CN115146477B - Cooperative control method, system, medium, equipment and terminal of full-automatic cutting machine - Google Patents
Cooperative control method, system, medium, equipment and terminal of full-automatic cutting machine Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D5/00—Arrangements for operating and controlling machines or devices for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/27—Means for performing other operations combined with cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
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Abstract
The invention belongs to the technical field of collaborative design of full-automatic cutting machines, and discloses a method, a system, a medium, equipment and a terminal for collaborative control of a full-automatic cutting machine, wherein a collaborative design framework based on digital twinning is proposed by means of body theory; analyzing and calculating the working principle, the mechanism structure and the power device of the full-automatic cutting machine, and constructing a digital twin model in mechanical, electrical and automatic environments; according to the virtual verification scheme, completing the configuration and signal mapping operation of a virtual simulator, importing a digital twin model and a motion parameter index, and implementing the virtual debugging of software in a ring; and (3) testing whether the detection result is consistent with the expected result through a system function, selecting leather materials, soft cloth and different knife templates to carry out blanking tests, and verifying and analyzing the digital twin model. The method and the device successfully avoid risks in actual debugging by verifying the correctness of the digital twin virtual debugging result through on-site debugging of the device, and greatly shorten the debugging time and cost.
Description
Technical Field
The invention belongs to the technical field of collaborative design of full-automatic cutting machines, and particularly relates to a collaborative control method, a system, media, equipment and a terminal of a full-automatic cutting machine.
Background
Currently, the global industry is facing challenges to improving productivity, reducing time to market, employing more flexible manufacturing modes, and improving resource and energy efficiency to meet individual customer needs. In this context, conventional product designs have failed to meet demand in dependence on a single discipline, and multi-discipline coupling of mechanical, electronic, communication, and control has certainly become a development direction for future mechanical design and automation technology. Conventional complex product designs are serial involving stages of conceptual design, mechanical design, electrical design, automated design, prototype fabrication and debugging, each requiring repeated verification and modification, which results in continuous rework of the previous stage. Especially during physical prototype test debugging and even actual production runs, undetected design errors can cause significant damage to the equipment. In the cutting machine industry, the past single-variety mass production has lost market share, and customer demands, individualization and diversification are continuously emerging. The design mode of the traditional cutting machine needs to be changed, flexible change of each link is rapidly realized, production becomes more flexible, and the whole industrial chain of design, debugging and manufacturing is penetrated. Thus, the extension of the development cycle, the continual change in design, and the increase in cost present significant problems and challenges to conventional manufacturing enterprises.
The appearance of digital twinning provides an effective way for the consistent expression of ideal design information and actual operating conditions of complex mechanical products. In the field of intelligent manufacturing, digital twinning can realize virtual-real mapping, so that iteration efficiency of product design and manufacturing is improved, and the method has a great pushing effect on manufacturing industry upgrading and is also considered as a key technology for realizing information physical fusion. The design of the full-automatic cutting machine is used as a complex mechanical product, the design of the full-automatic cutting machine comprises the disciplines of machinery, hydraulic pressure, electricity, automation, control and the like, the design of the full-automatic cutting machine by all enterprises is still in the traditional research and development stage at present, and a great amount of field debugging is still required for the design test. With the development of social economy, the demands of customers have changed greatly, designs have diversified, and the development of cutting machines has also presented the above problems faced with complex mechanical products.
With the increase of the complexity of products and the increasingly diversified design, in order to adapt to the design requirements of modern engineering products, the multi-disciplinary collaborative design is utilized to solve the conflict among disciplines, and the product research and development period and cost are reduced. Existing studies have largely surrounded three aspects: collaborative modeling, collaborative simulation, and collaborative design optimization. In the collaborative design modeling technology direction, rosenman et al propose a three-dimensional virtual world environment that provides real-time multi-user collaboration for designers at different locations and allows different design disciplines to model their architectural views into different representations. In the collaborative design simulation technology direction, wang et al propose a service-oriented model based on collaborative computing technology, integrate a simulation model as a service, and thus perform simulation tasks in the product design. In the technical direction of collaborative design optimization, the proposed collaborative approximation method is easy to solve the problems of complex time-consuming analysis and complicated sensitivity calculation.
Along with the change of production modes and social demands and the intelligent development of complex products, the final target of product development often has great difference. Although collaborative design has been developed significantly in modeling, simulation and optimization, mature collaborative design techniques can be better combined at different design stages, taking into account the overall design process of complex products and integration and sharing problems between design models. At present, a large number of multi-disciplinary designs cause a problem of non-synergistic effect in manufacturing enterprises, different professions and different disciplines are designed separately, so that trial-manufacture debugging period is prolonged, and the existing simulation platform cannot perform linkage operation analysis of a complex mechanical model. Therefore, an information integration model of complex product collaborative design is established, and further research is required for establishing a multidisciplinary unified modeling simulation platform and an integration technology.
As the demand for personalized product functions by customers increases, the product structure becomes more and more complex. As a complex mechanical product, the fully automatic cutting machine is designed in the related fields of machinery, electricity, automation and the like, and more compact multidisciplinary collaborative design and integration are required. However, the lack of multidisciplinary coordination in conventional design methods results in a hurdle in the interaction between the design stages, and a dislocation between product design information and prototype fabrication. Moreover, the development of complex mechanical products requires on-site verification through prototype manufacturing, however, continuous reworking and modification processes occur during physical prototype test debugging and even actual production running, and undetected design errors may cause significant damage to equipment, thereby prolonging the development cycle and increasing the cost. To make up for this gap, a new digital twin drive collaborative design approach is needed.
Through the above analysis, the problems and defects existing in the prior art are as follows:
(1) The traditional design method of the full-automatic cutting machine lacks multi-disciplinary coordination, so that interaction barriers exist between design stages, and a dislocation exists between product design information and prototype manufacturing.
(2) The conventional design method of the full-automatic cutting machine has continuous reworking and modification processes, and undetected design errors can cause great damage to equipment, so that the development period is prolonged, and the cost is increased.
(3) At present, a large number of multi-disciplinary designs cause a problem of non-synergistic effect in manufacturing enterprises, so that trial-manufacture debugging period is prolonged, and the existing simulation platform cannot perform linkage operation analysis of a complex mechanical model.
(4) Aiming at the research and development of complex production mechanical equipment involving multidisciplinary knowledge of mechanical engineering, electrical engineering, automatic engineering and the like, the problem of communication barrier among different engineers exists, parallel design is difficult to realize, and the progress and success rate of product research and development are difficult to guarantee.
Disclosure of Invention
Aiming at the problems existing in the prior art, the invention provides a full-automatic cutting machine cooperative control method, a system, a medium, equipment and a terminal, in particular to a full-automatic cutting machine cooperative control method, a system, a medium, equipment and a terminal based on digital twinning.
The invention is realized in such a way that a full-automatic cutting machine cooperative control method comprises the following steps:
optimizing the design flow of the complex mechanical product from two angles of discipline professional cooperation, design and test cooperation, providing a modeling and simulation scheme by means of ontology theory, interface modeling and a digital cooperation platform, and providing a digital twin-based collaborative design method framework; analyzing and calculating the working principle, the mechanism structure and the power device of the full-automatic cutting machine, and constructing a digital twin model in mechanical, electrical and automatic environments;
according to a virtual verification scheme, completing the configuration and signal mapping operation of a virtual simulator, and importing a digital twin model and a motion parameter index, so as to implement virtual debugging of software in a ring; according to the debugging problem, sequentially carrying out an integral optimization scheme on the design; and downloading the constructed virtual verification signals, programs and controls into hardware equipment, testing whether the detection result is consistent with the expected result through the system function, selecting leather materials, soft cloth and different knife templates for blanking test, and verifying and analyzing the digital twin model.
Further, the cooperative control method of the full-automatic cutting machine comprises the following steps:
step one, carrying out collaborative design based on digital twinning;
step two, constructing a digital twin model of the full-automatic cutting machine;
and thirdly, performing virtual debugging and on-site debugging of the full-automatic cutting machine.
Further, the collaborative design based on digital twin in the first step includes:
by means of ontology, various information is described based on product concept relations, and a collaborative design digital information model is constructed. The complex mechanical product decomposes functions, disciplines and roles, decomposes into different subsystems based on functions, divides the design into modules based on disciplines and decomposes different tasks according to different roles. Combining multidisciplinary collaborative modeling and multidisciplinary collaborative simulation, and inducing and presenting a joint simulation integrated graph of different disciplines, platforms and software based on the software interface mode of each platform; under the cooperation of a product full life cycle management data platform Teamcenter, functional components are decomposed by adopting a hierarchical structure, management and data exchange are carried out for an operation process, and collaborative simulation of complex products is completed through mechanical, electrical, communication and automation platforms.
Introducing a digital twin concept into the collaborative design research and development of a complex mechanical product, and providing a collaborative design framework based on digital twin, wherein the collaborative design framework comprises three stages of concept design, detailed design and virtual verification; the conceptual design stage comprises physical space data integration and module division; the detailed design stage combines multidisciplinary collaborative modeling and simulation ideas, including mechanical-based collaborative design, electrical-based collaborative design and automation-based collaborative design; by adopting a TIA-MCD combined virtual debugging scheme, the software in-loop virtual debugging is realized by utilizing the construction of an NX-MCD mechanical environment, the construction of a TIA Portal environment, the construction of a virtual simulator and the signal mapping operation, and the PLC program debugging and the equipment simulation verification are completed.
Further, the constructing of the digital twin model of the full-automatic cutting machine in the second step includes:
(1) Mechanical environment construction
Through the analysis to the design demand of cutting machine, combine NX-MCD module motion simulation function, confirm the flow scheme that realizes cutting machine motion simulation includes: importing a model, defining a basic electromechanical object, defining a kinematic pair, an actuator and a simulation sequence, running motion simulation and optimizing a virtual prototype; judging whether the requirements are met, if not, returning to run the motion simulation; if yes, finishing the motion simulation of the cutting machine.
(2) Electrical environment construction
Realizing system development and debugging based on Portal platform; selecting Siemens S7-1500 series PLC for configuration design, adding CPU1511-1 PN PLC and common PC station in TIA Portal, adding OPC server and common IE network card in PC station, connecting PLC and IE network card port, establishing S7 connection, and completing configuration; defining variable addresses and data types in PLC variables under a PLC item; and writing a PLC program according to the functional model and the cutting machine control condition defined in the MCD.
(3) Automated environment construction
HMI simulators are used to simulate operator panels, test and optimize operational concepts or interfaces that are already in the engineering stage. After an NX-MCD environment and a TIA Portal environment are built, adding HMI equipment; based on SIMATIC smart panel TP700 Comfort, an operation interface, a coordinate correction setting interface, a tool magazine setting interface, a blanking setting interface and an IO parameter interface are constructed.
Further, the constructing the digital twin model of the full-automatic cutting machine in the second step further includes:
(1) The feeding transmission horizontally drives the ball screw through the servo motor, 4040 ball screw transmission with the lead of 3804mm is selected, the 40 ball linear guide rail bears and guides the load, the ball screw drives the feeding plate to slide on the bearing, the friction coefficient is valued to be 1.6, and the total mass of the feeding plate and the punching plate is 350kg. Carrying out calculation in the following formula to obtain an axial load of about 5500N;
F a ＝μmg；
Wherein T is a Representing driving torque, F a Represents the friction resistance of the guide surface, mu represents the friction coefficient, g represents the gravitational acceleration, m represents the weight of the transported object, L represents the lead of the feed screw, eta 1 Representing the positive efficiency of the feed screw.
The transmission process is uniform operation, the friction force mu of the ball screw guide is 0.003, and the calculated axial load is brought into a formula to obtain the friction resistance F of the guide surface a 16.5N; efficiency eta of ball screw 1 0.96, the torque T of the ball screw is 10.5N.m;
wherein P represents power, unit kW; n represents the rotation speed, r/min; t represents torque, and the unit N.m, 9550 is a calculation coefficient; a servo motor with the power of 5kW and 15 N.m is selected.
(2) Calculating a servo motor required by multi-angle rotation, taking a friction coefficient mu of a positioning disc and an aluminum synchronous large belt pulley as 0.18, taking the total mass of an object borne by the synchronous large belt pulley as about 50kg, and carrying the total mass into a formula to calculate F as 88N. The punch part selects a synchronous large belt wheel with 110 teeth, the output shaft part of the speed reducer selects a small synchronous wheel with 16 teeth, the transmission ratio is 55/8, the required rotating speed of the punch reaches 1r/s, and the output shaft rotating speed of the speed reducer is 6.875r/s; when the cylindrical load is rotated about its axis, the moment of inertia J is 1.5625 based on the cylinder mass of 50kg and the cylinder radius of 0.25 m. The normal rotation speed is required to be reached within 0.5s, the angular acceleration beta is calculated to be 120, and the calculated moment of inertia is brought into a formula to obtain the torque moment of 187.5 N.m;
M＝Jβ；
Wherein M represents torsional moment, J represents moment of inertia, beta represents angular acceleration, M represents cylinder mass, and r represents cylinder radius; a servo motor with the power of 4kW and 10 N.m is selected.
(3) The automatic pulling plate mechanism selects a rodless cylinder for transmission, the mass m of the manganese steel knife plate is 1.38kg according to the production requirement, the friction force mu between manganese steel and nylon is 0.3-0.5, and the f is 6.762N by taking 0.5 and taking the friction force calculation formula;
wherein F is the maximum load, L 0 Representing the distance from the center of gravity of the object carried by the rodless cylinder to the center of the rodless cylinder. Selecting cylinder diameter 2 according to distance between tool magazine box and punch0mm, a rodless cylinder with a stroke of 750mm, a sigma of 0.55 is taken, and L is actually measured 0 The maximum load of the cylinder is calculated to be 1.42kg, the mass of the cutter template is 1.38kg, and the bearing mass is within the range specified by the selected rodless cylinder at 8.4 cm.
(4) The tool magazine box adopts a servo motor to drive double-side ball screws to lift the tool magazine, 3232 ball screws are selected, the total mass of the tool magazine box is 200kg, the servo motor drives a 200kg load through the ball screws, and the ball screws are vertically installed;
wherein T is torque, mg is gravity, and Pb is lead of the screw rod; a servo motor with a brake of 3000r/min and 15 N.m.5 kW is selected.
(5) The transverse movement of the milling mechanism is carried out by adopting a three-phase asynchronous motor to drive a ball screw, a 3205 ball screw with a pitch of 5mm is selected, and the lifting of the milling cutter is finished by adopting an SC cylinder with a cylinder diameter of 100;
F L ＝10P(πR 1 2 -πR 2 2 )；
F T ＝0.5×10πR 1 2 ；
F Y ＝F T +mg；
wherein F is L Representing the cylinder tension, F Y Representing the pressure of the milling cutter mechanism to the rubber plate when the cylinder is ejected, F T Is thrust, R 1 Is the diameter radius of the cylinder, R 2 For the radius of the piston rod, P represents the air pressure; the milling cutter is a 6-blade disc milling cutter with the diameter of 125 mm; the transmission part of the milling cutter selects a model Y132S-8 of a three-phase asynchronous motor of 750r/min and 2.2 kW; and selecting a three-phase asynchronous motor with the speed of 1500r/min and the power of 1.5kW, namely the model Y90L-4.
The invention further aims to provide a full-automatic cutting machine applying the full-automatic cutting machine cooperative control method, wherein the full-automatic cutting machine consists of a frame, a ball screw, a servo motor, a blanking plate, a pressing cylinder, a feeding frame, a feeding roller, a screw rod seat, a milling cutter, a synchronous wheel, a hydraulic cylinder and a motor.
The flexible flaky materials of cloth, leather, textiles and other synthetic materials of paper boards are conveyed to a feeding plate through a roller device of a feeding frame by an automatic feeding device, and a servo motor is adopted to drive a ball screw for transmission; the two sides of the feeding plate are provided with blocking blocks, the two sides of the machine body are provided with pneumatic compression bars, and before the punch is used for cutting, the pneumatic compression bars automatically descend to compress the punched cloth; the punching device is used for realizing left-right transverse movement of a punching head under the gantry beam frame, a servo motor is used for driving a synchronous large belt wheel on the punching head by a speed reducer, 360-degree rotary movement is realized, and automatic typesetting is performed on complex patterns; when the cutting pattern needs to be replaced, the cutter mould starts to change the cutter, the cutter magazine cutter changing device pre-stores the machined required number of cutter templates, and the cutter changing operation between the punch and the cutter magazine is completed through the automatic drawing device of the rodless cylinder; after blanking is completed, polishing and milling operation is performed on the feeding plate, and the milling device and the feeding device realize milling operation from left to right and from front to back in sequence.
Further, according to the functional division of the full-automatic cutting machine, the whole structure of the cutting machine is divided into an automatic feeding mechanism, a stamping mechanism, an automatic drawing knife plate mechanism, a knife magazine knife changing mechanism and a milling mechanism.
The automatic feeding mechanism consists of a raw material placing rack, a material pressing part and a feeding part; the raw material placing rack comprises a carrier roller, a carrier roller bracket, a coil material mandrel and a baffle plate, and is used for placing coil materials of different types, lengths and styles; the material pressing part comprises a feeding plate head part, a feeding plate tail part, three air cylinders at the milling cutter and a material pressing rod, and is used for fixing raw materials; the feeding part consists of a feeding plate, and a servo motor is adopted to drive a ball screw for transmission.
The stamping mechanism consists of a guide sliding block, a punch pin, a speed reducer, a hydraulic cylinder and a punch knife hook; the punch head column is connected with the guide sliding block and moves along the horizontal direction in the stamping process along with the guide sliding block; the hydraulic cylinder is used for outputting main power of stamping and determining the blanking force; the punch head adopts a synchronous wheel structure, and the rotating head realizes 360-degree rotation; a synchronous wheel is arranged on a motor shaft, a synchronous belt is arranged on the wheel, linear motion is obtained, and high-precision positioning and servo motor protection are realized at any position; the clamping device is arranged at the positions of the punch and the cutter plate, the cutter changing cylinder can eject the cutter hook of the cutter plate from the cutter template, and after a new cutter plate is changed, the cutter changing cylinder contracts, so that the cutter hook of the cutter plate clamps the cutter plate.
The automatic drawing knife board mechanism consists of a rodless cylinder, a linear guide rail, a triaxial cylinder, a bolt, a connecting plate and a knife board transition frame; a rodless cylinder with 20 cylinder diameters is selected, a linear guide rail is arranged beside the rodless cylinder, and a triaxial cylinder is adopted to jack the bolt, so that the stability of the bolt inserted into the cutting board is ensured.
The tool magazine tool changing mechanism consists of a tool magazine frame, a motor, a tool template, a linear bearing, a ball screw, a guide rod and a tensioning wheel; the tool magazine box adopts a servo motor to drive double-side ball screws to lift the tool magazine, two sides adopt synchronous wheel linkage, and the pitch of the ball screws is 32mm; the servo motor selects a model with a brake; the front and the back of the tool magazine case are provided with stop rods, the mini cylinder at the top of the magazine case controls the stop rods to open and close, the stop rods are opened during tool changing, and the stop plates are closed after tool changing; in the tool changing process, the motor and the tensioning wheel drive the ball screws at the two ends, so that the tool magazine can stably lift and adjust the height in a designated manner, and the self-defined tool changing operation is completed by matching with an automatic drawing plate mechanism.
The milling system consists of a milling cutter, a milling cutter motor, a milling cutter seat, a milling cutter cylinder, a milling cutter frame, a screw rod and a milling cutter seat motor; the milling device is used for realizing three-degree-of-freedom movement, namely, the transverse movement of the milling cutter seat on the ball screw driven by the motor, the vertical movement of the milling cutter motor under the telescopic action of the cylinder and the high-speed rotation of the milling cutter driven by the milling cutter motor; the frame body part is composed of 40160 aluminum profiles, and a linear guide rail is embedded in a groove of the aluminum profiles for guiding the movement of the mechanism; the back of the connecting plate is provided with a milling groove, so that a ball screw can conveniently pass through, two side supports are arranged at the rear of the machine body, a three-phase asynchronous motor is connected with the ball screw through a coupler, and a special clamp is manufactured when a motor plate on the support is welded with the support so as to ensure the coaxiality of a motor shaft and the ball screw; when the milling cutter mechanism mills, the air cylinder ejects the milling cutter and compresses the punching plate.
Another object of the present invention is to provide a computer device, which includes a memory and a processor, wherein the memory stores a computer program, and the computer program, when executed by the processor, causes the processor to execute the full automatic cutting machine cooperative control method.
Another object of the present invention is to provide a computer-readable storage medium storing a computer program which, when executed by a processor, causes the processor to execute the full automatic cutting machine cooperative control method.
Another object of the present invention is to provide an information data processing terminal for implementing the full-automatic cutting machine.
In combination with the above technical solution and the technical problems to be solved, please analyze the following aspects to provide the following advantages and positive effects:
first, aiming at the technical problems in the prior art and the difficulty in solving the problems, the technical problems solved by the technical proposal of the invention are analyzed in detail and deeply by tightly combining the technical proposal to be protected, the results and data in the research and development process, and the like, and some technical effects brought after the problems are solved have creative technical effects. The specific description is as follows:
Firstly, the invention analyzes defects existing in the traditional design mode, and focuses on optimizing the collaborative design flow from two angles of subject professional collaboration and design test collaboration. And (3) analyzing the model concept and the relation by applying the ontology theory, and constructing a multidisciplinary collaborative modeling and simulation scheme so as to improve interoperability among multidisciplinary models. On the basis, a collaborative design method framework based on digital twin is provided, a multidisciplinary high-fidelity model is built through different research and development stages and different disciplinary angles, and the digital twin virtual debugging technology is applied to debug and verify the model in a virtual environment, so that an optimal digital twin model in the virtual environment is obtained.
Secondly, the working principle and the requirements of the full-automatic cutting machine are analyzed, equipment is divided into five parts of an automatic feeding mechanism, a stamping mechanism, an automatic drawing plate mechanism, a tool magazine tool changing mechanism and a milling mechanism according to the data integrated in physical space and the requirements of clients, and structural analysis and power device calculation are respectively carried out on each mechanism. A complete digital twin model is then built in a mechanical, electrical and automated environment to provide model and parameter indicators for the implementation of the virtual debugging scheme.
Furthermore, the invention realizes the virtual debugging of the full-automatic cutting machine. And according to the virtual verification scheme, completing the configuration and signal mapping operation of the virtual simulator, and importing the constructed digital twin model and the motion parameter index, thereby implementing the virtual debugging of the software in the ring. The method is used for analyzing the problems in debugging one by one, giving an optimization scheme, and comparing before and after optimization, so that the virtual environment verification of the virtual body of the product is realized.
Finally, the invention realizes the field debugging test and verification of the full-automatic cutting machine. And constructing a field debugging scene, downloading the constructed virtual verification signal, program and control into hardware equipment, testing whether the detection result is consistent with the expected result through the system function, selecting leather materials, soft cloth and different knife templates for blanking test, and verifying and analyzing the digital twin model. The test result effectively verifies the correctness of virtual debugging, greatly shortens the debugging time and cost, solves the problems and anomalies possibly occurring in the actual debugging process in advance, and has stronger practical application value.
Secondly, the technical scheme is regarded as a whole or from the perspective of products, and the technical scheme to be protected has the following technical effects and advantages:
The invention introduces the digital twin concept into the design research and development of complex mechanical products, and provides a digital twin-based collaborative design method which solves the difficulty of complex mechanical product design in different disciplinary fields from two angles of multidisciplinary collaboration and design test collaboration. In order to intuitively and intuitively illustrate and verify the feasibility of the design method, the invention takes the development of a full-automatic cutting machine as a case, completely presents the fusion design flow of multiple disciplines such as machinery, electricity, control, automation and the like in the development process, and constructs a digital twin model based on the multiple disciplines environment. According to the invention, through a virtual debugging scheme, integration and debugging are carried out on appearance simulation, functional simulation, interference detection, electrical control and the like, and errors of a whole machine design problem and a control program are verified in advance, so that the continuous reworking design and even machine damage problem of a full-automatic cutting machine in a field test stage are reduced, and meanwhile, the product research and development period and the product delivery time are shortened, so that the industrial competitiveness is improved.
The invention completes the field debugging test and verification of the full-automatic cutting machine, firstly completes the construction of the field debugging scene, then downloads the virtual verification signals, programs and control of the framework into hardware equipment together, tests whether the detection result is consistent with the expected result through the system function, selects leather materials, soft cloth and different knife templates for blanking test, and verifies and analyzes the digital twin model. The correctness of the digital twin virtual debugging result is verified by directly debugging the equipment on site, the risk in actual debugging is successfully avoided, compared with the traditional design flow, the debugging time and cost are greatly shortened, the problems and the anomalies possibly occurring in the actual debugging process are solved in advance, and the digital twin virtual debugging method has a strong practical application value.
Thirdly, as inventive supplementary evidence of the claims of the present invention, the following important aspects are also presented:
(1) The expected benefits and commercial values after the technical scheme of the invention is converted are as follows:
the collaborative design method provided by the invention supports the production mechanical equipment to realize multi-department collaboration from the conceptual design to the production evaluation stage, reuse the prior knowledge, shorten the time to market and make a more reasonable decision. The preliminary prediction can shorten the development period by at least 2 months, improve the competitiveness of enterprises, provide reference value for the digital design of the current enterprises and provide theoretical support for the upgrading of the manufacturing industry.
(2) The technical scheme of the invention fills the technical blank in the domestic and foreign industries:
the invention fills the defect of the digital twin technology in the product design field at home and abroad, is only widely applied to manufacturing and operation and maintenance, and has no unified design frame in the aspect of product design and no practical application. The product design method provided by the invention provides a case support for product development of the full-automatic cutting machine, combines a digital twin technology and a collaborative design theory, provides brand new thought and reference significance for intelligent design of complex products, and promotes further development of the digital twin technology in the intelligent manufacturing industry.
(3) Whether the technical scheme of the invention solves the technical problems that people want to solve all the time but fail to obtain success all the time is solved:
the present manufacturing industry is generally faced with the problem of incongruity among great multidisciplinary engineering, the ideas provided by the invention can eliminate barriers among electric, mechanical and automatic engineers, realize parallel design and parallel engineering, and ensure the consistence of an idealized virtual prototype and real production and operation information of products in the physical world, thereby improving the development progress and success rate of the products.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments of the present invention will be briefly described below, and it is obvious that the drawings described below are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flowchart of a cooperative control method of a full-automatic cutting machine according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a cooperative control method of a full-automatic cutting machine according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a P-W relationship in a multidisciplinary collaborative design provided by an embodiment of the present invention;
FIG. 4 is a schematic diagram of a model of a digital prototype in the field of multidisciplinary collaborative design provided by an embodiment of the present invention;
FIG. 5 is a schematic diagram of software integration of a multidisciplinary collaborative design provided by an embodiment of the present invention;
FIG. 6 is a layout diagram of the overall structure of a fully automatic gantry cutting machine provided by an embodiment of the present invention;
FIG. 7 is a schematic diagram of a functional model of a fully automatic cutting machine according to an embodiment of the present invention;
FIG. 8 is a simulation flow chart of an NX-MCD provided by an embodiment of the invention;
FIG. 9 is a schematic diagram of an electrical environment construction provided by an embodiment of the present invention;
FIG. 10 is a graph of punch traverse speed versus time and a graph of position versus time provided by an embodiment of the present invention;
FIG. 11 is a schematic diagram of a debug problem provided by an embodiment of the present invention;
FIG. 12 is a schematic diagram of an optimization result provided by an embodiment of the present invention;
FIG. 13 is a diagram showing the cutting effect of leather materials according to an embodiment of the present invention;
fig. 14 is a view showing a cutting effect of soft cloth according to an embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the following examples in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Aiming at the problems existing in the prior art, the invention provides a cooperative control method, a system, a medium, equipment and a terminal of a full-automatic cutting machine, and the invention is described in detail below with reference to the accompanying drawings.
1. The embodiments are explained. In order to fully understand how the invention may be embodied by those skilled in the art, this section is an illustrative embodiment in which the claims are presented for purposes of illustration.
As shown in fig. 1, the cooperative control method of the full-automatic cutting machine provided by the embodiment of the invention comprises the following steps:
s101, carrying out collaborative design based on digital twinning;
s102, constructing a digital twin model of the full-automatic cutting machine;
s103, performing virtual debugging and on-site debugging of the full-automatic cutting machine.
The full-automatic cutting machine provided by the embodiment of the invention consists of a frame, a ball screw, a servo motor, a blanking plate, a pressing cylinder, a feeding frame, a feeding roller, a screw rod seat, a milling cutter, a synchronous wheel, a hydraulic cylinder and a motor.
According to the functional division of the full-automatic cutting machine, the whole structure of the cutting machine is divided into an automatic feeding mechanism, a stamping mechanism, an automatic drawing knife plate mechanism, a knife magazine knife changing mechanism and a milling mechanism.
The automatic feeding mechanism consists of a raw material placing frame, a material pressing part and a feeding part; the raw material placing rack comprises a carrier roller, a carrier roller bracket, a coil material mandrel and a baffle plate, and is used for placing coil materials of different types, lengths and styles; the material pressing part comprises three cylinders and a material pressing rod at the head part and the tail part of the feeding plate and at the milling cutter, and is used for fixing raw materials; the feeding part consists of a feeding plate, and a servo motor is adopted to drive a ball screw for transmission.
The stamping mechanism consists of a guide sliding block, a punch pin, a speed reducer, a hydraulic cylinder and a punch knife hook; the punch head column is connected with the guide sliding block and moves along the horizontal direction in the stamping process along with the guide sliding block; the hydraulic cylinder is used for outputting main power of stamping and determining the blanking force; the punch head adopts a synchronous wheel structure, and the rotating head realizes 360-degree rotation; a synchronous wheel is arranged on a motor shaft, a synchronous belt is arranged on the wheel, linear motion is obtained, and high-precision positioning and servo motor protection are realized at any position; the clamping device is arranged at the positions of the punch and the cutter plate, the cutter changing cylinder can eject the cutter hook of the cutter plate from the cutter template, and after a new cutter plate is changed, the cutter changing cylinder contracts, so that the cutter hook of the cutter plate clamps the cutter plate.
The automatic drawing knife board mechanism consists of a rodless cylinder, a linear guide rail, a triaxial cylinder, a bolt, a connecting plate and a knife board transition frame; a rodless cylinder with 20 cylinder diameters is selected, a linear guide rail is arranged beside the rodless cylinder, and a triaxial cylinder is adopted to jack the bolt, so that the stability of the bolt inserted into the cutting board is ensured.
The tool magazine tool changing mechanism consists of a tool magazine frame, a motor, a tool template, a linear bearing, a ball screw, a guide rod and a tensioning wheel; the tool magazine box adopts a servo motor to drive double-side ball screws to lift the tool magazine, two sides adopt synchronous wheel linkage, and the pitch of the ball screws is 32mm; the servo motor selects a model with a brake; the front and the back of the tool magazine case are provided with stop rods, the mini cylinder at the top of the magazine case controls the stop rods to open and close, the stop rods are opened during tool changing, and the stop plates are closed after tool changing; in the tool changing process, the motor and the tensioning wheel drive the ball screws at the two ends, so that the tool magazine can stably lift and adjust the height in a designated manner, and the self-defined tool changing operation is completed by matching with an automatic drawing plate mechanism.
The milling system consists of a milling cutter, a milling cutter motor, a milling cutter seat, a milling cutter cylinder, a milling cutter frame, a screw rod and a milling cutter seat motor; the milling device is used for realizing three-degree-of-freedom movement, namely, the transverse movement of the milling cutter seat on the ball screw driven by the motor, the vertical movement of the milling cutter motor under the telescopic action of the cylinder and the high-speed rotation of the milling cutter driven by the milling cutter motor; the frame body part is composed of 40160 aluminum profiles, and a linear guide rail is embedded in a groove of the aluminum profiles for guiding the movement of the mechanism; the back of the connecting plate is provided with a milling groove, so that a ball screw can conveniently pass through, two side supports are arranged at the rear of the machine body, a three-phase asynchronous motor is connected with the ball screw through a coupler, and a special clamp is manufactured when a motor plate on the support is welded with the support so as to ensure the coaxiality of a motor shaft and the ball screw; when the milling cutter mechanism mills, the air cylinder ejects the milling cutter and compresses the punching plate.
The technical scheme of the invention is further described below with reference to specific embodiments.
1. Collaborative design method framework based on digital twin
1.1 multidisciplinary collaborative modeling and simulation schemes
1.1.1 concept and relationship analysis in collaborative design
The invention describes various information based on product concept relationship by means of ontology, and constructs a collaborative design digital information model. An ontology is a conceptual representation of a domain, with emphasis on the sharing and reusability of knowledge. The use of ontologies to build models facilitates interoperability between information sharing and multidisciplinary models at different stages and different disciplines. The invention decomposes the complex mechanical product from three angles of function, discipline and role, and sequentially decomposes the complex mechanical product into different subsystem developments based on the function, divides the design into various modules based on the discipline and decomposes different tasks according to different roles. As shown in fig. 3. The complex product is decomposed into a plurality of sub-functional systems based on functionality, and the sub-systems are subdivided into components, the component properties being defined based on disciplines. And finally decomposing the tasks one by one based on the roles to obtain the task requirements of the roles. The complex product system is divided into four granularity levels of a system, a subsystem, a component and a part. Taking the research and development process of the full-automatic cutting machine as an example, the development process is divided into five subsystems of automatic feeding, rotating punch, automatic lifting of a tool magazine, automatic drawing of a cutting board and rubber plate milling, wherein the rotating punch system is continuously decomposed into a plurality of modules such as motor power, pneumatic lifting, locking devices, cutter die angle control and speed reducers based on functions, and the components obtained through decomposition can be defined from a plurality of subjects, such as the pneumatic lifting can be defined from the subjects of hydraulics, dynamics and the like.
After the product is hierarchically divided, constraint meeting the product function is realized according to logic, component concepts are used as cores to describe in detail, and four layers of divided systems, sub-systems, components and parts are arranged at different stages, and different disciplines are the lowermost disciplines. And the method from decomposition to combination realizes the purpose transmission from top to bottom and the result feedback from bottom to top. A model of a digitization prototype in the collaborative design area was built as shown in fig. 4. Wherein the solid diamond arrows are aggregated relationships, representing relationships between whole and part. The solid triangle arrow is a generalized relationship, representing the relationship between a parent and a child that inherits all the structure and behavior of the parent. The dashed triangle arrow is a contract between two entities that implement the relationship, one entity defining a contract, the other entity guaranteeing that the contract is fulfilled. The dashed triangle arrow is a dependency, meaning that a change in a particular thing will affect another element.
1.1.2 modeling and simulation methods
The invention aims at physical objects which can be produced in a practical way, and aims at multidisciplinary collaborative modeling. The multidisciplinary collaborative modeling is to "assemble" software models from multiple different scientific fields of machinery, control, electronics, architecture, etc. into a larger simulation model for more accurately simulating the operation of an actual system. After the modeling of the multiple fields is completed, the models in different fields of science are required to be coordinated and operated cooperatively.
The invention solves the problem of data interaction between multidisciplinary software by means of the integrated function and various interfaces of the modeling software which is developed into perfect modeling software at present, so as to realize multidisciplinary modeling. And using an interface-based multidisciplinary modeling method, and adopting interfaces among multidisciplinary commercial software to conduct multidisciplinary modeling. The method only needs to use the simulation software interconnection module, and is simple and easy to use. Taking NX as an example, the invention uses an electromechanical integrated concept design module (Mechatronics Concept Designer, MCD) to provide an integrated idea for equipment-level production, and the information mapping interface comprises: OPC DA, OPC UA, matlab, PLCSIM Adv, TCP, UDP and the like can well realize multidisciplinary collaborative modeling of complex products based on the interfaces.
The invention combines multidisciplinary collaborative modeling and multidisciplinary collaborative simulation, and based on the mode of each platform software interface, the invention generalizes and presents the joint simulation integrated graph of different disciplines, different platforms and different software, as shown in figure 5. Under the cooperation of a product full life cycle management data platform Teamcenter, a hierarchical structure is adopted to decompose functional components, management and data exchange are carried out for the next operation process, and then the collaborative simulation of the whole complex product is completed through platforms such as machinery, electricity, communication, automation and the like.
1.2 digital twin design method frame establishment
The invention introduces the digital twin concept into the collaborative design research and development of complex mechanical products, proposes a collaborative design method framework based on digital twin, greatly shortens the product research and development flow, carries out high-fidelity simulation on physical products and presents complete product information in a virtual environment as far as possible, expands the function of virtual debugging, and thereby reduces the stages of physical trial production. As shown in fig. 2, the framework flow of the digital twin design method provided by the embodiment of the invention comprises three stages of conceptual design, detailed design and virtual verification.
1.2.1 conceptual design phase
Digital twinning is used as a mapping of the physical world, can integrate a large amount of real data, and can better regulate product concepts by transmitting feedback from clients and data of the previous generation of products in real time. Therefore, the product concept is divided into three parts of functional knowledge, behavioral knowledge and structural knowledge by combining multidisciplinary knowledge collaboration.
(1) Physical space data integration
By means of the digital twin integrated historical data, designers can analyze the sales conditions, market demands, user groups and characteristics of similar products in the market. In view of the investment plan, the designer may guide the material selection, manufacturing process, pricing, etc. of the product, thereby ensuring maximization of profits.
(2) Module division
The invention divides the process into three parts to cope with designs of different stages and different forms, which are sequentially function-oriented, manufacturing-oriented and service-oriented methods, and the product design is carried out by the corresponding method to support the operation of the product in the whole life cycle. The functional design is established in the aspect of personalized demands of users, and the personalized design of products is carried out through the integration of market and group data, and meanwhile, the satisfaction degree of delivery is improved. The method can accurately improve the matching degree of the product design and the manufacturing stage, and reduce the non-idealized error existing in actual manufacturing. The service-oriented design is established under the mature application of the current digital twin technology, namely the operation and maintenance digital twin body. The digital twinning in the operation and maintenance stage provides the functions of equipment fault prediction, maintenance planning and equipment full life cycle management and control, so that research and development key points possibly existing in product design are ensured, or the weak links of the previous generation of product design are determined, and the method has the advantages that the optimization of the next batch of products can be guided, and the updating and updating of the products are established on the continuous optimization design to finally reach the optimal degree.
1.2.2 detailed design phase
At this stage, in combination with multidisciplinary collaborative modeling and simulation ideas, mainly comprises mechanical collaborative design, electrical collaborative design and automated collaborative design.
(1) Mechanology-based collaborative design
In the mechanical design stage, the NX tool can be used for carrying out hybrid modeling and simultaneously carrying out electromechanical integrated conceptual design compared with other three-dimensional software, and the electromechanical integrated conceptual design (Mechatronics Concept Designer, MCD) is a module of the NX, so that simulation support is provided for engineers to virtually create, simulate and test machine equipment and the like required by products and production. Compared with a traditional electromechanical concept design platform, the functional design of the NX-MCD is more outstanding, the model can be modeled through corresponding modules and subjected to concept setting, and then the model is directly simulated, so that the virtual reality development time is greatly shortened. The integrated level is high, the integrated field is wide, the comprehensiveness is strong, and the defect that the conceptual design of the traditional electromechanical product is too single is overcome. Meanwhile, the automatic function in the traditional electromechanical product design is covered, and a user familiar with the traditional electromechanical concept design tool can quickly adapt to an NX-MCD electromechanical integrated design platform.
After a complete three-dimensional model is established, an NX-MCD simulation environment needs to be built. In the design of electromechanical integration concept, the basic electromechanical object is the basis, and the method is to add electromechanical characteristics to the existing three-dimensional model, so that the three-dimensional model has realistic physical characteristics and can have the motion attribute under a physical system. Specifically, the rigid body enables the geometric model to have mass and gravity characteristics, and the collision body enables the model to have collision characteristics. In the electromechanical integrated design, the motion simulation of the model needs to be performed through a kinematic pair and an actuating mechanism. On the basis of the rigid body and the collision body of the cutting machine defined in the above step, the movement mode of the object is defined through a kinematic pair. The actuator defines a driving device for linear movement or rotary movement, and the common actuator has speed and position control, wherein the speed control can control the electromechanical object to run at a set speed, and the position control is used for controlling the target position of the moving geometric body so that the geometric body stops after moving to a specified position at a specified speed. Therefore, the control of the movement speed and the movement position is realized by setting the speed or the position, and virtual devices such as a collision sensor, a distance sensor, a position sensor, a limit switch, a relay and the like can also be arranged.
The simulation of the machinery is carried out at the stage to simulate the actual physical performance, and the simulation encompasses the mechanical kinematics, dynamics, physical dynamic interference and the like. The NX-MCD provides an open interface for various subjects, and provides conditions for the subsequent implementation of electromechanical integrated debugging and management of product structures, electrical control and the like.
(2) Collaborative design based on electrics
The method mainly comprises the construction of a TIA (wireless communication system) blogging environment and the writing of a PLC program. The Bo-TiW software (Totally Integrated Automation Portal, TIA) is a fully integrated automation software platform, and is more convenient to electrically and automatically design complex products based on the platform, and mainly realizes configuration and programming work of a controller PLC and distributed equipment. Configuration of devices and networks, such as hardware, controllers, and PC systems, is achieved through TIA, where PC station, regular IE, OPC server, setting subnet, and connecting network operations are created.
In this stage, the PLC can be written by means of TIA portal software, in which the usual blocks comprising OB, FC, FB and DB can be operated directly in software, according to the functional partitioning and control requirements in the conceptual design. Besides manual programming by an engineer, the powerful time sequence automatic generation program function of the NX-MCD software can export a simulated time sequence diagram, convert the simulated time sequence diagram into a file in a PLC Open XML format, and automatically generate a sequence function diagram of the PLC in an automatic development environment such as TIA Portal Step7, thereby accelerating the development of the PLC program. Since the software is not yet fully coupled, the manual modification of the instructions is required with a small amount of warnings during the migration process, but the resulting effect is still significant compared to pure manual programming. Variable addresses and data types need to be defined under the PLC project in Portal, addresses need to be reasonably distributed, the accuracy of subsequent signal mapping is guaranteed, and preparation is made for subsequent automatic design and virtual debugging.
(3) Automation-based collaborative design
At present, the design and manufacture of complex mechanical products are not independent of automatic design, enterprises generally depend on the degree of automation in order to pursue high benefits, and market advantages are improved by means of high-new automation technologies. Automated design is an urgent need in the product design stage, and an automation level is an effective way to improve product performance and functions. The advantages of complex products are often reflected in automation technology, and the integrated automation can better meet the requirements of customers and market share. In the automatic collaborative design stage, the combination of functions and technical schemes is often analyzed. For this reason, it is necessary to complete the design of the control function and the operation function. Based on the functional requirements of the above-mentioned mechanical and electrical design, a human-machine interface (Human Machine Interface, HMI) is built, the presented interface representing a great deal of complexity of automation. An operator panel may be simulated in the HMI to test and optimize operating concepts or interfaces already in the engineering stage. HMI software is generally divided into two parts, namely system software running in HMI hardware and picture configuration software running under the Windows operating system of a PC. Generally, all man-machine interfaces are connected by a PLC to solve the man-machine interaction problem of the PLC, play the role of an upper computer and complete connection through configuration and downloading. The HMI not only can perform data and text input operation, but also can display the working state of the equipment in real time and record the production data of the equipment. Considering that in other disciplines, the design development is based on the Siemens platform, the HMI software of the invention selects Siemens series WinCC software, so that the HMI software can be applied to the TIA Portal platform conveniently.
(4) Construction of digital twin model of product
In the detailed design stage, models in a mechanical environment, an electrical environment and an automation environment are constructed, but the models are still in a relatively independent state, and how to integrate information and interact data under each design platform is the key for constructing a digital twin model of a product.
The management of model information is realized through the PLM database platform Teamcenter (TC), the model information plays a role of data integration, and the TC has strong functions in the field of the whole life cycle of the product, including product design, manufacturing planning and engineering stages. Also with the help of the S7-PLCSIM Advanced virtual simulator, the virtual simulator acts as a virtual PLC device, and can download complete programs into the virtual PLC device, simulate logic control programs and provide simulation communication functions. Under the virtual environment, all preparation works are completed, namely, mechanical, electrical and automatic models, data management, virtual simulation, communication connection and the like are established, so that a product digital twin model is constructed. The built model can be subjected to virtual debugging in a software loop mode and a hardware loop mode at the later stage, virtual equipment is directly optimized in a virtual environment according to data and results fed back by the debugging, and finally the digital twin model of the product with the best design stage is obtained.
1.2.3 virtual verification phase
The digital twin virtual debugging technology is one of optimal schemes combined with multidisciplinary collaborative simulation, so that the functions of motion simulation, PLC control simulation, man-machine interaction simulation and the like can be realized, and the effects of appearance simulation, functional analysis, behavior analysis, performance analysis, environment simulation and the like of the product are achieved. The virtual debugging mechanism is to simulate the behavior of a virtual product in a physical environment on a computer through a virtual technology. The product can be tested in advance before field debugging, and in general, verification control is the most widely applied requirement of debugging, and corresponding feedback actions are completed through signals and instructions. A logical block is a logical device defined with input/output and internal logical computing capabilities. The signal is an important part in virtual debugging, the interaction between the PLC and the model information is mainly realized through the signal, and the relation between the logic block and the signal is a corresponding relation.
A TIA-MCD combined virtual debugging scheme is adopted, namely a series of operations such as construction of an NX-MCD mechanical environment, construction of a TIA Portal environment, construction of a virtual simulator, signal mapping and the like are adopted, so that software in-loop virtual debugging is realized, and PLC program debugging and equipment simulation verification are completed. For complex mechanical devices, man-machine interaction techniques are indispensable. In the virtual verification stage, the human-computer interaction interface can completely present all functions of the complex mechanical equipment, after the PLC program is developed, the human-computer interface HMI is developed based on the equipment model in the NX-MCD, and verification results are more conveniently and intuitively checked through button operations corresponding to the functions on the human-computer interface.
After a series of virtual debugging processes are performed, the designed complex mechanical equipment is inevitably problematic, so performance analysis is required to be performed aiming at debugging results, the equipment operation stage is checked in real time, and real-time data and motion curves of the equipment are detected. The real-time data can observe the speed, the position, the acceleration, the stress condition of the X, Y, Z axis direction and the like, and the motion curve can observe the position-time relationship, the speed-time relationship, the force-time relationship and the like. The model of each stage in the virtual environment is convenient to improve design and optimize through visual data and graphs, so that the optimal digital twin model can be obtained.
2. Digital twin model construction of full-automatic cutting machine
2.1 fully automatic cutting machine working principle and demand analysis
The cutting machine is composed of a frame, a blanking plate, a feeding frame, a pressing cylinder, a ball screw, a milling cutter, a synchronous wheel, a hydraulic cylinder, a motor and the like, and fig. 6 is the overall arrangement of the designed full-automatic cutting machine. Fig. 6 (a) is a side view, and fig. 6 (b) is a front view.
The working principle of the full-automatic cutting machine is as follows: flexible flaky materials such as cloth, leather, textiles and other synthetic materials of paper boards are conveyed to a feeding plate through a roller device of a feeding frame by an automatic feeding device, a ball screw is driven by a servo motor to drive, two sides of the feeding plate are provided with blocking blocks, pneumatic pressing rods are arranged on two sides of a machine body, the pneumatic pressing rods can automatically descend before punching heads cut, punched cloth is pressed, and the defect of insufficient cutting precision caused by running of the cloth is avoided. The punching device can realize left and right lateral movement of the punching head under the gantry beam frame, adopts a servo motor to drive a synchronous large belt wheel on the punching head, realizes 360-degree rotary motion, so that complex patterns are typeset automatically, and waste of materials can be saved greatly through setting typesetting by a computer end. When the cutting pattern needs to be replaced, the cutter dies begin to be replaced, the cutter templates with the required processed number are prestored in the cutter magazine cutter replacing device, and the cutter replacing operation between the punch and the cutter magazine is completed through the automatic drawing device of the rodless cylinder. After blanking is completed, the feeding plate is required to be polished and milled, and the milling device and the feeding device realize milling work from left to right and from front to back in sequence.
The full automatic cutter functional model is shown in fig. 7.
2.2 structural analysis and Power plant calculation for fully automatic cutting machine
According to the functional division of the full-automatic cutting machine, the whole structure of the cutting machine is divided into an automatic feeding mechanism, a stamping mechanism, an automatic drawing knife plate mechanism, a knife magazine knife changing mechanism and a milling mechanism.
2.2.1 automatic feeding mechanism
The automatic feeding mechanism consists of three parts. Firstly, a raw material placing frame mainly comprises a carrier roller, a carrier roller bracket, a coil material mandrel and a baffle plate, and the function of the raw material placing frame is to place coil materials of different types, lengths and styles. Secondly, the material pressing part consists of a feeding plate head part, a tail part, three air cylinders at the milling cutter and a material pressing rod, the pneumatic compression rod can automatically descend to press the blanked cloth before the punch is used for cutting, and the material pressing part can play a role in fixing raw materials and avoid the raw materials from slipping in the blanking process. And finally, a feeding part is formed by a feeding plate, a servo motor is adopted to drive a ball screw for transmission, the transmission precision is ensured, the two sides of the feeding plate are provided with blocking blocks, and the problem of insufficient cutting precision caused by offset of the punching plate is effectively avoided.
The feeding transmission horizontally drives the ball screw through the servo motor, 4040 ball screw transmission with the lead of 3804mm is selected, the 40 ball linear guide rail bears and guides, the ball screw drives the feeding plate to slide on the bearing, certain additional friction exists in consideration of the axis error of the wheel, the friction coefficient is valued to be 1.6, and the total mass of the feeding plate and the punching plate is 350kg. The calculation carried over into equation (1) yields an axial load of about 5500N.
F a ＝μmg (1)
Wherein T is a Representing driving torque, F a Represents the friction resistance of the guide surface, mu represents the friction coefficient, g represents the gravitational acceleration, m represents the weight of the transported object, L represents the lead of the feed screw, eta 1 Representing the positive efficiency of the feed screw.
The transmission process is operated at a constant speed, the friction force mu of the ball screw guide is 0.003 and the calculated axial load is brought into the (1) to obtain the friction resistance F of the guide surface a 16.5N; efficiency eta of ball screw 1 The torque T applied to the ball screw was 10.5 N.m, which was 0.96 and was obtained by the carry-over equation (2).
Where P represents power (kW), N represents rotational speed (r/min), T represents torque (N.m), and 9550 is a calculation coefficient.
Because of the custom requirements and actual production requirements, the feeding speed required by the servo feeding system is greater than 1m/s, and the pitch of the ball screw is 40mm, the feeding speed is 2m/s, and the motor rotating speed is 3000r/min obtained by taking in formula (3). The selected rotational speed and torque are brought into the formula (4), and P is 3.3kW, so that a servo motor with the power of 5kW and 15 N.m is selected for safety.
2.2.2 stamping mechanism
The stamping mechanism consists of a guide sliding block, a punch column, a speed reducer, a hydraulic cylinder, a punch knife hook and the like. The punch head column is connected with the guide sliding block and moves along the horizontal direction in the stamping process along with the guide sliding block. The hydraulic cylinder is the main power output of stamping and determines the blanking force. The punch part adopts a synchronous wheel structure, the rotating head can rotate 360 degrees, and as the servo motor has high angle positioning precision, the synchronous wheel is arranged on a motor shaft and the synchronous belt is arranged on the wheel, linear motion can be obtained, high-precision positioning can be realized at any position, and the belt provides flexible transmission, so that the servo motor can be well protected. The clamping device is arranged at the positions of the punch and the cutter plate, the cutter changing cylinder can eject the cutter hook of the cutter plate from the cutter template, and after a new cutter plate is changed, the cutter changing cylinder contracts, so that the cutter hook of the cutter plate clamps the cutter plate.
Firstly, calculating a servo motor required by multi-angle rotation, taking a friction coefficient mu of a positioning disk and an aluminum synchronous large belt pulley as 0.18, carrying an object with a total mass of about 50kg by the synchronous large belt pulley, and carrying the object into a formula (1) to calculate F to be about 88N. The punch head part selects a synchronous large belt wheel with 110 teeth, the speed reducer output shaft part selects a small synchronous wheel with 16 teeth, the transmission ratio is 55/8, and the required rotating speed of the punch head reaches 1r/s, so that the speed reducer output shaft rotating speed is 6.875r/s, namely 412.5r/min.
When the cylindrical load is rotated about its axis, 50kg of cylinder mass and 0.25m of cylinder radius are brought into formula (6), resulting in a moment of inertia J of 1.5625. The normal rotational speed is required to be reached within 0.5s, the angular acceleration β obtained by taking into formula (7) is 120, and the calculated moment of inertia is taken into formula (5), resulting in a torque of 187.5n·m.
M＝Jβ (5)
Wherein M represents a torsional moment, J represents a moment of inertia, β represents an angular acceleration, M represents a cylinder mass, and r represents a cylinder radius.
The torque M required for a small synchronizing wheel is 27.3 N.m, since the transmission ratio is 55/8. According to the output shaft rotation speed, the torque needs to be increased to ensure the stability of the punch rotation and the accuracy in stopping, and the reduction ratio is selected to be 1:4, a speed reducer. Thus, the torque of the servo motor is 6.8 N.m, and 10 N.m is selected. Then, the resultant was carried into the formula (4) to obtain P of 3.14kW, and thus, a servo motor of 4kW or 10 N.multidot.m was used.
Then, a power device for calculating the stamping and traversing is adopted, a servo motor is also adopted for horizontally driving a ball screw at the traversing position of the stamping device, a 4040 lead ball screw with a lead of 2750mm is adopted, the weight of a punch is borne by a linear guide rail, and the coefficient is generally selected to be 0.25 due to uncontrollable actual installation. The two linear guides were then 0.5, the total mass of the punches was about 800kg, and the axial load 3920N was obtained by bringing in (1). The ball guide mu is 0.003, the ball screw efficiency eta is 0.96, and the friction resistance F is obtained by taking the ball guide mu into the formula (1) a 11.76N, and then brought into (2) to obtain the driving torque T a 5.364 N.m. In general, for safety, the actual torque should be 1.5 times of the theoretical value data, and the torque required by the servo motor is 8 N.m, so that the servo motor with the torque of 10 N.m is selected.
Because the transverse moving speed of the punch is required to be not lower than 1500mm/s, the screw pitch of the ball screw is 40mm, and the rotating speed obtained by the carrying-in type (3) is 2250r/min. And selecting a servo motor with the rotating speed of 3000r/min and the torque of 10 N.m according to the obtained torque and the type of the servo motor. Since the power P obtained in the carrying-in formula (4) was 3.14kW, a servo motor of 4kW or 10 N.multidot.m was used.
2.2.3 automatic pulling plate mechanism
The automatic drawing knife board mechanism consists of a rodless cylinder, a linear guide rail, a triaxial cylinder, a bolt, a connecting plate, a knife template transition frame and the like. The speed of pull is guaranteed to the rodless cylinder of selecting 20 cylinder diameters, is equipped with linear guide by the rodless cylinder, guarantees the accuracy when bolt back-and-forth movement, adopts triaxial cylinder to jack-up the bolt, guarantees the stability that the bolt inserted the cutting board.
The automatic pulling plate mechanism selects a rodless cylinder for transmission, the mass m of the manganese steel knife plate is 1.38kg according to production requirements, the friction force mu between manganese steel and nylon is generally between 0.3 and 0.5, and the f is 6.762N by taking 0.5 and taking the friction force calculation formula.
Wherein F is the maximum load, L 0 Representing the distance from the center of gravity of the object carried by the rodless cylinder to the center of the rodless cylinder.
According to the distance between the tool magazine box and the punch, selecting a rodless cylinder with a cylinder diameter of 20mm and a stroke of 750mm, taking L which is actually measured, wherein sigma is 0.55 0 From this, a maximum load of the cylinder of about 1.42kg, a die plate mass of 1.38kg, a load mass within the range specified by the selected rodless cylinder, was calculated for the 8.4cm carried into equation (8).
2.2.4 tool magazine tool changing mechanism
The tool magazine tool changing mechanism consists of a tool magazine frame, a motor, a tool template, a linear bearing, a ball screw, a guide rod, a tensioning wheel and the like. The tool magazine box adopts a servo motor to drive the double-side ball screw to lift the tool magazine, and two sides adopt synchronous wheel linkage, so that the pitch of the ball screw is selected to be 32mm in consideration of the requirements on speed and precision. The servo motor with the brake is generally used in the occasion of vertical or inclined plane movement, and timely brakes the lifting of the tool magazine, so that the phenomenon that the tool magazine impacts the ground due to overlarge weight can be effectively reduced. Be equipped with the pin around the tool magazine case, control the pin control by the mini cylinder at magazine top and open and shut, the pin is opened during the tool changing, and the tool changing ends baffle closure to prevent that the ground from being uneven leads to the cutting board landing. The tool changing process is realized by driving ball screws at two ends by a motor and a tensioning wheel, the stable lifting and the appointed height adjustment of the tool magazine are realized, and the whole self-defined tool changing operation is completed by matching with an automatic drawing plate mechanism.
The tool magazine box adopts a servo motor to drive double-side ball screws to lift the tool magazine, the ball screws are 3232 type ball screws, the total mass of the tool magazine box is 200kg, the servo motor drives a 200kg load through the ball screws, and the ball screws are vertically installed.
Wherein T is torque, mg is gravity, and Pb is lead of the screw rod.
And (3) carrying out the formula (9), wherein the torque T required by the servo motor to lift the load is about 10 N.m without considering friction factors, and the actual value of the servo motor is larger than the value according to the actual production requirement. Considering that the lifting requirement of the tool magazine meets both the precision and the speed, the specified lifting speed is 1m/s, the ball screw pitch is 32mm, the ball screw rotating speed is 31.25r/s, namely 1875r/min, the torque is 15 N.m, the power P obtained by the carrying-in formula (4) is 4.7kW, and finally a servo motor with a brake of 3000r/min and 15 N.m.5 kW is selected.
2.2.5 milling mechanism
The milling system comprises a milling cutter, a milling cutter motor, a milling cutter seat, a milling cutter cylinder, a milling cutter frame, a screw rod, a milling cutter seat motor and the like. The milling device mainly realizes the movement in three degrees of freedom, namely, the lateral movement of the milling cutter seat on the ball screw driven by the motor, the vertical movement of the milling cutter motor under the telescopic action of the cylinder and the high-speed rotation of the milling cutter driven by the milling cutter motor. The frame body part is composed of 40160 aluminum profile, a linear guide rail is embedded in a groove of the aluminum profile so as to guide the movement of the mechanism, a milling groove is formed in the back of the connecting plate, a ball screw is convenient to pass through, supports on two sides are installed at the rear of the frame body, a three-phase asynchronous motor is connected with the ball screw through a coupler, and a special clamp is manufactured when a motor plate on the support is welded with the support so as to ensure the coaxiality of a motor shaft and the ball screw. When the milling cutter mechanism mills, the air cylinder ejects the milling cutter and compresses the punching plate.
The transverse movement of the milling mechanism is carried out by adopting a three-phase asynchronous motor to drive a ball screw, and the milling mechanism is required to fully contact with the stamping plate as much as possible in the milling process, so that the speed cannot be too high, 3205 ball screws with the screw pitch of 5mm are selected, the lifting of the milling cutter is finished by adopting an SC cylinder with the 100 cylinder diameter, and the pressure of the milling cutter on the rubber plate is ensured by adopting a cylinder with the large cylinder diameter.
F L ＝10P(πR 1 2 -πR 2 2 ) (10)
F T ＝0.5×10πR 1 2 (11)
F Y ＝F T +mg (12)
Wherein F is L Representing the cylinder tension, F Y Representing the pressure of the milling cutter mechanism to the rubber plate when the cylinder is ejected, F T Is thrust, R 1 Is the diameter radius of the cylinder, R 2 For the piston rod radius, P represents the air pressure (typically 0.5 MPa).
And (3) preliminarily selecting 100-50 adjustable cylinders of Adand SCJ, wherein the diameter of each cylinder is 100mm, and the diameter of a piston rod is 25mm. Numerical substitution (10) for calculating F L 368N, which is greater than 300N, F is obtained from formulas (11) and (12) T 392.5N, F Y 692.5N, and the total weight of parts required to be lifted by the air cylinder is 30kg, so that the selected air cylinder meets the requirements. The milling cutter is a 6-blade disc milling cutter with a diameter of 125 mm.
Selecting a motor driven by a milling cutter, and obtaining cutting force of 800N/mm through table lookup 2 . The milling speed of the milling cutter spindle is kept at 500-1000 r/min because of the nylon plate made of the PP material, and the milling speed is not too high, otherwise, the PP material is overheated and melted and blackened, so that a three-phase asynchronous motor with 750r/min and 2.2kW, namely the Y132S-8 type, is selected as the milling cutter transmission part.
Selecting a milling traversing motor, wherein the friction force mu of the ball screw guide is 0.003, the ball screw efficiency eta is 0.96, the ball screw lead is 2131mm, and F is calculated as above Y For 692.5N, taking into account that the acting force in the milling process mainly passes through friction force, calculating by pressure and friction coefficient, increasing reasonable milling power value, selecting F a The value is 21N. Substituting into the formula (2), calculating to obtain a driving torque T of about 7.4 N.m, so that a three-phase differential torque of 1500r/min and 1.5kW is selectedThe step motor is Y90L-4 model.
2.3 digital twin model construction
2.3.1 mechanical Environment construction
The whole flow scheme for realizing the motion simulation of the cutting machine is determined by analyzing the design requirement of the cutting machine and combining with the motion simulation function of the NX-MCD module. The complete flow design is shown in fig. 8.
The invention sets the corresponding rigid body and collision body attributes for the cylinder, the compression bar, the milling cutter, the tool magazine, the knife board, the punching board, the punch head, the portal frame and the like of the cutting machine. Motion simulation of the model needs to be performed through a kinematic pair and an actuator. On the basis of the rigid body and the collision body of the cutting machine defined in the above step, the movement mode of the object is defined through a kinematic pair. The actuator defines a driving device for linear movement or rotary movement, and a common actuator has speed and position control, and the speed or position of the actuator is set to control the movement speed and the movement position. The speed control can control the electromechanical object to run at a set speed, and the position control is used for controlling the target position of the moving geometric body, so that the geometric body stops after moving to a specified position according to the specified speed, and therefore, the invention performs the position control and the speed control on the electromechanical object.
The simulation sequence plays a role of controlling the actuator in the NX MCD, and the kinematic pair and the actuator set above can be controlled based on time or event using the simulation sequence, including position control, speed control, and the like. The simulation sequence may also create conditional statements to control when to trigger the execution and failure of position control, speed control, or kinematic pairs. Designing simulation sequences according to the real working condition of the full-automatic cutting machine, and sequentially completing the design requirements: replacing the custom cutter; automatic material taking and feeding; cutting by a self-defined angle; and milling the feeding plate after finishing the work.
2.3.2 Electrical Environment construction
Based on Portal platform, can accomplish system development and debugging through high-efficient configuration fast and directly perceivedly. Siemens S7-1500 series PLC is selected for configuration design to ensure data safety and communication stability. CPU1511-1 PN PLC and a common PC station are added in TIA Portal, OPC server and a common IE network card are added in PC station, the ports of the PLC and the IE network card are connected, S7 connection is established, and configuration is completed, as shown in figure 9. In order to connect and configure the NX-MCD and TIA Portal signals in the later stage, variable addresses and data types are defined in PLC variables under the PLC item, and the addresses need to be reasonably distributed, so that the accuracy of the mapping of the subsequent signals is ensured.
In the design of an automatic tool changing control program, an original cutter plate is taken out, and after a required cutter position number is selected, a cutter magazine is lifted to a designated cutter plate position; at this time, the automatic drawing plate mechanism accurately sends the bolt to the position of the cutter plate of the cutter magazine through the linear guide rail arranged on the rodless cylinder, the bolt is lifted by adopting the triaxial cylinder, the designated cutter plate is drawn out, and finally the automatic drawing device resets. In the blanking control program design, blanking interval distance and blanking times are set, when a blanking button is pressed down, a punch head is sequentially pressed down from the leftmost side of a material, the punch head is continuously pressed down according to the set interval distance, then when the transverse distance reaches the maximum value, a punching plate of a feeding mechanism can automatically move by one unit, and the punch head is repeatedly pressed down from left to right from a second row until the pressing times reach a set value, and movement is stopped. Pressing the punching press rotary button, single setting rotation 45 degrees, servo motor rotates, realizes that the tool bit is 45 degrees rotatory, can continue the operation of pushing down. In the automatic feeding control program, after a feeding start button is pressed (the point is triggered once), the PLC controls the motor to rotate forward, the stamping plate starts to move a certain distance (the distance value is set randomly), the pneumatic pressing rod can automatically descend to press the blanked cloth, and the problem that the cutting precision is insufficient due to running of the cloth is avoided. In the milling control program, left-right lateral movement control, up-down movement control and milling cutter rotation speed control are set. Pressing a milling button, pressing the milling cutter downwards, milling the rubber plate from left to right, reaching a maximum transverse distance, and resetting the milling cutter; the punch plate is moved by one unit and the milling cutter again performs milling.
2.3.3 automated Environment construction
The HMI simulator, HMI Simulation, may simulate an operator panel to test and optimize operating concepts or interfaces already in the engineering phase. After an NX-MCD environment and a TIA Portal environment are established, HMI equipment is added finally, and the invention constructs debugging interfaces such as an operation interface, a coordinate correction setting interface, a tool magazine setting interface, a blanking setting interface, an IO parameter interface and the like based on the SIMATIC smart panel TP700 Comfort.
The invention provides a collaborative design method framework based on digital twinning, which improves the design efficiency of complex mechanical products in the related fields of machinery, electricity, automation and the like, alleviates the barriers among different engineers, realizes parallel design in the time dimension as much as possible, improves the specific gravity of a virtual body in the product design process, and increases the description of the real information of the product in the physical world under the virtual environment. Provides reference value for the digital design of the current enterprises and theoretical support for the upgrade of the manufacturing industry. The paper takes the research and development of a full-automatic cutting machine as a case, and is designed by using a digital twin collaborative design method. As the product is a customized product, the function is more, the delivery time is shortened from 8 months to 5 months of the development and delivery time of a general new product, and the economic benefit brought by enterprises is directly converted. The specific research results of the invention are as follows:
(1) Optimizing the design flow of the complex mechanical product from two angles of discipline professional cooperation, design and test cooperation, and providing a modeling and simulation scheme by means of ontology theory, interface modeling-based digital cooperation platform and the like. On the basis, a collaborative design method framework based on digital twinning is provided, and the framework has certain reference value for new product manufacturing and production factory construction.
(2) Through the conceptual design stage of the frame, physical space data and customer requirements are integrated, and the working principle, the mechanism structure and the power device of the full-automatic cutting machine are analyzed and calculated. And builds a complete digital twin model in a mechanical, electrical and automated environment during the detailed design phase. Thereby providing model and parameter indexes for the implementation of the virtual debugging scheme.
(3) Virtual debugging of the full-automatic cutting machine is realized. And according to the virtual verification scheme, completing the configuration and signal mapping operation of the virtual simulator, and importing the constructed digital twin model and the motion parameter index, thereby implementing the virtual debugging of the software in the ring. And finally, according to the debugging problem, sequentially carrying out an integral optimization scheme on the design.
(4) The method comprises the steps of constructing a field debugging scene, downloading a constructed virtual verification signal, a program and control into hardware equipment, testing whether a detection result is consistent with an expected result through a system function, selecting leather materials, soft cloth and different knife templates for blanking test, and verifying and analyzing a digital twin model. The correctness of the digital twin virtual debugging result is verified by directly debugging the equipment on site, the risk in actual debugging is successfully avoided, compared with the traditional design flow, the debugging time and cost are greatly shortened, the problems and the anomalies possibly occurring in the actual debugging process are solved in advance, and the digital twin virtual debugging method has a strong practical application value.
2. Application example. In order to prove the inventive and technical value of the technical solution of the present invention, this section is an application example on specific products or related technologies of the claim technical solution.
According to the implementation of the proposed collaborative design scheme, from the concept design, the digital twin technology is used for collecting and integrating data at the stage, and the data is used as the mapping of physical products, so that a product knowledge base, real user data, product historical design data and the like can be collected, and the improvement of new products is guided. The modular design is completed, the process is divided into three parts to cope with designs of different stages and different forms, the design is sequentially a method facing functions, manufacturing and service, and the product design is carried out through the corresponding method to support the operation of the product in the whole life cycle.
The implementation is in a detailed design stage, combines multidisciplinary collaborative modeling and simulation ideas, mainly comprises mechanical collaborative design, electrical collaborative design and automatic collaborative design, and thus builds models in mechanical environment, electrical environment and automatic environment. After a complete three-dimensional model is built, virtual devices such as an NX-MCD simulation environment, a basic electromechanical object, a rigid body, an actuating mechanism, a collision sensor, a distance sensor, a position sensor, a limit switch, a relay and the like are built. Then, the TIA Bo-pass environment is built and the PLC program is written, and a human-machine interface (Human Machine Interface, HMI) is built based on the requirements of the mechanical and electrical design on functions. Management of model information is then achieved through PLM database platform Teamcenter (TC), with the aid of an S7-PLCSIM Advanced virtual simulator acting as a virtual PLC device.
In the virtual verification stage, a TIA-MCD combined virtual debugging scheme is adopted, namely, a series of operations such as construction of an NX-MCD mechanical environment, construction of a TIAPortal environment, construction of a virtual simulator, signal mapping and the like are adopted, so that software in-loop virtual debugging is realized, and PLC program debugging and equipment simulation verification are completed. For complex mechanical devices, man-machine interaction techniques are indispensable. In the virtual verification stage, the human-computer interaction interface can completely present all functions of the complex mechanical equipment, after the PLC program is developed, the human-computer interface HMI is developed based on the equipment model in the NX-MCD, and verification results are more conveniently and intuitively checked through button operations corresponding to the functions on the human-computer interface. After a series of virtual debugging processes are performed, the designed complex mechanical equipment is inevitably problematic, so performance analysis is required to be performed aiming at debugging results, the equipment operation stage is checked in real time, and real-time data and motion curves of the equipment are detected. The real-time data can observe the speed, the position, the acceleration, the stress condition of the X, Y, Z axis direction and the like, and the motion curve can observe the position-time relationship, the speed-time relationship, the force-time relationship and the like. The model of each stage in the virtual environment is convenient to improve design and optimize through visual data and graphs, so that the optimal digital twin model can be obtained.
In the field debugging stage, firstly, the construction of a field debugging scene is completed, then virtual verification signals, programs and controls of a framework are downloaded into hardware equipment, whether a detection result is consistent with an expected result or not is tested through a system function, leather materials, soft cloth and different knife templates are selected for blanking tests, and verification and analysis are performed on a digital twin model. The correctness of the digital twin virtual debugging result is directly verified by on-site debugging of the equipment, the risk in actual debugging is avoided, the debugging time and cost are shortened, the problems and the anomalies possibly occurring in the actual debugging process are solved in advance,
3. evidence of the effect of the examples. The embodiment of the invention has a great advantage in the research and development or use process, and has the following description in combination with data, charts and the like of the test process.
The invention has the advantage over traditional design flow in that it is synergistic from two perspectives of discipline specialized synergy and design trial. And constructing a multidisciplinary high-fidelity model through different research and development stages and different disciplinary angles, and performing debugging verification of the model in a virtual environment by applying a digital twin virtual debugging technology, so as to obtain an optimal digital twin model in the virtual environment.
The virtual verification method solves the problems that continuous reworking and modification can occur in the physical prototype test debugging and even actual production running process, and the undiscovered design errors can cause great damage to equipment, and the test effect is as follows aiming at the constructed virtual model concrete example process of the full-automatic cutting machine and by constructing an equipment platform.
1. Virtual debugging realization of full-automatic cutting machine
1.1 virtual simulator configuration
After the model of the full-automatic cutting machine in different environments is built, a part playing the role of virtual hardware is needed, real PLC hardware is not needed, program debugging and equipment simulation verification are carried out in the virtual environment, namely, the process is carried out through a virtual simulator. S7-PLCSIM Advanced is a high-function simulator under Siemens flag, which can simulate a PLC logic control program and simulate communication. The external signal configuration of the NX-MCD comprises a plurality of data interfaces, and the external signal configuration has the best configuration effect with PLCSIM Advanced configuration with little delay under multiple experiments, thereby being convenient for the best virtual debugging effect. First, the manager runs S7-PLCSIM Advanced V2.0, defined as PLC12, with the manager identity, then configures in Portal software, and downloads the PLC program into the virtual simulator. PLCSIM Advanced will turn from a yellow light to a green light, indicating a successful connection. If the Portal is disconnected with the Portal by mistake, the green lamp is turned to a flashing red lamp. Finally, the items are turned to be online in Portal, a monitoring button is started in a program block window to enter a monitoring state, the information transmission state can be conveniently and intuitively checked, the running result of the program is judged through the colors of lines, instruction elements and parameters in the program, and the program state information is fed back in real time, so that the program is convenient to change and optimize.
1.2 Signal mapping
In the virtual debugging process, the transmission of signals is indispensable, the signals are used for the interaction of motion control and external signals, and the connection of the signals is a key step. And constructing signals and external signals in a signal mapping window according to the PLC variable table and the model signals created in the NX-MCD. And carrying out one-to-one configuration by matching corresponding to the signals, and establishing signal mapping.
1.3 software in-loop virtual debugging
All preparation work before virtual debugging is completed, a debugging environment of TIA Portal, NX-MCD, PLCSIM Advanced, winCC and Teambnter is built, and the mechanical structure, motion interference and control system of the full-automatic cutting machine model can be observed in real time through a play instruction in the NX-MCD, a Start button of the PLCSIM Advanced, starting monitoring after the Portal is switched to be on-line, and starting simulation under a WinCC picture, so that the display and simulation can be performed under the virtual environment.
In addition, signals of the appointed objects can be added into the viewer through a window of the viewer during running, running parameters during model movement are constructed, real-time data and movement curves are detected, and the real-time data can observe the speed, the position, the acceleration, the deceleration, the stress condition of the X, Y, Z axis direction and the like; the motion profile may observe its position-time relationship, velocity-time relationship, force-time relationship, etc., as shown in fig. 10.
Through real-time monitoring of the PLC program in Portal and real-time data of the motion state and the running time viewer of the corresponding NX-MCD model, the normal running (from the whole green line to the end) of the PLC program can be seen, the model does not generate interference and collision, and the relation of 'speed-time and position-time' is observed. In the punching process, the position of the cutting machine is changed continuously along with the change of time, and the speed is also stable. The whole virtual debugging process can detect possible abnormality and error at any stage of machinery, electricity and automation in real time, and the design requirement is met by continuously debugging and modifying, so that the digital twin model of the full-automatic cutting machine with the best effect at the design stage is obtained.
1.4 debugging problem and optimization scheme
1.4.1 debug problem analysis
The following problems exist by finding out that the full-automatic cutting machine in the process of virtual debugging:
(1) In the simulation process of taking and returning the cutter by the rodless cylinder, the gap between the cutter and the cutter plate at the bottom of the punch is found to be very small when the pin of the rodless cylinder is at the lowest position, and the gap is only 1.0314mm after measurement, so that the simulation process does not conform to the production practice, and the condition of cutter collision interference can be caused when the gap is too small. When the plug pin takes the tool and pushes the punch blade into the tool magazine, the punch blade is hooked and arranged on the same horizontal line with the tool magazine, as shown in (a) of fig. 11. After the completion of the warehouse entry of the knife board, when the rodless cylinder plug is moved down to be separated from the knife board, it was found that the rodless cylinder plug was not completely separated from the knife board, as shown in (b) of fig. 11. In practice, if there is a condition that the rodless cylinder pins cannot be completely separated from the cutter plates, the cutter plates in storage are brought out by the pins. The collision avoidance in the simulation process by means of an overall upward movement of the magazine, which requires additional computer control to perform the operation, is obviously not an optimal solution.
(2) In the PLC debugging stage, regarding the design part of the automatic tool changing control program, the original thought of the automatic drawing tool plate mechanism is to carry out pin up-down displacement and front-back displacement according to time intervals to be sent to the tool magazine tool plate position, and then to carry out tool changing operation by ascending and descending of the tool magazine. After debugging, it is found that, due to the large customer requirement, the multifunctional knife template needs to be switched back and forth for use, so that the knife changing procedure is complex, the time span is increased, and the phenomena of knife dropping and knife blank are caused frequently, as shown in (c) in fig. 11. There may be program upsets, machine sticking, and consequences of ineffective tool change cutting in actual production runs.
(3) After the man-machine interaction interface feeds back the information of the tool magazine and the tool changing operation is carried out for a plurality of times, the interface information can not obtain the accurate number of the tool board when the tool is running, and the number storage of the tool magazine tool plate is disordered, and the tool number one-key zero clearing operation cannot be operated normally. In addition to the problem of the mismatch of the cutter numbers, the push rod telescoping operation of the front door of the magazine cylinder cannot normally push open and close the command, and only the manual switch can be closed at the time of the cutter changing operation, as shown in (d) of fig. 11.
1.4.2 optimization scheme and Pre-and post-optimization comparison
According to the debugging result, the following optimization scheme is given:
three solutions are provided for the first problem, the first is that in the conceptual design stage of the cutting machine, the original calculated structure local arrangement can be modified, for example, the height of the punch pin is reduced, the height of the rodless cylinder bolt is unchanged, the height of the punch pin is reduced, and the height of each cutter position corresponding to the punch pin is correspondingly increased, so that the situation of collision interference is avoided. However, this solution is chosen to be abandoned, considering that such a modification inevitably results in a reduction of the stroke of the cylinder in the punch, which affects the range of values of the blanking force. The length of the rodless cylinder bolt is reduced, so that the rodless cylinder bolt can ensure a certain gap with the knife board at the lowest point. However, considering that the height of the rodless cylinder bolt is reduced, the rodless cylinder bolt and the cutter plate are not firmly connected, and when the cutter plate with uneven quality is encountered, the rodless cylinder bolt may be broken and the like. And therefore this solution is not easily adopted. The third improvement of the assembly of the mechanism is that the whole height of the rodless cylinder is reduced, and the corresponding excessive connecting seat is also reduced. Compared with the former two, the scheme has the advantages that excessive changes are not needed, the height adjustability is obvious, the additional problem caused by changing the design is avoided, and the optimization result is shown in (a) of fig. 12.
Aiming at the second problem, uncertainty errors occur in time intervals caused by complexity problems, and the time quantity is obviously not strict enough in consideration of long-time tool changing operation of technicians and service life of machines in actual production, because in the design of the machines, two sensors are added at two ends of a gantry beam frame and at the thread tail end of a rodless cylinder, signal feedback real-time displacement is added in NX-MCD (machine-made digital controller), the time quantity is changed into displacement, the original instructions according to the time intervals are canceled in tool changing operation, trigger sensors are set, and the tool changing operation is automatically carried out after the positions reached by the tool plates each time. After the optimization, the cutter magazine does not have the phenomena of cutter falling and blank cutter when a cutter changing instruction is carried out, the No. 2 cutter plate is used for normally changing cutters, the No. 3 cutter plate is used for normally taking cutters, and no time delay phenomenon occurs during operation, so that the solution is proved to have the effect, and the optimization result is shown in (b) in fig. 12.
Aiming at the third problem, starting from three angles of a machine sensor, a PLC program and a man-machine interaction interface instruction, feeding back the numbers of all the blades in the cutter magazine during operation according to the requirements of customers, adding a displacement sensor in the Z-axis direction of the cutter magazine of the cutting machine, and real-time information of the positions of all the blades, and displaying the positions of the blades of the cutter magazine normally according to real-time data detected in a 'run-time viewer' in NX-MCD. And then monitoring the PLC program, wherein the cutter changing module is provided with a received input signal, real-time cutter position data stored in the variable table is provided, all the displayed cutter position information has the phenomena of unchanged data and abnormal jumping, and after continuous debugging, monitoring and verification are carried out, so that the problem of matching of variable names is found, a plurality of cutter plates correspond to the same real-time information, and along with ascending and descending of the cutter magazine, the cutter number is lack of marks, and only the position information is provided. According to the occurrence, firstly, the variables are in one-to-one correspondence in the variable table, then the cutter number variables corresponding to the position information are added, finally, in the man-machine interface instruction, the button corresponding instruction is rebinding according to the added variables and the modification of the program, the obtained debugging effect man-machine interface feedback data are displayed normally, and the optimization result is shown in (c) in fig. 12. Program and variable are added before and after tool changing operation of the tool magazine, push rod telescopic operation of the front door of the tool magazine cylinder normally pushes open and closes instructions, and the optimization result is shown in (d) of fig. 12.
2. Full-automatic cutting machine field debugging test and verification
2.1 field debugging scene construction
The establishment of a piece of equipment or an automatic production line comprises a lot of work, the product cannot be guaranteed to have no problem during the whole design period from the initial design to the final physical prototype debugging process, only the scheme is determined on the basis of theory, in fact, along with the processing of various parts, the installation of hardware and the addition of a control system, various uncertainties often exist in the physical prototype debugging process, the designed product can only be continuously tried by mistake to modify the control program and improve the design, and the final scheme can not be established until the debugging is qualified, so that normal manufacturing production is realized.
According to the design scheme provided by the invention, the collaborative design of the full-automatic cutting machine is completed under a virtual environment, the pre-debugging work of the equipment is completed through a virtual debugging technology, and the design problem of the whole machine and the error of a control program are verified in advance, so that the continuous reworking design and even the machine damage problem of the full-automatic cutting machine in the field test stage are reduced. Based on the above work, it is next necessary to complete field commissioning tests and test verification of the fully automatic cutting machine to verify the integrity and rationality of the design. And building a field debugging scene, including equipment assembly and a debugging interface.
2.1.1 Equipment Assembly
According to the design requirement, build complete full-automatic cutting machine equipment, the complete machine contains 1300 a plurality of big or small parts altogether, mainly adopts basic processing methods such as turning milling planing mill, punching, tapping, and complicated part needs machining center to accomplish, carries out operations such as cutting, plane grinding, welding and milling right angle to panel, finally electroplates. At some parts with disordered wires and chains and the computer end touch screen, the shielding cover is designed to cover the parts, so that the safety of operators and the appearance of the whole machine are ensured. The whole machine equipment comprises a designed five-big mechanism, the numerical values of the X axis and the Y axis of the punch and the rotating angle beta value can be set on a control screen by adopting an upper computer control method, and the punch can automatically perform blanking work according to the position set by a user. The tool magazine for storing ten cutting tools is provided, a user can select the used tools on the control screen, and the machine can automatically perform tool changing operation according to the user. The whole driving mode is mainly composed of servo motors, ball screws and other components in consideration of positioning and efficiency problems.
2.1.2 debug interfaces
The early stage is realized in a full-automatic cutter Software-in-the-Loop (Software-in-the-Loop) mode through a virtual debugging technology, the debugging work of a physical object digital model is completed, and the accuracy of virtual debugging is required to be verified. The method downloads the configured program into real Siemens PLC hardware, builds a physical environment consistent with the joint debugging virtual environment on site, directly performs debugging and verification on equipment by using a site debugging means, and directly compares the result of the site debugging with the virtual debugging result.
2.2 debug results analysis
2.2.1 System functional test
In the test stage, the functional test is carried out aiming at the correctness of the full-automatic cutting machine interface and the button, and the work born by the functional test is to test whether the system accords with the expectations of a user according to the function of the system design. The five-major mechanism of the stamping mechanism, the automatic feeding mechanism, the automatic drawing knife board mechanism, the tool magazine tool changing mechanism and the milling mechanism are sequentially subjected to operation tests for several times, and the test case table is shown in table 1.
TABLE 1 test case Table
2.2.2 test verification and analysis
According to the numerical value set by virtual debugging, the cutting pressure, the unit cutting transverse distance, the single cutting time interval, the punch rotating angle and the typesetting number are all set, and a punching mechanism blanking test is taken as an example. The size of the punching cutting area is 1600 x 260mm, the distance between sample sheets is 2.0mm, a No. 1 cutter template, a No. 2 cutter template and a No. 3 cutter template are selected respectively, the No. 1 cutter template is cut in a common mode, the No. 2 cutter templates and the No. 3 cutter templates are automatically densely arranged according to the cutter template patterns, red patterns and blue patterns in the corresponding drawings are sequentially corresponding, and the densely arranged number is set to 50 times.
The blanking effect can not be accurately reflected only through naked eye observation, and whether the standard is reached or not is judged by converting the blanking effect into a finished product to be cut. In view of the difference of materials, a part of the positions and thickness gaps for selecting materials are reserved in the virtual debugging stage, so that in the field debugging process, the cut materials are firstly required to be selected.
Considering that leather materials are difficult to separate under the condition of incomplete blanking and are easier to observe than other flexible material indentations, in order to accurately represent whether blanking reaches the standard, leather materials with larger cutting difficulty are selected. Cutting is carried out through the setting of the cutting parameters, whether the difference exists between the cutting process on site and the completion of virtual debugging or not is observed according to the cutting finished product of leather materials, the blanking index under the ideal virtual environment is reached or not, and the complete effect diagram of cutting in the No. 1 cutter template, the No. 2 cutter template and the No. 3 cutter template is shown in fig. 13.
According to the cutting effect diagram of the No. 1 cutter template, incomplete cutting can be observed, the phenomenon of unseparation exists at the edge of each graph, and manual secondary separation is needed, so that the edge is irregular, the working procedure is complex, and the on-site production standard is not met. And then, the cutting and pressing angle and the interval are adjusted, the No. 2 cutter template and the No. 3 cutter template are selected for testing, the blanking is complete according to the two later effect figures, the unit figures do not need to be cut again, the samples are naturally separated, and the test result is ideal. According to 3 kinds of knife templates cutting tests, all normal in the whole equipment debugging process can be seen, the equipment is cut by the input typesetting mode, the phenomenon of disordered knife and knife jumping does not occur, the cutting interval is 2mm, and the phenomenon of indentation overlapping does not occur between single graphs. In the test process, the equipment stops running when reaching the designated times, namely 50 times, and is consistent with the set instruction, namely the input blanking numerical value 50, and redundant cutting and pressing procedures do not appear in the two tests of the No. 2 and No. 3 cutter templates. Finally, observing the stamping plate under the leather material, finding that the plate surface is smooth and has fine indentations, indicating that the stamping pressure is set normally and the stamping plate is not damaged.
Since the cutting object of the customized full-automatic cutting machine is oriented to various nonmetallic materials, and leather materials are relatively hard, in order to improve the persuasion of the test, a soft material, namely soft cloth, is selected for the cutting test, but the thickness of the soft cloth is extremely thin, so that the number of layers is 30. The test selects No. 1 and No. 3 knife templates, and the complete effect graph of cutting is shown in FIG. 14.
According to the effect diagram of cutting the soft cloth, the cutting of the No. 1 and No. 3 knife templates is complete, and all the placed 30 layers of soft cloth are fully cut. Because No. 3 knife template belongs to thin cutter, and soft cloth is frivolous easy smooth, and too close typesetting leads to the cloth skew easily, and No. 3 knife template part material cuts and appears the flaw, and No. 1 knife template belongs to wide cutter, so the effect of cutting is fine. Therefore, a solution can be provided, in actual production and manufacture, when the cutting object is made of light, thin and soft materials, and when a small cutter is selected, the typesetting interval can be properly increased for cutting, and a large cutter can be normally cut.
From this, it was concluded that the test was acceptable. The correctness of the virtual debugging result is verified through the test, after the complete virtual debugging modification and optimization is carried out on the whole machine, the blanking operation result is consistent with the virtual blanking effect, the risk of errors in field debugging and the procedure of disassembling and adjusting parameters of equipment are reduced, and the equipment such as a punching head, a punching plate and the like are effectively protected.
It should be noted that the embodiments of the present invention can be realized in hardware, software, or a combination of software and hardware. The hardware portion may be implemented using dedicated logic; the software portions may be stored in a memory and executed by a suitable instruction execution system, such as a microprocessor or special purpose design hardware. Those of ordinary skill in the art will appreciate that the apparatus and methods described above may be implemented using computer executable instructions and/or embodied in processor control code, such as provided on a carrier medium such as a magnetic disk, CD or DVD-ROM, a programmable memory such as read only memory (firmware), or a data carrier such as an optical or electronic signal carrier. The device of the present invention and its modules may be implemented by hardware circuitry, such as very large scale integrated circuits or gate arrays, semiconductors such as logic chips, transistors, etc., or programmable hardware devices such as field programmable gate arrays, programmable logic devices, etc., as well as software executed by various types of processors, or by a combination of the above hardware circuitry and software, such as firmware.
The foregoing is merely illustrative of specific embodiments of the present invention, and the scope of the invention is not limited thereto, but any modifications, equivalents, improvements and alternatives falling within the spirit and principles of the present invention will be apparent to those skilled in the art within the scope of the present invention.
Claims (3)
1. The full-automatic cutting machine cooperative control method is characterized by comprising the following steps of:
optimizing the design flow of the complex mechanical product from two angles of discipline professional cooperation and design and test cooperation, providing a modeling and simulation scheme based on an interface modeling and digital cooperation platform by means of ontology theory, and providing a collaborative design method framework based on digital twin; analyzing and calculating the working principle, the mechanism structure and the power device of the full-automatic cutting machine, and constructing a digital twin model in mechanical, electrical and automatic environments;
according to the virtual verification scheme, completing the configuration and signal mapping operation of a virtual simulator, importing a digital twin model and a motion parameter index, and implementing the virtual debugging of software in a ring; according to the debugging problem, sequentially optimizing the whole design; downloading the constructed virtual verification signal, program and control into hardware equipment, testing whether the detection result is consistent with the expected result through the system function, selecting leather materials, soft cloth and different knife templates for blanking test, and verifying and analyzing the digital twin model;
the cooperative control method of the full-automatic cutting machine comprises the following steps:
Step one, carrying out collaborative design based on digital twinning;
step two, constructing a digital twin model of the full-automatic cutting machine;
step three, virtual debugging and on-site debugging of the full-automatic cutting machine are carried out;
the constructing of the digital twin model of the full-automatic cutting machine in the second step comprises the following steps:
(1) Mechanical environment construction
Through the analysis to the design demand of cutting machine, combine NX-MCD module motion simulation function, confirm the flow scheme that realizes cutting machine motion simulation includes: importing a digital twin model of a full-automatic cutting machine, defining a basic electromechanical object, defining a kinematic pair, an actuator and a simulation sequence, running motion simulation and optimizing a virtual prototype; judging whether the requirements are met, if not, returning to run the motion simulation; if yes, finishing the motion simulation of the cutting machine;
(2) Electrical environment construction
Realizing system development and debugging based on Portal platform; selecting Siemens S7-1500 series PLC for configuration design, adding CPU1511-1 PN PLC and a common PC station in TIA Portal environment, adding OPC server and a common IE network card in the common PC station, connecting CPU1511-1 PN PLC and a common IE network card port, establishing Siemens S7-1500 series PLC connection, and completing configuration;
(3) Automated environment construction
The HMI simulator is used for simulating an operator panel, testing and optimizing operation concepts or interfaces which are in engineering stage; after an NX-MCD module and a TIA Portal environment are built, adding HMI equipment; based on the SIMATIC smart panel TP700 Comfort, an operation interface, a coordinate correction setting interface, a tool magazine setting interface, a blanking setting interface and an IO parameter interface are constructed;
adding a signal to feed back a real-time displacement to Portal software in an NX-MCD module, changing the time into the displacement, canceling an instruction which is originally according to a time interval by the operation of changing the cutter, setting a trigger sensor, and automatically changing the cutter after the position reached by the cutter plate each time; the full-automatic cutting machine consists of a frame, a ball screw, a servo motor, a blanking plate, a pressing cylinder, a feeding frame, a feeding roller, a screw rod seat, a milling cutter, a synchronous wheel, a hydraulic cylinder and a motor;
the cloth is conveyed to a feeding plate through an automatic feeding device by a roller device of a feeding frame, and a servo motor is adopted to drive a ball screw for transmission; the two sides of the feeding plate are provided with blocking blocks, the two sides of the machine body are provided with pneumatic compression bars, and before the punch of the punching device cuts, the pneumatic compression bars automatically descend to compress punched cloth; the punch of the stamping device transversely moves left and right under the gantry beam frame, a servo motor is adopted to drive a synchronous large belt wheel on the punch by a speed reducer, 360-degree rotary motion is realized, and automatic typesetting is carried out on complex patterns; when the cutting pattern needs to be replaced, the cutter is replaced, the cutter templates with the required processed number are prestored in a cutter changing device of the cutter magazine, and the cutter changing operation between the punch and the cutter magazine is completed through automatic drawing and pulling of the cutter templates by a rodless cylinder; after blanking is completed, polishing and milling operation is carried out on the feeding plate, and the milling device and the automatic feeding device realize milling operation from left to right and from front to back in sequence;
The whole structure of the cutting machine is divided into an automatic feeding device, a stamping device, a rodless cylinder automatic drawing knife board device, a knife magazine knife changing device and a milling device;
the automatic feeding device consists of a raw material placing rack, a material pressing part and a feeding part; the raw material placing rack comprises a carrier roller, a carrier roller bracket, a coil material mandrel and a baffle plate, and is used for placing coil materials of different types, lengths and styles; the material pressing part comprises a feeding plate head part, a feeding plate tail part, three air cylinders at the milling cutter and a material pressing rod, and is used for fixing raw materials; the feeding part consists of a feeding plate, and a servo motor is adopted to drive a ball screw for transmission;
the stamping device consists of a guide sliding block, a punch pin, a speed reducer, a hydraulic cylinder and a punch knife hook; the punch head column is connected with the guide sliding block and moves along the horizontal direction in the stamping process along with the guide sliding block; the hydraulic cylinder is used for outputting main power of stamping and determining the blanking force; a synchronous wheel is arranged on a motor shaft, a synchronous belt is arranged on the wheel, linear motion is obtained, and high-precision positioning and servo motor protection are realized at any position; the punch and the knife board are provided with a clamping device, the knife changing cylinder ejects the knife hook of the knife board from the knife template, and after a new knife board is changed, the knife changing cylinder contracts, so that the knife hook of the knife board clamps the knife board;
The automatic drawing knife board device consists of a rodless cylinder, a linear guide rail, a triaxial cylinder, a bolt, a connecting plate and a knife board transition frame; selecting a rodless cylinder with 20 cylinder diameters, arranging a linear guide rail beside the rodless cylinder, and jacking a bolt by adopting a triaxial cylinder to ensure the stability of the bolt inserted into a knife board;
the tool magazine tool changing device consists of a tool magazine frame, a motor, a tool template, a linear bearing, a ball screw, a guide rod and a tensioning wheel; the tool magazine box adopts a servo motor to drive double-side ball screws to lift the tool magazine, two sides adopt synchronous wheel linkage, and the pitch of the ball screws is 32 mm; the servo motor selects a model with a brake; the front and the back of the tool magazine case are provided with stop rods, the mini cylinder at the top of the magazine case controls the stop rods to open and close, the stop rods are opened during tool changing, and the stop plates are closed after tool changing; in the tool changing process, a motor and a tensioning wheel drive ball screws at two ends to realize stable lifting and designated height adjustment of the tool magazine, and the tool magazine is matched with a rodless cylinder to automatically pull a tool plate device to finish the self-defined tool changing operation;
the milling device consists of a milling cutter, a milling cutter motor, a milling cutter seat, a milling cutter cylinder, a milling cutter frame, a screw rod and a milling cutter seat motor; the milling device is used for realizing movement in three degrees of freedom directions; the frame body part is composed of 40160 aluminum profiles, and a linear guide rail is embedded in a groove of the aluminum profiles for guiding the movement of the mechanism; the back of the connecting plate is provided with a milling groove, so that a ball screw can conveniently pass through, two side supports are arranged at the rear of the machine body, a three-phase asynchronous motor is connected with the ball screw through a coupler, and a special clamp is manufactured when a motor plate on the support is welded with the support so as to ensure the coaxiality of a motor shaft and the ball screw; when the milling cutter device mills, the air cylinder ejects the milling cutter and compresses the punching plate.
2. A computer device comprising a memory and a processor, the memory storing a computer program that, when executed by the processor, causes the processor to perform the full automatic cutter cooperative control method of claim 1.
3. A computer readable storage medium storing a computer program which, when executed by a processor, causes the processor to perform the full automatic cutter cooperative control method of claim 1.
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