Sawing machine feeding control method and sawing machine
Technical Field
The invention relates to a sawing machine control method and a sawing machine, in particular to a sawing machine feeding control method and a sawing machine.
Background
Sawing is an important component in metal cutting processes, and sawing machines are necessary equipment for performing the sawing process. The saw blade movement is a composite movement of a sawing movement in a horizontal direction and a saw blade feeding movement in a vertical direction, the sawing movement speed is usually determined according to material parameters of a sawed workpiece, and the saw blade feeding movement speed also needs to consider the section shape, the sawing width and the like of the workpiece. Research on the control of the feed of sawing machines has been a hot direction in the industry.
The Chinese patent with application number of 2015101069013 discloses a control method for constant-power sawing of a band sawing machine and an intelligent band sawing machine thereof. The power sensor detects the feedback current of the frequency converter, the feedback current passes through the rotary encoder and then is transmitted to the lower computer, and the lower computer adjusts the opening degree of the feeding flow valve through the feeding flow valve control motor according to the acquired rotating speed and torque data of the main motor, so that the lifting speed of the piston rod of the feeding oil cylinder is changed. According to the technical scheme, the power of the driving main motor is fully utilized, the influence of the sawing working condition on the service life of the saw blade and the limit condition of the feeding force of different materials are considered, and the intelligent sawing of the band sawing machine is realized. The saw frame feeding in the technical scheme is executed through the oil cylinder, and is in a feedback control mode, although the fatigue life of the saw blade is prolonged, the cutting efficiency is not improved.
The Chinese patent with application number 2012101576921 discloses a saw frame feeding system with constant sawing force and variable feeding speed and a method thereof, the system consists of a saw frame, a hydraulic system and a control system, an oil cylinder drives the saw frame to move up and down along an upright post, the system implements variable feeding speed feedforward control based on workpiece sawing width variable according to the selected type and parameters of the cross section of a workpiece, the measured displacement of the saw frame and the hardness of a workpiece material, and performs closed-loop feedback feeding control of constant sawing force according to the oil pressure value of the oil cylinder acquired by a pressure sensor, thereby improving the cutting efficiency and reducing the consumption of saw blades. Although the technical scheme discloses the feed-forward and feedback composite feed control of the saw frame, the feed of the saw frame is still performed by adopting the oil cylinder and is limited by the control precision, the feed-forward control must be implemented by combining the saw frame displacement measured in real time, a control system cannot calculate a complete feed-forward control feed speed curve and does not realize true complete feed-forward and feedback control, so the feed-forward and feedback composite feed control efficiency of the saw frame is not satisfactory, and the cutting efficiency cannot be thoroughly improved.
In summary, when the sectional area of the sawed workpiece changes greatly and a large load suddenly occurs, the existing cutting mode only depending on feedback cutting control has the problem of serious saw blade loss, and the existing feedforward and feedback control mode can not realize complete feedforward control, which is embodied as follows: firstly, feeding action is executed by adopting hydraulic cylinders such as an oil cylinder and the like, so that the feeding speed is unstable, the feeding position cannot be judged, the feeding position can be obtained only by matching measurement of a measuring part, and sudden change of saw cutting resistance cannot be judged for advanced control; secondly, due to the unstable feeding speed and the uncertainty of the feeding position, the target torque (load) of the sawed workpiece cannot be determined in advance according to different materials, different shapes, different tooth shapes and different linear velocities of the workpiece, the single-tooth cutting amount of the saw blade cannot be accurately calculated, the single-tooth torque equivalent of the saw blade cannot be determined, and therefore a feedforward control curve cannot be calculated in advance and accurately executed.
Therefore, the sawing machine feed control method and the sawing machine adopting the control method have great significance for the field, and the sawing machine is researched and developed based on a high-precision actuating mechanism, realizes complete feedforward control and closed-loop feedback control of a control system, and improves the feedforward and feedback composite feed control efficiency of a saw frame, so that the cutting efficiency of the sawing machine is thoroughly improved.
Disclosure of Invention
The invention aims to provide a sawing machine feeding control method for improving the feed-forward and feedback composite feeding control efficiency of a saw frame, and solves the problems in the background technology.
The invention also aims to provide a sawing machine, and a sawing machine feed control method adopting feed-forward and feedback composite feed control.
The technical scheme adopted by the invention for solving the technical problems is as follows:
a sawing machine feed control method, comprising the steps of:
s1, setting the material of the workpiece, the shape of the saw cutting face, the size of the saw cutting face, the tooth shape of the saw blade of the sawing machine and the linear speed of the saw blade as basic cutting parameters;
s3, calculating to obtain the saw blade single tooth cutting amount and the saw blade single tooth torque equivalent according to the basic cutting parameters through the control unit of the sawing machine, calculating to obtain the saw blade feeding speed value by combining the basic cutting parameters and the corresponding saw blade feeding speed formula, establishing a feedforward control curve of the saw blade feeding speed, and controlling the initial feeding speed of the saw blade in the cutting-in stage through the execution unit by the control unit according to the feedforward control curve;
and S4, acquiring real-time sawing force values when the workpiece is sawn through a control unit of the sawing machine, fitting on the basis of the feedforward control curve to obtain a feedforward-feedback control curve, and controlling the feeding speed of the saw blade in the cutting-in stage process through the feedforward-feedback control curve by the control unit through an execution unit.
Preferably, the method further comprises the steps of:
and S2, before the saw blade completely cuts into the workpiece, the control unit of the sawing machine controls the feeding speed of the saw blade at a cutting-in speed which is lower than the initial feeding speed of the cutting-in stage of the saw blade.
Preferably, the method further comprises the steps of:
s5, before the end of the blade cut-in phase, the feed speed of the blade is controlled by the control unit of the saw at a cut-out speed, which is lower than the feed speed during the blade cut-in phase.
Preferably, in step S3, the saw blade feed speed formula is:
wherein f (h) is the feeding speed of the saw blade, T is the target torque, i.e. the constant torque (load) value required to control the execution unit to reach when cutting the workpiece, S is the linear speed of the saw blade, T is the linear speed of the saw blade0The torque equivalent of a single tooth of the saw blade, namely a target torque value corresponding to the cutting amount of the single tooth of the saw blade, W (h) is the cutting width of the workpiece, and h is the height of the cutting position of the workpiece from the bottom surface of the workpiece.
Preferably, the calculation formula of the target torque is:
wherein beta is the cutting amount of a single tooth of the saw blade, and t is the tooth spacing of the saw blade.
Preferably, when the shape of the saw cutting face in the basic cutting parameters is a circle, the calculation formula of the cutting width of the workpiece is as follows:
wherein r is the radius of the circular saw section.
Preferably, when the shape of the saw cutting surface in the basic cutting parameters is an H shape, the calculation formula of the cutting width of the workpiece is as follows:
when (h)1+h2)/2<h≤h1When 0 is less than or equal to h<(h1-h2) At/2, W (h) is 2 XW2
When (h)1-h2)/2≤h≤(h1+h2) At/2, W (h) is W1
In the formula, h1Height of the vertical bar of H-shaped saw section, H2Height of the cross-bar being H-shaped saw cut1Maximum cross-sectional width of the H-saw section, W2The minimum cross-sectional width of the H-saw facet.
A sawing machine comprises a sawing frame, a control unit and an execution unit, wherein the control unit is electrically connected with the execution unit, the output end of the execution unit is connected with the sawing frame, the execution unit comprises a servo electric cylinder, and the control unit executes any one of the sawing machine feeding control methods.
Preferably, the control unit comprises an upper computer provided with a human-computer interaction interface, a lower computer provided with a programmable controller, a digital-to-analog converter and a frequency converter, and the frequency converter is electrically connected with the execution unit.
Preferably, the servo electric cylinder comprises a motor, a speed reducer and a screw rod, one end of the screw rod is connected with the saw frame, the other end of the screw rod is connected with the motor through the speed reducer, and the motor is electrically connected with the control unit.
The invention has the beneficial effects that:
according to the sawing machine feed control method and the sawing machine, on the basis of taking the high-precision servo electric cylinder as an execution unit, the control unit is used for establishing a feedforward control curve of the saw blade feed speed, collecting real-time saw cutting force values when a workpiece is sawn, and fitting the feedforward control curve and the feedback control curve on the basis of the feedforward control curve to obtain the feedforward-feedback control curve, so that complete feedforward and feedback composite feed control of the saw machine feed speed is realized, and the cutting efficiency of the sawing machine is remarkably improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the provided drawings without creative efforts.
FIG. 1 is a schematic flow chart of a control method in embodiment 1 of the present invention;
FIG. 2 is a schematic flow chart of a control method in embodiment 2 of the present invention;
FIG. 3 is a front view of the present invention;
FIG. 4 is a rear view of the saw machine of the present invention;
FIG. 5 is a schematic view of a workpiece of the present invention having a circular saw cut shape;
FIG. 6 is a schematic view of the workpiece of the present invention having a saw cut with an H-shaped profile;
figure 7 is a schematic view of the tooth spacing of a saw blade of the present invention.
In the figure: 1. the cutting machine comprises a saw frame, 2, a control unit, 3, an execution unit, 201, an upper computer, 301, a motor, 302, a speed reducer, 303, a lead screw, r, the radius of a circular saw cutting surface, h, the height of a workpiece cutting position from the bottom surface of a workpiece, W, the cutting width of the workpiece, h1H-shapedHeight of the vertical bar of the sawn section h2Height of the cross bar of the H-shaped saw cut plane, W1Maximum cross-sectional width of H-shaped saw section, W2The minimum cross section width of the H-shaped saw section, t, the tooth spacing of the saw blade, beta and the single-tooth cutting amount of the saw blade.
Detailed Description
The technical solution of the present invention is further specifically described below by way of specific examples in conjunction with the accompanying drawings. It is to be understood that the practice of the invention is not limited to the following examples, and that any variations and/or modifications may be made thereto without departing from the scope of the invention.
In the present invention, all parts and percentages are by weight, unless otherwise specified, and the equipment and materials used are commercially available or commonly used in the art. The methods in the following examples are conventional in the art unless otherwise specified. The components or devices in the following examples are, unless otherwise specified, standard parts or parts known to those skilled in the art, the structure and principle of which are known to those skilled in the art through technical manuals or through routine experimentation.
Example 1:
as shown in fig. 1, a method for controlling the feeding of a sawing machine specifically includes the following steps:
s1, setting the material of the workpiece, the shape of the saw cutting face, the size of the saw cutting face, the tooth shape of the saw blade of the sawing machine and the linear speed of the saw blade as basic cutting parameters;
s3, calculating to obtain the saw blade single tooth cutting amount and the saw blade single tooth torque equivalent according to the basic cutting parameters through the control unit of the sawing machine, calculating to obtain the saw blade feeding speed value by combining the basic cutting parameters and the corresponding saw blade feeding speed formula, establishing a feedforward control curve of the saw blade feeding speed, and controlling the initial feeding speed of the saw blade in the cutting-in stage through the execution unit by the control unit according to the feedforward control curve;
and S4, acquiring real-time sawing force values when the workpiece is sawn through a control unit of the sawing machine, fitting on the basis of the feedforward control curve to obtain a feedforward-feedback control curve, and controlling the feeding speed of the saw blade in the cutting-in stage process through the feedforward-feedback control curve by the control unit through an execution unit.
Through the sawing machine feeding control method, the control unit realizes complete feedforward and feedback composite feeding control on the execution unit, the control unit can calculate a feedforward control curve of the feeding speed of the saw blade in advance through the method, and then defines the upper limit value and the lower limit value of the feeding speed of the saw blade under feedback control by taking the feedforward control curve as a center through collecting real-time sawing force values, so that a feedforward-feedback control curve is obtained through fitting, the feeding speed of the saw blade in the cutting-in stage process is controlled, and the performance of the saw blade is exerted to the maximum.
As shown in fig. 3 and 4, the sawing machine includes a saw frame 1, a control unit 2 and an execution unit 3, the control unit 2 is electrically connected to the execution unit 3, an output end of the execution unit 3 is connected to the saw frame 1, the execution unit 3 includes a servo electric cylinder, and the control unit 2 executes the sawing machine feeding control method of the steps S1, S3 and S4.
Example 2:
as shown in fig. 2, the method for controlling the feeding of the sawing machine specifically comprises the following steps:
s1, setting the material of the workpiece, the shape of the saw cutting face, the size of the saw cutting face, the tooth shape of the saw blade of the sawing machine and the linear speed of the saw blade as basic cutting parameters;
s2, before the saw blade completely cuts into the workpiece, the feed speed of the saw blade is controlled by the control unit of the sawing machine at the cut-in speed, and the cut-in speed is lower than the initial feed speed of the saw blade in the cut-in stage;
s3, calculating to obtain the saw blade single tooth cutting amount and the saw blade single tooth torque equivalent according to the basic cutting parameters through the control unit of the sawing machine, calculating to obtain the saw blade feeding speed value by combining the basic cutting parameters and the corresponding saw blade feeding speed formula, establishing a feedforward control curve of the saw blade feeding speed, and controlling the initial feeding speed of the saw blade in the cutting-in stage through the execution unit by the control unit according to the feedforward control curve;
s4, acquiring real-time sawing force values when a workpiece is sawn through a control unit of the sawing machine, fitting on the basis of a feedforward control curve to obtain a feedforward-feedback control curve, and controlling the feeding speed of the saw blade in the cutting-in stage process through an execution unit by the feedforward-feedback control curve through the control unit;
s5, before the end of the blade cut-in phase, the feed speed of the blade is controlled by the control unit of the saw at a cut-out speed, which is lower than the feed speed during the blade cut-in phase.
By the sawing machine feeding control method, the negative influence of sudden change of the sawing force generated by sudden change of the sawing width of the workpiece is eliminated, and the saw is cut at a lower feeding speed before the saw blade completely cuts into the workpiece (cut-in feeding) and before the cut-in stage of the saw blade is finished (cut-out feeding), and the sawing speed of the saw blade is reduced; when the saw blade is in the process of saw cutting, the control unit realizes complete feedforward and feedback composite feeding control on the execution unit, the control unit calculates a feedforward control curve of the feeding speed of the saw blade in advance through the method, and defines the upper limit value and the lower limit value of the feeding speed of the saw blade under feedback control by taking the feedforward control curve as a center through collecting real-time saw cutting force values, so that a feedforward-feedback control curve is obtained through fitting, the feeding speed of the saw blade in the process of the saw cutting process is controlled, and the performance of the saw blade is exerted to the maximum.
In step S3, the saw blade feed speed formula is:
wherein f (h) is the feeding speed of the saw blade, T is the target torque, i.e. the constant torque (load) value required to control the execution unit to reach when cutting the workpiece, S is the linear speed of the saw blade, T is the linear speed of the saw blade0The torque equivalent of a single tooth of the saw blade, namely a target torque value corresponding to the cutting amount of the single tooth of the saw blade, W (h) is the cutting width of the workpiece, and h is the height of the cutting position of the workpiece from the bottom surface of the workpiece. As shown in fig. 5.
The calculation formula of the target torque is as follows:
wherein beta is the cutting amount of a single tooth of the saw blade, and t is the tooth spacing of the saw blade. As shown in fig. 7.
When the shape of the saw cutting surface in the basic cutting parameters is circular, the calculation formula of the cutting width of the workpiece is as follows:
wherein r is the radius of the circular saw section.
When the shape of the saw cutting surface in the basic cutting parameters is H-shaped, the calculation formula of the cutting width of the workpiece is as follows:
when (h)1+h2)/2<h≤h1When 0 is less than or equal to h<(h1-h2) At/2, W (h) is 2 XW2
When (h)1-h2)/2≤h≤(h1+h2) At/2, W (h) is W1
In the formula, h1Height of the vertical bar of H-shaped saw section, H2Height of the cross-bar being H-shaped saw cut1Maximum cross-sectional width of the H-saw section, W2The minimum cross-sectional width of the H-saw facet. As shown in fig. 6.
The cutting amount beta of the single tooth of the saw blade can be calculated by the linear speed of the saw blade, the tooth distance of the saw blade and the feeding speed of a reference saw blade, the feeding speed of the reference saw blade is a linear value based on the suggested reference feeding speed value set by the execution unit for cutting workpieces made of different materials through pre-calculation simulation, and the actual feeding speed f (h) of the saw blade in the cutting process fluctuates by taking the feeding speed of the reference saw blade as a center. Saw blade single tooth torque equivalent t0The steel is an empirical value, the values of workpieces made of different materials are different, the value range is 3.2-3.5 for 45# steel, and the value range is 2.8-3.0 for Q235 steel.
The method of the embodiment can obviously improve the cutting efficiency, takes 45# round steel with the diameter of 200mm as an example, and cuts off for 6 minutes according to the traditional cutting mode with constant feeding speed, and the cutting efficiency is 52cm2Min, according to the method of this example,cutting time 2 minutes, cutting efficiency 150cm2/min。
As shown in fig. 3 and 4, the sawing machine includes a saw frame 1, a control unit 2 and an execution unit 3, the control unit 2 is electrically connected to the execution unit 3, an output end of the execution unit 3 is connected to the saw frame 1, the execution unit 3 includes a servo electric cylinder, and the control unit 2 executes the sawing machine feeding control method from step S1 to step S5.
The control unit 2 comprises an upper computer 201 provided with a human-computer interaction interface, a lower computer provided with a programmable controller, a digital-to-analog converter and a frequency converter, wherein the frequency converter is electrically connected with the servo electric cylinder.
The servo electric cylinder comprises a motor 301, a speed reducer 302 and a lead screw 303, one end of the lead screw 303 is connected with the saw frame 1, the other end of the lead screw 303 is connected with the motor 301 through the speed reducer 302, and the motor 301 is electrically connected with the control unit 2.
The above-described embodiments are only preferred embodiments of the present invention, and are not intended to limit the present invention in any way, and other variations and modifications may be made without departing from the spirit of the invention as set forth in the claims.