CN115319003A

CN115319003A - Automatic counting and controlling system for forging

Info

Publication number: CN115319003A
Application number: CN202211035269.4A
Authority: CN
Inventors: 薛文锋; 张淋云; 程文汐; 薛越之
Original assignee: Shanghai Changjiang Yunxi Digital Technology Co ltd
Current assignee: Shanghai Changjiang Yunxi Digital Technology Co ltd
Priority date: 2022-08-26
Filing date: 2022-08-26
Publication date: 2022-11-11

Abstract

The invention discloses an automatic counting and controlling system for forging, which comprises an optical fiber sensor, a conveyor belt, a servo motor, a box, a counter, a PLC (programmable logic controller) and an industrial screen, wherein the optical fiber sensor is arranged on the box; the optical fiber sensors are arranged at the end parts of the three slideways and used for counting the number of products passing through the slideways; conveying the products falling off from the normal material slide way to a collecting station through a conveying belt; the servo motor drives the conveyor belt to rotate positively and negatively, and the box is used for collecting products output by the conveyor belt; the counter is arranged at the two ends of the conveyor belt and counts the products passing through the end part of the conveyor belt; the PLC controller realizes master control, the count value of the counter is sent to the PLC controller to control the servo motor to rotate positively and negatively, and the PLC controller sends the data counted by the counter to a computer in a planning workshop in real time; the industrial screen is used for displaying the counted product quantity. The invention can know the quantity of products produced in the heating process and the quantity of products in the air-cooling process box in real time, and the counted quantity is very accurate; and production planning personnel can conveniently control the production progress.

Description

Automatic counting and controlling system for forging

Technical Field

The invention relates to the technical field of forging, in particular to an automatic counting and controlling system for forging.

Background

Forging is a process of using forging machinery to apply pressure to a metal blank to make it plastically deform to obtain a forging with certain mechanical properties, certain shape and size. The defects of as-cast porosity and the like generated in the smelting process of metal can be eliminated through forging, the microstructure is optimized, and meanwhile, because the complete metal streamline is preserved, the mechanical property of the forging is generally superior to that of a casting made of the same material.

At present, in the forging industry, the product generally uses the mode of manual counting, and statistics process output quantity and the packing quantity of final product appear, the problem that appears is as follows:

with the above technique, the following problems arise:

1. the heating process cannot count the number of good products/defective products/scrapped products in real time, and no early warning mechanism increases the manufacturing cost.

2. The air cooling process uses loaders to weigh the boxes, and then the number of products in the boxes is manually calculated according to each product model, and the actual number and the manually calculated number sometimes differ greatly.

3. Air cooling process box change needs manual operation, and the trouble just needs someone to pay attention to whether the current case is full of boxes often.

4. The output quantity of air cooling cannot be fed back in real time, and a statistical worker must go to the site to weigh the box. Production planning personnel do not know the production progress of the work order and are not beneficial to subsequent production scheduling.

Disclosure of Invention

The invention aims to solve the defects in the prior art and provides an automatic counting and controlling system for forging.

In order to achieve the purpose, the invention adopts the following technical scheme:

an automatic counting and control system for forging, comprising:

the optical fiber sensors are arranged at the end parts of the high-temperature material slide way, the low-temperature material slide way and the normal material slide way and are used for counting the number of products passing through the slide ways;

the conveying belt is erected below the end part of the normal material slide way, and products sliding off the normal material slide way are conveyed to the collecting station through the conveying belt;

the servo motor is connected with the conveyor belt and drives the conveyor belt to rotate forwards and backwards;

boxes at both ends of the conveyor belt for collecting products output by the conveyor belt;

counters mounted at both ends of the conveyor belt, the counters counting products passing through the ends of the conveyor belt;

the PLC controller is electrically connected with the servo motor and the counter, the count value of the counter is sent to the PLC controller, the PLC controller controls the servo motor to rotate positively and negatively, and the PLC controller sends the data counted by the counter to a computer in a planned workshop in real time;

and the industrial screens are two in number, are electrically connected with the PLC, display the product number counted by the two counters and the three optical fiber sensors on the industrial screens, one industrial screen is arranged at the air cooling process, and the other industrial screen is arranged at the hot pressing process.

According to the further technical scheme, a frequency converter is connected to the servo motor, the PLC is electrically connected with the frequency converter, and the frequency converter controls the rotating speed of the servo motor.

The further technical scheme of the invention is that the device also comprises a control panel, the control panel is arranged on the conveyor belt and electrically connected with the PLC, and four control buttons are arranged on the control panel and respectively control the positive and negative rotation, the operation and the rotating speed of the servo motor.

According to a further technical scheme, the automatic feeding device further comprises an alarm, the alarm is arranged on the conveyor belt and electrically connected with the PLC, and when the count value of the counter reaches a set value, the PLC controls the servo motor to rotate reversely and controls the alarm to give an alarm.

According to a further technical scheme, the two ends of the conveying belt are provided with unpowered rollers which are arranged in a downward inclined mode, and products slide into the box body through the unpowered rollers.

According to a further technical scheme, the counter is an infrared photoelectric sensor.

According to the further technical scheme, the two sides of the conveying belt are provided with the baffle plates, and the baffle plates limit products.

The technical scheme of the invention is that the industrial screen is a touch screen type screen.

According to a further technical scheme, the device comprises two annular ground rails, wherein chains are arranged in the annular ground rails and driven by a motor, universal wheels are arranged at the bottoms of the box bodies, movable insertion rods are arranged at the bottoms of the box bodies and inserted into the chains in the annular ground rails, a plurality of box bodies are distributed on each annular ground rail, and the annular ground rails drive the box bodies to pass through a product unloading position.

According to a further technical scheme, the conveying device further comprises a moving plate arranged on the ground, the moving plate is arranged corresponding to the end portion of the conveying belt, two boxes are placed on the moving plate, a pushing piece is arranged on the moving plate, and the pushing piece drives the moving plate to reciprocate, so that the two boxes on the moving plate are located below the conveying belt one by one.

Compared with the prior art, the invention has the beneficial effects that:

according to the system, a manager or a field operator can know the number of the products in the box in real time, the number of the products is counted accurately, and a production planning person can master the production progress of the products conveniently. In addition, field workers can know the time for replacing the boxes through the screen without staring at the field all the time, and meanwhile, when the boxes need to be replaced, the alarm can give an alarm so that the workers can replace the boxes in time.

Drawings

FIG. 1 is a schematic structural view of three skids according to the invention;

FIG. 2 is a schematic structural view of the present invention;

FIG. 3 is a schematic view of the adjusting lever and the bracket according to the present invention;

FIG. 4 is a block diagram of the system of the present invention;

FIG. 5 is a schematic view of the structure of the box and the circular ground rail of the present invention;

FIG. 6 is a schematic view of the box and the movable plate of the present invention.

Reference numbers in the figures:

1. a conveyor belt; 2. a servo motor; 3. a box; 4. a counter; 5. a PLC controller; 6. an industrial screen; 7. a frequency converter; 8. a control panel; 9. a control button; 10. identifying; 11. an alarm; 12. an unpowered roller; 13. a baffle plate; 14. adjusting a rod; 15. a support; 16. an annular ground rail; 17. a movable inserted link; 18. moving the plate; 19. a drive member.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.

The invention discloses an automatic counting and controlling system for forging.

As shown in fig. 1 to 4, the forging automatic counting and controlling system comprises an optical fiber sensor, a conveyor belt 1, a servo motor 2, a box 3, a counter 4, a PLC controller 5 and an industrial screen 6.

Specifically, the optical fiber sensors are arranged at the end parts of the high-temperature material slide way, the low-temperature material slide way and the normal material slide way and used for counting the number of products passing through the slide ways.

Specifically, the conveyor belt 1 is erected below the end part of the normal material slide way, and products sliding off the normal material slide way are conveyed to the collecting station through the conveyor belt 1.

The conveyer belt 1 includes support body, driving shaft, driven shaft and the area body. A support plate or a shaft body structure is fixed on the frame body of the conveying belt 1 to support the top belt body of the conveying belt 1. Preferably, a support plate is fixed on the frame body of the conveyor belt 1.

In addition, the bottom of the frame body of the conveyor belt 1 is provided with rollers and foot cups. The height of the foot cup can be adjusted, when the foot cup contacts the ground and the roller is suspended, the foot cup is used for supporting the conveyor belt 1, so that the conveyor belt 1 is stably parked on the ground; when the roller contacts the ground and the goblets are suspended, the roller is used for supporting the conveyor belt 1 so as to be convenient for moving the position of the conveyor belt 1.

In this embodiment, servo motor 2 is connected with the driving shaft on the conveyer belt 1, and servo motor 2 drive driving shaft is square changes, drives conveyer belt 1 and carries out clockwise or anticlockwise operation. The servo motor 2 can be directly connected with the driving shaft and also can be connected with the driving shaft through a chain wheel assembly or a belt wheel assembly. Preferably, the servo motor 2 is fixed on the frame body of the conveyor belt 1, and a rotating shaft of the servo motor 2 is fixed with the driving shaft.

The two ends of the conveyor belt 1 are provided with collecting stations for products, the box bodies are placed at the collecting stations at the two ends of the conveyor belt 1, and the products which are subjected to hot pressing are conveyed to the collecting stations through the conveyor belt 1 and fall into the corresponding box bodies.

Counter 4 demountable installation is at the both ends of 1 support body of conveyer belt, and counter 4 counts the product through 1 tip of conveyer belt.

The PLC controller 5 is electrically connected with the servo motor 2 and the counter 4, the counting value of the counter 4 is sent to the PLC controller 5 in real time, the PLC controller 5 sends the data counted by the counter 4 to a computer in a planning workshop in real time, and the PLC controller 5 controls the servo motor 2 to operate.

When the automatic counting device works, the counting threshold value of the counter 4 is set, when the counting value of the current counter 4 reaches the threshold value, namely full products are collected in the box body at the current collecting station, the controller controls the servo motor 2 to rotate reversely, the numerical value of the current counter 4 is automatically cleared, the other counter 4 starts counting from zero, and the box body at the other collecting station starts collecting the products from zero.

The number of the industrial screens 6 is two, the industrial screens 6 are electrically connected with the PLC 5, each industrial screen 6 is divided into two areas, and the two areas correspondingly display the product number counted by the two counters 4 respectively. One of the industrial screens 6 is installed at an air cooling process (output position), and the other industrial screen 6 is installed at a hot pressing process, so that hot pressing operators can observe the product quantity of each box 3 and master the box changing time. The industrial screen 6 can be vertically placed on the ground through the mounting rack and can also be fixed on the wall surface through the mounting rack.

Due to different products, time consumption for forging corresponding products is different, and if the rotating speed of the servo motor 2 is inconvenient, the products can be accumulated or sparse on the conveyor belt 1 when being transported.

In order to avoid the above situation, a frequency converter 7 is arranged on the servo motor 2 to form a variable speed servo motor 2, the PLC 5 is electrically connected with the frequency converter 7, and the frequency converter 7 controls the rotating speed of the servo motor 2 so that the products keep a proper interval on the conveyor belt 1. In the present exemplary embodiment, the frequency converter 7 is integrated into the servomotor 2.

In addition, this system still includes control panel 8, and control panel 8 is fixed in one side middle part of conveyer belt 1 support body, and control panel 8 is connected with PLC controller 5 electricity, installs four control button 9 on the control panel 8, and four control button 9 are arranged in a row or are the matrix setting, and control button 9 controls corotation, reversal, operation and the rotational speed of servo motor 2 respectively.

In order to facilitate the identification of the four control buttons 9, the four control buttons 9 may be labeled 10, for example, four character marks a, B, C, and D are correspondingly formed on the four control buttons 9 in sequence.

When a control button 9 with a mark A is pressed, the conveyor belt 1 rotates forwards, namely runs clockwise;

the control button 9 with the mark B is pressed, and the conveyor belt 1 rotates reversely, namely runs anticlockwise;

the control button 9 with the mark C is pressed, and the conveyor belt 1 runs or stops;

the rotation speed of the conveyor belt 1 can be regulated by rotating the control button 9 with the mark D.

Further, an indicator 10 such as a pivot symbol, a start/pause symbol, and a speed symbol may be formed on the control panel 8. Of course, the sign 10 may take other forms.

In-service use, after the box 3 of 1 one end of conveyer belt collected full product, the product was collected to another box 3 to the reversion of conveyer belt 1, at this in-process, need in time trade the box to collecting full box 3, if not trade the box in time, then probably lead to continuing to packing into the box 3 of product, continue to pack into the case, cause the product can't collect in the box 3.

In this embodiment, this system still includes the siren 11 of being connected with PLC controller 5 electricity, and fixed mounting can be dismantled in one side of the 1 support body of conveyer belt to siren 11, and when the count value of counter 4 reached the settlement numerical value, PLC controller 5 control servo motor 2 reversal, and control siren 11 and send out the police dispatch newspaper to in order to remind the staff to change the case.

In addition, the product falls into the box 3 directly from the conveyor belt 1, and the product has larger potential energy due to the height difference between the conveyor belt 1 and the box 3, so that the product is damaged.

Therefore, the unpowered rollers 12 which are arranged in a downward inclined mode are fixed at the two ends of the conveyor belt 1, generally, the inclination angle of the unpowered rollers 12 is within the range of 10-30 degrees, products slide into the box body through the unpowered rollers 12, and the impact force generated when the products fall into the box body is effectively reduced.

In addition, conveyer belt 1's support body both sides demountable installation has support 15, and the top of support 15 is installed and is slided the regulation pole 14 that sets up along the width direction of support body, adjusts pole 14 and contradicts on support 15 through the bolt, and the one end of adjusting pole 14 is slided and is provided with baffle 13, and baffle 13 carries on spacingly to the product, avoids the product to roll from conveyer belt 1's both sides and falls.

In this embodiment, the counter 4 is an infrared photoelectric sensor, and the counter 4 has a saving function, that is, the counter can save the previous count after power failure, and keep the count if not cleared. And after zero clearing, the number displayed on the industrial screen 6 corresponding to the box 3 is 0.

The industrial screen 6 is a touch screen type screen, and an application program on the industrial screen 6 provides two zero clearing buttons which can respectively reset the number of products on the two counters 4 to zero. In addition, the application program on the industrial screen 6 is provided with a button for starting the operation/pause of the conveyor belt 1, a forward/reverse button and a setting button, and the setting button can enter the setting program to set the threshold value on the counter 4 and the operation speed of the conveyor belt 1 (i.e. the rotation speed of the servo motor 2).

In this embodiment, the PLC controller 5 is embedded with MES software, the counter 4 can share data, and the MES software can access the counter 4 in real time through Modbus TCP protocol to read the number in the counter 4 (the number of products falling into the box 3). The production planner can see the on-site production schedule (the amount of output in box 3) at the office.

In actual use, the worker needs to move the box 3 filled with the product to the product unloading position, namely, the product of the two collecting stations is conveyed to the product unloading position, a large amount of labor force needs to be consumed, and more time is wasted.

In order to unload fast, reduce the labour, this application still discloses another kind of embodiment, including two annular ground rails 16, two annular ground rails 16 parallel arrangement are in the caulking groove on ground, install the chain in the annular ground rail 16, and the chain is by motor drive, is fixed with the universal wheel in the bottom of case 3, and installs movable inserted bar 17 in the bottom one end of case 3, and the vertical downward setting of movable inserted bar, movable inserted bar 17 can insert in the chain in the annular ground rail 16. A plurality of boxes 3 are distributed on each annular ground rail 16, and the annular ground rails 16 drive the boxes 3 to pass through a product unloading position.

In addition, a position sensor is arranged on the ground and is electrically connected with the PLC 5 and the motor; the motor drives the chain to run, the chain drives the box 3 to run, when the position sensor detects the box 3, a signal is sent to the PLC 5, the PLC 5 controls the motor to stop running, and the box 3 is positioned right below the end part of the conveyor belt 1; when the box 3 is full of products, the PLC controller 5 controls the motor to operate, so that the next box 3 is positioned right below the end part of the conveyor belt 1, and the PLC controller 5 controls the servo motor 2 to rotate reversely to convey the products to the box 3 on the other annular ground rail 16.

In order to ensure that the box 3 is positioned right below the end of the conveyor belt 1 for collecting the products, a guide plate of the box 3 is arranged below the end of the conveyor belt 1 for guiding the box 3, so that the products transported on the conveyor belt 1 fall into the box 3,

in addition, the movable insertion rod 17 is inserted in a support plate at the end part of the box body 3, a pedal is hinged on the support plate, one end of the pedal is provided with a waist-shaped groove for the movable insertion rod 17 to penetrate through, and the pedal is pressed on the support plate by the movable insertion rod 17 in an initial state; by stepping down the pedal, the movable insertion rod 17 is lifted up by the pedal, so that the movable insertion rod 17 is separated from the chain.

The technical scheme occupies larger field area and increases a large amount of cost.

Therefore, the application also discloses another embodiment, including setting up movable plate 18 on ground, movable plate 18 and the cooperation of sliding on ground, the cooperation mode of sliding specifically can be slide rail and slider complex mode, and the movable plate corresponds the setting with the tip of conveyer belt 1, and two cases 3 have been placed to the location on the movable plate 18, installs the driving piece 19 of being connected with movable plate 18 on the ground, and driving piece 19 drive movable plate 18 reciprocating motion for two cases 3 on the movable plate 18 are located conveyer belt 1 under one by one.

In particular, the driving member 19 may be an electric screw structure.

The implementation principle of the invention is as follows:

through this system, managers or field operation personnel can know the product quantity in case 3 in real time, and the statistics quantity of product is very accurate, makes things convenient for production planning personnel to master the production progress of product. In addition, field staff can know the time for changing the box through a screen without staring at the field all the time, and meanwhile, when the box needs to be changed, the alarm 11 gives an alarm so that the staff can change the box in time.

Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless specifically defined otherwise.

The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered as the technical solutions and the inventive concepts of the present invention within the technical scope of the present invention.

Claims

1. An automatic counting and control system for forging is characterized by comprising:

the conveying belt (1) is erected below the end part of the normal material slide way, and products sliding off the normal material slide way are conveyed to a collecting station through the conveying belt (1);

the servo motor (2), the servo motor (2) is connected with the conveyor belt (1), and the servo motor (2) drives the conveyor belt (1) to rotate forward and backward;

-boxes (3), said boxes (3) being located at both ends of the conveyor belt (1), said boxes (3) being intended to collect the products delivered by the conveyor belt (1);

the counters (4), the counters (4) are installed at two ends of the conveyor belt (1), and the counters (4) count products passing through the end of the conveyor belt (1);

the PLC controller (5), the PLC controller (5) is electrically connected with the servo motor (2) and the counter (4), the count value of the counter (4) is sent to the PLC controller (5), the PLC controller (5) controls the servo motor (2) to rotate forward and backward, and the PLC controller (5) sends the data counted by the counter (4) to a computer in a planning workshop in real time;

and the number of the industrial screens (6) is two, the industrial screens (6) are electrically connected with the PLC (5), the industrial screens (6) display the product number counted by the two counters (4) and the three optical fiber sensors, one industrial screen (6) is arranged at an air cooling process, and the other industrial screen (6) is arranged at a hot pressing process.

2. The automatic counting and controlling system for forging according to claim 1, wherein a frequency converter (7) is connected to the servo motor (2), the PLC (5) is electrically connected to the frequency converter (7), and the frequency converter (7) controls the rotation speed of the servo motor (2).

3. The automatic counting and controlling system for forging according to claim 2, further comprising a control panel (8), wherein the control panel (8) is disposed on the conveyor belt (1), the control panel (8) is electrically connected with the PLC (5), four control buttons (9) are disposed on the control panel (8), and the control buttons (9) respectively control the forward and reverse rotation, operation and rotation speed of the servo motor (2).

4. The automatic counting and controlling system for forging according to claim 1, further comprising an alarm (11), wherein the alarm (11) is disposed on the conveyor belt (1), the alarm (11) is electrically connected to the PLC controller (5), and when the counting value of the counter (4) reaches a set value, the PLC controller (5) controls the servo motor (2) to rotate reversely and controls the alarm (11) to give an alarm.

5. An automatic counting and controlling system for forging according to claim 1, wherein the conveyor belt (1) is provided with unpowered rollers (12) at both ends, the unpowered rollers (12) are arranged in a downward inclination manner, and products slide into the box (3) through the unpowered rollers (12).

6. An automatic forging counting and control system according to claim 1, wherein the counter (4) is an infrared photoelectric sensor.

7. The automatic counting and control system for forging according to claim 1, wherein baffle plates (13) are arranged on two sides of the conveyor belt (1), and the baffle plates (13) limit the products.

8. An automatic counting and control system for forging according to claim 1, characterized in that said industrial screen (6) is a touch screen type screen.

9. The automatic counting and controlling system for forging according to claim 1, further comprising two annular ground rails (16), wherein chains are arranged in the annular ground rails (16), the chains are driven by a motor, universal wheels are arranged at the bottom of the box (3), movable inserting rods (17) are arranged at the bottom of the box (3), the movable inserting rods (17) are inserted into the chains in the annular ground rails (16), a plurality of boxes (3) are distributed on each annular ground rail (16), and the annular ground rails (16) drive the box (3) to discharge materials through products.

10. The automatic counting and controlling system for forging according to claim 1, further comprising a moving plate (18) disposed on the ground, wherein the moving plate (18) is disposed corresponding to the end of the conveyor belt (1), two boxes (3) are placed on the moving plate (18), a driving member (19) is disposed on the moving plate (18), and the driving member (19) drives the moving plate (18) to reciprocate, so that the two boxes (3) on the moving plate (18) are located below the conveyor belt (1) one by one.