are connected in sequence;
the infrared thermometer 4 is used for collecting forming temperature data of the forming unit 6;
the transmitter 2 is used for receiving the forming temperature data collected by the infrared thermometer 4 and converting data signals;
and the programmable logic controller 8 is connected with the upper computer 1 and is used for receiving the forming area temperature data after signal conversion and transmitting the forming area temperature data into the upper computer 1. The programmable logic controller 8 adopts S7-200SMART PLC, the number of single I/O points reaches 60 points, the execution time of a basic instruction is 0.15 mu S, and meanwhile, a CPU module of the PLC is provided with an Ethernet interface and integrates 3-path high-speed pulse output;
the relay 11 is connected with the direct current power supply 12 and used for controlling the output current of the direct current power supply 12 according to the adjustment quantity output by the upper computer 1 and realizing online temperature control.
The forming unit 6 is used for performing incremental forming on the processed plate. The forming unit 6 comprises a forming tool 5, a first metal electrode 7, a second metal electrode 10 and a plate material 9 to be processed;
the forming tool 5 is used for progressively forming the panel 9 to be processed. The forming tool 5 is connected with the infrared thermometer 4;
the first metal electrode 7 is arranged on the forming tool 5 and is connected with the positive electrode of the direct current power supply 12;
one end of the second metal electrode 10 is connected with the plate 9 to be processed, and the other end is connected with the relay 11.
As shown in fig. 2, a real-time control method for the self-resistance electric heating incremental forming temperature is also provided, which comprises the following steps:
s1, setting the initial temperature through the upper computer 1, and calculating the effective current based on the temperature prediction model;
s2, controlling the forming tool 5 to be in contact with the plate 9 to be processed and connecting the direct-current power supply 12 to perform forming work;
s3, issuing a power-on command through the upper computer 1, and controlling the infrared thermometer 4 to collect the forming temperature to obtain a forming area temperature value;
s4, converting the collected forming area temperature value through the transmitter 2; receiving the temperature value of the forming area after signal conversion through a programmable logic controller 8 and transmitting the temperature value to an upper computer 1;
and S5, comparing the temperature value of the forming area with the preset temperature through the upper computer 1 to obtain a corresponding temperature adjustment amount, controlling the relay 11 according to the temperature adjustment amount, adjusting the current and carrying out online temperature control.
The above-described embodiments are merely illustrative of the preferred embodiments of the present invention, and do not limit the scope of the present invention, and various modifications and improvements of the technical solutions of the present invention can be made by those skilled in the art without departing from the spirit of the present invention, and the technical solutions of the present invention are within the scope of the present invention defined by the claims.
Claims (6)
1. A self-resistance electric heating incremental forming temperature real-time control system is characterized by comprising: the device comprises an upper computer (1), a temperature control unit (3), a forming unit (6) and a direct current power supply (12);
the upper computer (1) is connected with the temperature control unit (3);
the temperature control unit (3) and the forming unit (6) are sequentially connected with the direct current power supply (12);
the upper computer (1) is used for setting an initial temperature, calculating an effective current based on a temperature prediction model, and adjusting the forming temperature of the forming unit (6) in real time;
the temperature control unit (3) is used for monitoring and adjusting the forming temperature of the forming unit (6) in real time;
the forming unit (6) is used for carrying out progressive forming on the material to be processed.
2. The real-time control system for the self-resistance electric heating incremental forming temperature according to claim 1, wherein a temperature prediction model is included in the upper computer (1);
the construction process of the temperature prediction model comprises the following steps: calculating the resistance of the deformation area of the material to be processed according to the relation between the reference resistance and the resistance of the deformation area of the material to be processed, and obtaining the heat value of the deformation area to be processed according to the effective current and the resistance value of the deformation area of the material to be processed; obtaining mass flow according to the density of the material to be processed, the feeding speed of the forming unit (6) during forming and the cross section area of a contact area during incremental forming, and obtaining a set heat value of a deformation area to be processed according to the mass flow, the set initial temperature and the temperature of the plate to be processed; and obtaining a temperature prediction model according to the relation between the heat value of the deformation area to be processed and the set heat value of the deformation area to be processed.
3. The self-resistance electric heating incremental forming temperature real-time control system according to claim 1, wherein the temperature control unit (3) comprises an infrared thermometer (4), a transmitter (2), a programmable logic controller (8) and a relay (11) which are connected in sequence;
the infrared thermometer (4) is used for collecting forming temperature data of the forming unit (6);
the transmitter (2) is used for receiving the forming temperature data collected by the infrared thermometer (4) and performing data signal conversion;
the programmable logic controller (8) is connected with the upper computer (1) and is used for receiving the forming temperature data converted by the data signals and transmitting the forming temperature data to the upper computer (1);
the relay (11) is connected with the direct current power supply (12) and used for controlling the output current of the direct current power supply (12) according to the temperature adjustment quantity output by the upper computer (1) and carrying out online temperature control.
4. The system for controlling the temperature of the progressive self-resistance electric heating forming in real time according to claim 3, wherein the forming unit (6) comprises a forming tool (5), a first metal electrode (7), a second metal electrode (10) and a sheet material (9) to be processed;
the forming tool (5) is used for performing incremental forming on the plate (9) to be processed, and the forming tool (5) is connected with the infrared thermometer (4);
the first metal electrode (7) is arranged on the forming tool (5) and is connected with the direct current power supply (12);
one end of the second metal electrode (10) is connected with the processing plate (9), and the other end of the second metal electrode is connected with the relay (11).
5. The system for controlling the temperature of progressive forming through self-resistance electric heating according to claim 1, wherein the upper computer (1) can adjust the preset temperature in real time.
6. The real-time control method for the self-resistance electric heating progressive forming temperature according to any one of claims 1 to 5, characterized by comprising the following steps:
s1, setting an initial temperature through the upper computer (1), calculating an effective current based on a temperature prediction model, issuing a power-on command, and controlling the temperature control unit (3) to acquire the forming temperature of the forming unit (6) to obtain a forming temperature value;
s2, performing signal conversion on the collected forming area temperature value through the temperature control unit (3), and transmitting the converted forming area temperature value to the upper computer (1);
s3, comparing the temperature value of the forming area with the preset temperature through the upper computer (1) to obtain a corresponding temperature adjustment amount, controlling the temperature control unit (3) according to the temperature adjustment amount, adjusting the current and carrying out online temperature control.
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