CN114311272A - Automatic matching system for production line formula - Google Patents
Automatic matching system for production line formula Download PDFInfo
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- CN114311272A CN114311272A CN202111597794.0A CN202111597794A CN114311272A CN 114311272 A CN114311272 A CN 114311272A CN 202111597794 A CN202111597794 A CN 202111597794A CN 114311272 A CN114311272 A CN 114311272A
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The invention discloses an automatic matching system for production line formulas, which comprises a feeding module, a main line module, a PLC module and a servo control module, wherein the feeding module is used for establishing a gypsum board production data model according to gypsum board production result parameter data and adjusting batching parameters, the PLC module is used for reading and transmitting data, the main line module is used for conveying gypsum boards and adjusting the running speed of the main line module, and the servo control module is used for establishing a synchronous model and correcting the synchronous model according to fed real-time linear velocity data to recalculate to obtain the adjusted main line speed and transmit and implement the adjusted main line speed. According to the invention, the matching of production batching parameters and production speed in the gypsum board production process is realized through the feeding module and the servo control module, the stability of materials and speed in the production process is ensured, the labor cost is reduced, the manual intervention components in the production process are reduced, the loss of raw materials is reduced, the production cost is reduced, the optimization of the gypsum board production function is realized, and the automation level of gypsum board production is improved.
Description
Technical Field
The invention relates to the technical field of gypsum board production, in particular to an automatic matching system for a production line formula.
Background
The gypsum board is a material made of building gypsum as a main raw material, and is a building material with light weight, high strength, thin thickness, good sound insulation, heat insulation, fire prevention and other performances, a forming section of a gypsum board production line is a source of gypsum board production, whether a material in the forming section is stable directly determines the qualified rate of a finished gypsum board, so that the stability of production line operation and the stability of material addition are ensured as far as possible in the forming stage, namely the constant operation speed of each metering device in the forming stage is ensured, and the production quality of the gypsum board is easily influenced by the operation speed of each metering device and each transporting device in the gypsum board production process.
In addition, in the prior art, the feeding control and the transportation speed are usually adjusted manually, manual production intervention is more, the operation cost is higher, manual work cannot automatically match corresponding driving speed, feeding proportion and component according to the required production speed, and the product quality of the gypsum board is easily affected.
Disclosure of Invention
Therefore, the invention provides an automatic matching system for production line formulas, and solves the problems that in the prior art, manual work cannot automatically match corresponding driving speed, feeding proportion and component according to required production speed, and the product quality of a gypsum board is easily affected.
In order to solve the technical problems, the invention specifically provides the following technical scheme: an automatic matching system for production line formulas is provided with:
the feeding module is arranged at the feeding end of the gypsum board production line and used for feeding plaster, pulp water and additives to the feeding end of the gypsum board production line, adjusting the using amount of plaster, the adding amount of pulp water and the adding amount of additives according to a process formula and batching parameters input by the PLC module, and establishing a gypsum board production data model according to gypsum board production result parameter data;
the PLC module is used for calling the gypsum board production mathematical model according to production specifications, automatically matching various parameters required by production, sending the matched PLC module to the feeding module for executing various ingredient regulation and control through communication after matching is completed, and reading the main linear velocity data of the servo control module and distributing the main linear velocity data to the main line module;
the main line module is in communication connection with the PLC module and is used for conveying the gypsum board in the gypsum board production process and changing the running speed of the gypsum board according to main line speed data transmitted by the PLC module;
the servo control module is used for setting the gypsum board production line speed and establishing a synchronous model, the servo control module calculates and obtains the main line speed data based on the synchronous model and the gypsum board production line speed, detects the real-time line speed data of the gypsum board production line and compares the real-time line speed data with the gypsum board production line speed, and the servo control module corrects the synchronous model according to the comparison result to recalculate and obtain the adjusted main line speed and transmit and implement the adjusted main line speed.
As a preferable scheme of the invention, the feeding module comprises a plurality of feeding lines arranged at a feeding port of a gypsum board production line, a control valve arranged at a discharging end of the feeding lines, and a frequency converter arranged on the control valve, wherein the frequency converter is in communication connection with the PLC module and controls the opening of the control valve according to the batching parameters read by the PLC module.
As a preferred scheme of the invention, the feeding module further comprises a data processing unit, wherein the data processing unit is used for establishing a gypsum board production data model according to gypsum board production result parameters and gypsum board production process parameters, calculating batching parameters of a gypsum board according to the gypsum board production data model and the received gypsum board production linear velocity, and controlling the opening of the control valve by the frequency converter through the PLC module based on the batching parameters of the gypsum board;
the gypsum board production process parameters comprise the usage amount of the calcined gypsum, the usage amount of the calcined gypsum in unit square meter, the addition amount of pulp water, the addition amount of the pulp water in unit square meter, the production amount in unit hour, the addition amount of an additive, the addition amount of the additive in unit square meter, the single weight of a finished gypsum board, the single weight of a wet board, the production line speed of the gypsum board, the water-paste ratio, the evaporation amount and the adjustment coefficient of the gypsum board and the taste of the calcined gypsum.
As a preferred aspect of the present invention, the data processing step of the data processing unit includes:
step 100, analyzing and calculating by taking the width of the gypsum board as a meter and the thickness as b millimeters, and establishing a relation model between the usage amount of the plaster and the main line speed of the main line module;
step 200, calculating and forming a linear relational expression of the usage amount of the calcined gypsum and the production line speed of the gypsum board according to the quantity relation among the gypsum board production process parameters and a process formula model;
the linear relation between the usage amount of the calcined gypsum and the production line speed of the gypsum board is as follows: f ═ ((a-1) × N +1) × (1+ 0.5%) × 60 × a × 1000 × V;
wherein F is the usage amount of the calcined gypsum, A is the adjustment coefficient, N is the taste of the calcined gypsum, and V is the production line speed of the gypsum board;
step 300, calculating a linear relation between the addition amount of the pulp water and the speed of a gypsum board production line according to the quantitative relation among the addition amount of the pulp water, the usage amount of the calcined gypsum and the water-paste ratio;
the linear relation between the addition of the pulp water and the production line speed of the gypsum board is as follows: w water ═ G ((a-1) × N +1) × (1+ 0.5%) × 60 × a × 1000 × V;
wherein W is the added amount of the paper pulp water, and G is the water-paste ratio;
step 400, collecting empirical values in the production process to calculate the quantitative relation between the additive addition amount and the calcined gypsum usage amount, and calculating a linear relation between the additive addition amount and the gypsum board production line speed according to the quantitative relation
Linear relationship between additive addition and gypsum board production line speed: w is T ((a-1) N +1) (1+ 0.5%). is 60 a 1000V;
wherein T is the ratio of the usage amount of the plaster to the additive amount of the additive.
As a preferable scheme of the invention, the main line module comprises a forming belt and an open roller way, a plurality of uniformly distributed conveying rollers are arranged in the open roller way, the conveying rollers are connected with a driving motor, and the driving motor drives the forming belt to convey forwards through the conveying rollers.
As the preferred scheme of the invention, the servo control module comprises an upper computer, a virtual servo unit, a servo controller and a rotary encoder;
the upper computer is used for setting the production linear velocity of the gypsum board and transmitting the gypsum board to the PLC module for operation to obtain virtual shaft speed data, the virtual servo unit is used for establishing a virtual servo control shaft, receiving the virtual shaft speed data for operation and correcting the virtual shaft speed data according to the rotary encoder to obtain main linear velocity data and transmitting the main linear velocity data to the servo controller.
As a preferred aspect of the present invention, the servo controller is configured to synchronize the main linear velocity data of the virtual servo control shaft and control the driving motor to operate with the main linear velocity data, and the rotary encoder is configured to detect real-time linear velocity data of the conveying roller.
As a preferred scheme of the present invention, a plurality of data processing sections are disposed in the virtual servo unit, each data processing section corresponds to each section of the molding belt, a preliminary synchronization model corresponding to the virtual shaft speed data and the main line speed is established in the data processing section, and the main line speed data is calculated by the data processing section according to the preliminary synchronization model and the input virtual shaft speed data and is transmitted to the servo controller.
As a preferred embodiment of the present invention, the data processing section is in communication connection with the rotary encoder on the corresponding forming belt, and receives the real-time linear velocity data detected by the rotary encoder, the data processing section performs a ratio operation on the real-time linear velocity data and the virtual shaft velocity data to obtain an adjustment coefficient to establish an adjustment synchronization model, and calculates an adjustment main line velocity according to the synchronization model and the virtual shaft velocity data, and the data processing section transmits the adjustment main line velocity to the servo controller.
As a preferred aspect of the present invention, the servo controller includes a servo control axis and a database, the servo control axis controls the driving motor through a network, the database is established in the servo control axis, and the database stores corresponding driving motors and control parameters.
Compared with the prior art, the invention has the following beneficial effects:
according to the invention, the matching of production batching parameters and production speed in the gypsum board production process is respectively realized through the feeding module and the servo control module, the stability of materials and the stability of speed in the production process are ensured, the labor cost is reduced, the manual intervention components in the production process are reduced, the loss of raw materials is reduced, the production cost is reduced, the optimization of the gypsum board production function is realized, and the automation level of gypsum board production is 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 should be apparent that the drawings in the following description are merely exemplary, and that other embodiments can be derived from the drawings provided by those of ordinary skill in the art without inventive effort.
FIG. 1 is a block diagram of an automatic matching system for production line recipes according to an embodiment of the present invention;
FIG. 2 is a flow chart of data processing steps of a data processing unit in an embodiment of the present invention;
FIG. 3 is a block diagram of a virtual servo unit according to an embodiment of the present invention;
FIG. 4 is a block diagram of a servo controller according to an embodiment 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. 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.
As shown in figure 1, the invention provides an automatic matching system for production line formulas, which is characterized in that matching of production batching parameters and production speed in the gypsum board production process is respectively realized through a feeding module and a servo control module, so that stability of materials and speed in the production process are ensured, labor cost is reduced, manual intervention components in the production process are reduced, loss of raw materials is reduced, production cost is reduced, optimization of gypsum board production functions is realized, and the automation level of gypsum board production is improved.
The gypsum board production data model mainly comprises a feeding module, a main line module, a PLC module and a servo control module, wherein the feeding module is arranged at a feeding end of a gypsum board production line, the feeding module is used for feeding plaster, pulp water and additives to the feeding end of the gypsum board production line, adjusting the using amount of plaster, the adding amount of pulp water and the adding amount of additives according to a process formula and batching parameters input by the PLC module, and establishing a gypsum board production data model according to gypsum board production result parameter data; the PLC module is used for calling a gypsum board production mathematical model according to production specifications, automatically matching various parameters required by production, sending the matched PLC module to a loading module for executing various ingredient regulation and control through communication after matching is completed, and reading the main linear speed data of the servo control module and distributing the main linear speed data to the main line module; the main line module is in communication connection with the PLC module and is used for conveying the gypsum board in the gypsum board production process and changing the running speed of the gypsum board according to main line speed data transmitted by the PLC module; the servo control module is used for setting the gypsum board production line speed and establishing a synchronous model, the servo control module obtains main line speed data based on the synchronous model and gypsum board production line speed operation, detects real-time line speed data of a gypsum board production line and compares the real-time line speed data with the gypsum board production line speed, and the servo control module corrects the synchronous model according to a comparison result, recalculates the corrected main line speed and transmits and implements the corrected main line speed.
The PLC module mainly plays a role in reading data and transmitting data, the gypsum board production data model is automatically called by the PLC module according to production specifications to automatically match various parameters required by production, the parameters are sent to a feeding module control feeding part for executing various ingredient regulation and control through PLC module communication after matching is completed, and the automatic formula matching function is realized through controlling the frequency of the feeding part.
In order to realize the regulation and control of all ingredients, the feeding module mainly adopts the following preferred embodiment, the feeding module comprises a plurality of feeding lines arranged at the feeding port of a gypsum board production line, a control valve arranged at the discharging end of the feeding lines and a frequency converter arranged on the control valve, the frequency converter is in communication connection with the PLC module, and the opening degree of the control valve is controlled according to the ingredient parameters read by the PLC module.
In this embodiment, three feeding lines are mainly provided, and the three feeding lines are respectively used for feeding plaster, pulp water and additives (if other additives are required to be added, other feeding lines can be additionally provided), each feeding line is provided with a control valve, and the opening degree of the control valve can be controlled by a frequency converter, that is, the feeding amount of the plaster, the pulp water and the additives can be controlled by controlling the frequency converter, so that the product quality of the plaster board can be controlled.
In order to establish a gypsum board production data model, a data processing unit is further arranged in the feeding module and used for establishing the gypsum board production data model according to gypsum board production result parameters and gypsum board production process parameters, calculating batching parameters of the gypsum board according to the gypsum board production data model and the received gypsum board production line speed, and controlling the opening of the control valve through the PLC module based on the batching parameters of the gypsum board by controlling the frequency converter.
In the invention, the production line speed of the gypsum board is preset, the production line speed of the gypsum board is known data, the usage amount of the plaster, the addition amount of the pulp water and the addition amount of the additive can be directly calculated according to a gypsum board production data model, and the operation of the frequency converter is controlled by the obtained data of the usage amount of the plaster, the addition amount of the pulp water and the addition amount of the additive.
In this embodiment, the gypsum board production data model is established by using gypsum board production result parameters and gypsum board production process parameters, where the gypsum board production result parameters include gypsum board width data and gypsum board thickness data (the thickness data may be omitted in the practical application process of the present invention), and the gypsum board production process parameters include gypsum board usage, unit square meter of gypsum board usage, pulp water addition, unit square meter of pulp water addition, unit hour of production, additive addition, unit square meter of additive addition, finished gypsum board basis weight, wet board basis weight, gypsum board production line speed, water-gypsum ratio, gypsum board evaporation capacity and adjustment factor, and gypsum board taste.
As shown in fig. 2, the data processing steps of the data processing unit in this embodiment include:
step 100, analyzing and calculating by taking the width of the gypsum board as a meter and the thickness as b millimeters, and establishing a relation model between the usage amount of the plaster and the main line speed of the main line module;
step 200, calculating and forming a linear relational expression of the usage amount of the calcined gypsum and the production line speed of the gypsum board according to the quantity relation among the gypsum board production process parameters and a process formula model;
the linear relation between the usage amount of the calcined gypsum and the production line speed of the gypsum board is as follows: f ═ ((a-1) × N +1) × (1+ 0.5%) × 60 × a × 1000 × V
Wherein F is the usage amount of the calcined gypsum, A is the adjustment coefficient, N is the taste of the calcined gypsum, and V is the production line speed of the gypsum board;
step 300, calculating a linear relation between the addition amount of the pulp water and the speed of a gypsum board production line according to the quantitative relation among the addition amount of the pulp water, the usage amount of the calcined gypsum and the water-paste ratio;
the linear relation between the addition of the pulp water and the production line speed of the gypsum board is as follows: w water ═ G ((a-1) × N +1) × (1+ 0.5%) × 60 × a × 1000 × V;
wherein W is the added amount of the paper pulp water, and G is the water-paste ratio;
step 400, collecting empirical values in the production process to calculate the quantitative relation between the additive addition amount and the calcined gypsum usage amount, and calculating a linear relation between the additive addition amount and the gypsum board production line speed according to the quantitative relation
Linear relationship between additive addition and gypsum board production line speed: w is T ((a-1) N +1) (1+ 0.5%). is 60 a 1000V;
wherein T is the ratio of the usage amount of the plaster to the additive amount of the additive.
And obtaining a model of the usage amount of the calcined gypsum and the production line speed of the gypsum board, a model of the addition amount of the pulp water and the production line speed of the gypsum board, and a model of the addition amount of the additive and the production line speed of the gypsum board in the process, wherein the models are integrated into a gypsum board production data model.
The calculation process mentioned in step 200 above is as follows: firstly, obtaining W dry-W wet-E according to the single weight of the finished gypsum board, namely the single weight of a wet board and the evaporation amount; w is dry and is the single weight of the finished gypsum board (the single weight of the finished gypsum board is the weight of the dried gypsum board per square meter), W is wet and is the single weight of the wet board, E is the evaporation capacity, and W is dry and W is wet-E and is recorded as a quantity relation formula I; obtaining W wet ═ W + W water + W addition/S by using the wet board single weight as unit square meter of plaster of paris and unit square meter of pulp water addition and unit square meter of additive addition, wherein W water is pulp water addition, W is additive addition, S is production per hour, and W wet ═ F + W water + W addition/S is recorded as a quantity relation formula II; obtaining S60V a according to the hourly production of the gypsum board production linear velocity multiplied by 60 a, wherein V is the gypsum board production linear velocity, and the S60V a is marked as a number relation formula III; determining the usage amount of the plaster of paris and the water-paste ratio according to the usage amount of the pulp water to obtain W water, wherein G is the water-paste ratio, and recording W water, F G as a quantity relational expression IV; and fifthly, according to the process formula, the method comprises the following steps: the finished gypsum board was rated as five in quantitative relationship, where W dry is F1 ((a-1) × N +1) × (1+ 0.5%) where F1 is the unit amount of calcined gypsum used, a is the adjustment factor, N is the calcined gypsum taste, and W dry is F1 ((a-1) × N +1) ((1 + 0.5%); and sixthly, combining the quantity relations from one to four to obtain F ═ ((A-1) × N +1) × (1+ 0.5%) × 60 × 1.2 × 1000 × V (a linear relation between the usage of the calcined gypsum and the production line speed of the gypsum board).
Combining the linear relational expression and the quantitative relational expression to obtain the linear relational expression of the addition amount of the pulp water and the production line speed of the gypsum board, wherein the linear relational expression comprises the following steps: w water ═ G ((a-1) × N +1) × (1+ 0.5%) × 60 × a × 1000 × V.
The addition of foaming water and additives during the production process yields empirical values, both of which are linearly and positively correlated with the amount of plaster used, and the amount of plaster used is multiplied by a fixed factor T and the amount of additives and foaming solution used can be determined, so no separate calculation is made, and therefore, a linear relationship between the additive addition and the line speed of gypsum board production is calculated from the above quantitative relationship, i.e., W addition is T ((a-1) N +1) (1+ 0.5%) is 60 a 1000V.
The data processing unit receives the speed of the gypsum board production line, and can obtain the gypsum board usage, the pulp water addition and the additive addition through the linear relational expression, and then the gypsum board usage, the pulp water addition and the additive addition are transmitted to the PLC module, the PLC module controls the opening of the control valve so that the discharge amount of the corresponding feeding line is adjusted to the corresponding values of the gypsum board usage, the pulp water addition and the additive addition, in the actual calling process, the adjustment coefficient in the linear relational expression is related to the field production environment and the gypsum performance, so different adjustment systems are required to be summarized aiming at different production environments and gypsum performances, and the model required by gypsum board production can be better adapted according to the adjustment of the coefficient in the field production process.
The main line module mainly adopts the following preferred embodiment, the main line module comprises a forming belt and an open roller way, a plurality of uniformly distributed conveying rollers are arranged in the open roller way, the conveying rollers are connected with a driving motor, the driving motor drives the forming belt to convey forwards through the conveying rollers, and the driving motor is adopted to control the conveying speed of the belt.
The servo control module is mainly used for setting the production line speed of the gypsum board and establishing a synchronous model, the purpose of establishing the synchronous model by the servo control module is to enable the main line speed calculated according to the synchronous model to be consistent with the production line speed of the gypsum board, the servo control module mainly adopts the following preferred embodiment, and the servo control module comprises an upper computer, a virtual servo unit, a servo controller and a rotary encoder.
The upper computer is used for setting the production line speed of the gypsum board and transmitting the production line speed to the PLC module to calculate to obtain virtual shaft speed data, the virtual servo unit is used for establishing a virtual servo control shaft, the virtual servo unit receives the virtual shaft speed data to operate and corrects the virtual shaft speed data according to the rotary encoder to obtain main line speed data and transmits the main line speed data to the servo controller, the servo controller is used for synchronizing the main line speed data of the virtual servo control shaft and controlling the driving motor to operate according to the main line speed data, and the rotary encoder is used for detecting the real-time line speed data of the conveying roller.
Because a plurality of belt conveying lines exist in the gypsum board production line, the tensioning degrees of the belts are different, the tension on the belts is different, when the main line speed given by the servo controller is the same in the actual production process, the running speed of the actual gypsum board on the belt is different, therefore, a plurality of data processing sections (as shown in fig. 3) are arranged in the virtual servo unit, each data processing section corresponds to each section of molding belt, a preliminary synchronization model of corresponding virtual shaft speed data and main line speed is established in the data processing section, the main line speed data is calculated by the data processing section according to the preliminary synchronization model and the input virtual shaft speed data and is transmitted to the servo controller, in this embodiment, the preliminary synchronization model may be directly set to have the main line speed data equal to the virtual axis speed data, that is, the output value of the main line speed data calculated through the data processing section is consistent with the virtual axis speed data.
After the main line speed data is transmitted to the servo controller, the servo controller controls the driving motor to operate according to the main line speed, because of environmental factors such as belt tension, the operation speed of the gypsum board on a belt is different from the initially set gypsum board production line speed, therefore, an original synchronous model needs to be removed through a data processing section for deviation correction, in the embodiment, a rotary encoder is adopted for detecting and collecting the operation speed of the gypsum board, the data processing section is in communication connection with the rotary encoder on a corresponding forming belt and receives real-time line speed data detected by the rotary encoder, the data processing section performs ratio operation on the real-time line speed data and virtual shaft speed data to obtain a correction coefficient so as to establish a regulation synchronous model, and obtains a regulation main line speed according to the synchronous model and the gypsum board production speed operation, the data processing section transmits the adjusted main line speed to the servo controller.
The adjusting synchronization model in this embodiment is that the adjusting main line speed is calculated according to the known virtual shaft speed data and the deviation correction coefficient, and the adjusting main line speed is transmitted to the driving motor to operate according to the adjusting main line speed.
As shown in fig. 4, the servo controller in this embodiment includes a servo control shaft and a database, the servo control shaft controls the driving motor through a network, the database is established in the servo control shaft, the database stores corresponding driving motors and control parameters, and the setting of the database is convenient for the servo control shaft to drive the forming belt to operate at a corresponding speed according to the speed of the main line.
In the embodiment, the speed of the main line equipment is controlled in a one-master multi-slave servo control mode, and the real-time feedback of the rotary encoder is added, so that the real-time synchronization of the speed of each piece of equipment of the main line and the speed required by actual production can be ensured.
Therefore, the main implementation process of the present invention is that, when starting production, the gypsum board production line speed is input, when the gypsum board production line speed reaches the PLC module, the PLC module calls the gypsum board production data model of the feeding module and the synchronous model of the main line module, based on the gypsum board production data model and the synchronous model, the corresponding plaster usage amount, pulp water addition amount, additive addition amount and adjustment main line speed are calculated according to the gypsum board production line speed, the output amounts (plaster usage amount, pulp water addition amount, additive addition amount and adjustment main line speed) required by the plaster board production data model and the synchronous model are matched with the gypsum board production line speed, and then the output amounts are simultaneously output to the devices (frequency converter and driving motor) of the respective corresponding systems, and the frequency converter and the driving motor enable the gypsum board production line to operate according to the corresponding gypsum board production line speed and according to the corresponding gypsum board production line speed according to the plaster usage amount, pulp water addition amount, additive amount and adjustment main line speed The materials are loaded according to the required ingredients, so that the stability of the materials and the stability of the production speed in the production process are ensured.
In the invention, the PLC module can adopt Siemens PLC 1515sp, and the PLC has short scanning period and high corresponding speed, thereby ensuring that the blanking parameter and the main line speed parameter are simultaneously transmitted to the running equipment.
In addition, in the actual production process, the main line module and the feeding module are communicated with the PLC module in real time, the PLC module calculates the linear speed parameter and the feeding quantity parameter of the gypsum board production set by the current production through real-time feedback, whether the equipment runs with the parameters required by the gypsum board meeting the actual production standard specification is judged, if not, the PLC module adjusts the parameters in real time through a gypsum board production data model, and meanwhile, the adjusted parameters are transmitted to the upper computer to be displayed to the inspection personnel.
The above embodiments are only exemplary embodiments of the present application, and are not intended to limit the present application, and the protection scope of the present application is defined by the claims. Various modifications and equivalents may be made by those skilled in the art within the spirit and scope of the present application and such modifications and equivalents should also be considered to be within the scope of the present application.
Claims (10)
1. An automatic matching system for production line formulas is characterized by comprising:
the feeding module is arranged at the feeding end of the gypsum board production line and used for feeding plaster, pulp water and additives to the feeding end of the gypsum board production line, adjusting the using amount of plaster, the adding amount of pulp water and the adding amount of additives according to a process formula and batching parameters input by the PLC module, and establishing a gypsum board production data model according to gypsum board production result parameter data;
the PLC module is used for calling the gypsum board production mathematical model according to production specifications, automatically matching various parameters required by production, sending the matched PLC module to the feeding module for executing various ingredient regulation and control through communication after matching is completed, and reading the main linear velocity data of the servo control module and distributing the main linear velocity data to the main line module;
the main line module is in communication connection with the PLC module and is used for conveying the gypsum board in the gypsum board production process and changing the running speed of the gypsum board according to main line speed data transmitted by the PLC module;
the servo control module is used for setting the gypsum board production line speed and establishing a synchronous model, the servo control module calculates and obtains the main line speed data based on the synchronous model and the gypsum board production line speed, detects the real-time line speed data of the gypsum board production line and compares the real-time line speed data with the gypsum board production line speed, and the servo control module corrects the synchronous model according to the comparison result to recalculate and obtain the adjusted main line speed and transmit and implement the adjusted main line speed.
2. The automatic matching system for production line formulas as claimed in claim 1, wherein the feeding module comprises a plurality of feeding lines arranged at the feeding port of a gypsum board production line, a control valve arranged at the discharging end of the feeding lines, and a frequency converter arranged on the control valve, the frequency converter is in communication connection with the PLC module, and controls the opening degree of the control valve according to the batching parameters read by the PLC module.
3. The automatic matching system for production line formula of claim 2, wherein the feeding module further comprises a data processing unit, the data processing unit is used for establishing a gypsum board production data model according to gypsum board production result parameters and gypsum board production process parameters, calculating batching parameters of gypsum boards according to the gypsum board production data model and the received gypsum board production line speed, and controlling the opening of the control valve by the frequency converter through the PLC module based on the batching parameters of the gypsum boards;
the gypsum board production process parameters comprise the usage amount of the calcined gypsum, the usage amount of the calcined gypsum in unit square meter, the addition amount of pulp water, the addition amount of the pulp water in unit square meter, the production amount in unit hour, the addition amount of an additive, the addition amount of the additive in unit square meter, the single weight of a finished gypsum board, the single weight of a wet board, the production line speed of the gypsum board, the water-paste ratio, the evaporation amount and the adjustment coefficient of the gypsum board and the taste of the calcined gypsum.
4. The automatic matching system for production line recipe as claimed in claim 3, wherein the data processing step of the data processing unit comprises:
step 100, analyzing and calculating by taking the width of the gypsum board as a meter and the thickness as b millimeters, and establishing a relation model between the usage amount of the plaster and the main line speed of the main line module;
step 200, calculating and forming a linear relational expression of the usage amount of the calcined gypsum and the production line speed of the gypsum board according to the quantity relation among the gypsum board production process parameters and a process formula model;
the linear relation between the usage amount of the calcined gypsum and the production line speed of the gypsum board is as follows: f ═ ((a-1) × N +1) × (1+ 0.5%) × 60 × a × 1000 × V;
wherein F is the usage amount of the calcined gypsum, A is the adjustment coefficient, N is the taste of the calcined gypsum, and V is the production line speed of the gypsum board;
step 300, calculating a linear relation between the addition amount of the pulp water and the speed of a gypsum board production line according to the quantitative relation among the addition amount of the pulp water, the usage amount of the calcined gypsum and the water-paste ratio;
the linear relation between the addition of the pulp water and the production line speed of the gypsum board is as follows: w water ═ G ((a-1) × N +1) × (1+ 0.5%) × 60 × a × 1000 × V;
wherein W is the added amount of the paper pulp water, and G is the water-paste ratio;
step 400, collecting empirical values in the production process to calculate the quantitative relation between the additive addition amount and the calcined gypsum usage amount, and calculating a linear relation between the additive addition amount and the gypsum board production line speed according to the quantitative relation
Linear relationship between additive addition and gypsum board production line speed: w is T ((a-1) N +1) (1+ 0.5%). is 60 a 1000V;
wherein T is the ratio of the usage amount of the plaster to the additive amount of the additive.
5. The automatic matching system for production line formulas as claimed in claim 4, wherein the main line module comprises a forming belt and an open roller way, a plurality of uniformly distributed conveying rollers are arranged in the open roller way, the conveying rollers are connected with a driving motor, and the driving motor drives the forming belt to be conveyed forwards through the conveying rollers.
6. The automatic matching system for production line formulas according to claim 5, wherein the servo control module comprises an upper computer, a virtual servo unit, a servo controller and a rotary encoder;
the upper computer is used for setting the production linear velocity of the gypsum board and transmitting the gypsum board to the PLC module for operation to obtain virtual shaft speed data, the virtual servo unit is used for establishing a virtual servo control shaft, receiving the virtual shaft speed data for operation and correcting the virtual shaft speed data according to the rotary encoder to obtain main linear velocity data and transmitting the main linear velocity data to the servo controller.
7. The system as claimed in claim 6, wherein the servo controller is configured to synchronize the main linear velocity data of the virtual servo control axis and control the driving motor to operate with the main linear velocity data, and the rotary encoder is configured to detect real-time linear velocity data of the conveying roller.
8. The automatic matching system for production line recipes according to claim 7, wherein a plurality of data processing sections are provided in the virtual servo unit, each data processing section corresponds to each section of molding belt, a preliminary synchronization model corresponding to the virtual shaft speed data and the main line speed is established in the data processing section, and the main line speed data is calculated and transmitted to the servo controller by the data processing section according to the preliminary synchronization model and the input virtual shaft speed data.
9. The automatic matching system for production line recipes according to claim 8, wherein the data processing section is in communication connection with the rotary encoder on the corresponding molding belt and receives the real-time linear velocity data detected by the rotary encoder, the data processing section performs ratio operation on the real-time linear velocity data and the virtual shaft velocity data to obtain a rectification coefficient so as to establish a regulation synchronization model, and calculates an adjustment main line velocity according to the synchronization model and the virtual shaft velocity data, and the data processing section transmits the adjustment main line velocity to the servo controller.
10. The automatic matching system for production line recipes according to claim 9, wherein the servo controller comprises a servo control shaft and a database, the servo control shaft controls the driving motors through a network, the database is established in the servo control shaft, and the database stores the corresponding driving motors and control parameters.
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| CN105425734A (en) * | 2014-09-15 | 2016-03-23 | 北新集团建材股份有限公司 | Automatic control system of plasterboard production system |
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| CN105425734A (en) * | 2014-09-15 | 2016-03-23 | 北新集团建材股份有限公司 | Automatic control system of plasterboard production system |
| CN105799061A (en) * | 2016-03-31 | 2016-07-27 | 北新集团建材股份有限公司 | Automatic proportioning method and system |
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