CN201144127Y - Variable tension steel strip winding device for prestressed mold manufacturing - Google Patents

Abstract

The utility model discloses a variable tension steel band winding device used in the manufacture of prestressed moulds. It can automatically adjust the value of the winding tension of the steel strip according to the preset winding tension theoretical curve, and realize the closed-loop control of the winding tension and the automation of the mold manufacturing process. It includes an uncoiling mechanism, a leveling mechanism, a tension control mechanism, a tension detection mechanism, and a winding mechanism connected in sequence. The tension control mechanism is composed of a tension rough adjustment device and a tension fine adjustment device. A pressure sensor is installed in the tension detection mechanism. There is an encoder in the winding mechanism, and the pressure sensor and encoder input the real-time obtained winding tension and winding layer data into the automatic control system. The automatic control system is connected with the tension control mechanism and the winding mechanism to form a closed-loop automatic control under variable tension conditions. system.

Description

Variable tension steel strip winding device for prestressed mold manufacturing

technical field

The utility model relates to a variable tension steel strip winding device, which can automatically adjust the winding tension value of the steel strip according to a preset theoretical curve and is used for the manufacture of prestressed molds.

Background technique

In the field of material synthesis and processing such as synthetic diamond and other superhard materials, metal cold extrusion, cold forging, etc., the role of molds is very important. Due to the extremely harsh working conditions, the mold is subjected to an ultra-high workload. Usually, the pressure range is 2-10GPa, and the temperature range is 300-2000°C, resulting in a very short service life of the mold. The use of prestressed molds can effectively reduce the tangential tensile stress inside the mold, improve the fatigue strength of the mold, and prolong the service life. The steel strip winding prestressing mold is a new type of prestressing mold. Compared with the traditional multi-layer combined prestressing mold, it has the characteristics of compact structure, remarkable preloading effect, small cavity deformation and long service life. It represents the development direction of prestressed molds. The design process of the steel strip winding prestressed mold should first determine the reasonable preload according to the mold material, size and working load, and then design the theoretical curve of the number of winding layers and winding tension. The manufacture of steel strip winding prestressing mold involves variable tension automatic winding technology under closed-loop control mode. The variable tension steel strip winding device and its control method are important equipment and means to realize theoretical design, and have become the field of steel strip winding prestressing mold key technologies.

Contents of the invention

The purpose of this utility model is to solve the vacancies of the prior art, to provide a variable tension steel strip winding device for prestressed mold manufacturing, which can automatically adjust the value of the steel strip winding tension according to the preset winding tension theoretical curve, Realize the closed-loop control of winding tension and the automation of mold manufacturing process.

The purpose of this utility model is achieved by the following technical solutions:

A variable tension steel strip winding device for prestressed mold manufacturing, which includes an uncoiling mechanism, a leveling mechanism, a tension control mechanism, a tension detection mechanism, and a winding mechanism connected in sequence. The tension control mechanism consists of a tension coarse adjustment device, a tension fine The adjustment device is composed of two parts. A pressure sensor is installed in the tension detection mechanism, and an encoder is installed in the winding mechanism. The pressure sensor and encoder input the real-time obtained winding tension and winding layer data into the automatic control system. The automatic control system and the tension The control mechanism is connected with the winding mechanism to form a closed-loop automatic control system under variable tension conditions.

The uncoiling mechanism includes an uncoiling frame on which a mandrel is installed, and the steel strip is placed on the mandrel.

The leveling mechanism includes a leveling frame on which a guide wheel and a leveling roller set are installed. The leveling roller set is composed of two sets of leveling rollers arranged staggered up and down. Among them, there are at least two upper leveling rollers, and the lower leveling rollers There is at least one more leveling roller than the upper leveling roller.

The tension control mechanism is composed of a tension coarse adjustment device and a tension fine adjustment device, which are installed on the same body; the tension coarse adjustment device is located on the side close to the leveling mechanism; the tension coarse adjustment device and the tension fine adjustment device The structure is the same, both of which include a piston clamping cylinder, the end of the piston rod is connected to the upper platen, and the upper platen is matched with the guide rail, and the lower platen is installed on the fuselage; the tension control mechanism is also equipped with a proportional control electro-hydraulic servo system, The oil pressure and clamping force of the two clamping cylinders can be adjusted separately, and the electro-hydraulic servo system is connected with the automatic control system.

The tension detection mechanism includes a frame, and the middle part of the frame is an upper drum bracket, on which an upper drum is installed; a lower drum bracket is arranged symmetrically on both sides of the upper drum bracket, on which a lower drum is installed, and an upper drum is installed on the upper drum bracket. A pressure sensor is arranged at the middle position below the drum support, and the pressure sensor is connected with the automatic control system.

The winding mechanism includes a winding frame, on which a motor reduction unit is installed, which is connected to the main shaft through a coupling, the main shaft is connected to the chuck through a bearing group, an encoder is arranged on the main shaft, and the motor reduction unit and the encoder are connected to the automatic Control system connection.

The utility model comprises an uncoiling mechanism, a leveling mechanism, a tension control mechanism, a tension detection mechanism, a winding mechanism and an automatic automatic control system. The uncoiling mechanism is composed of an uncoiling frame, a mandrel, etc., and is driven by no power. The leveling mechanism is composed of a guide wheel, a leveling roller group, etc., and is driven by no power. The tension control mechanism is composed of two parts: a tension coarse adjustment device and a tension fine adjustment device. It is equipped with a proportional control electro-hydraulic servo system. winding tension. The tension detection mechanism is composed of a pressure sensor, upper and lower drums, brackets, etc. The pressure sensor is placed under the bracket of the upper drum, and the pressure detection signal is input into the automatic control system. The winding mechanism is composed of a motor reduction unit, a coupling, a chuck, a frame, an encoder, etc. The mold is clamped on the chuck and rotates accordingly. The information of the number of winding layers can be obtained through the encoder and converted into the radius of the mold real-time data. The automatic and automatic control system is composed of PLC, control panel, etc., which can input the design data of the winding prestressed mold, generate the theoretical curve of the motor torque and the oil pressure of the rough and fine adjustment clamping cylinder, and input the detection of the winding tension and the number of winding layers Data, output control information, and related programs are stored in the automatic control system.

The beneficial effects of the utility model: the system structure is simple, easy to use, and the closed-loop control of the winding tension and the automation of the mold manufacturing process can be realized according to the design data of the steel strip winding prestressing mold set.

Description of drawings

Fig. 1 is the equipment structural diagram of the present utility model;

Fig. 2 is the tension control mechanism of the present utility model;

Fig. 2 a is the A-A sectional view of Fig. 2;

Fig. 3 is the tension detection mechanism of the present utility model;

Fig. 3 a is the B-B sectional view of Fig. 3;

Fig. 4 is the winding mechanism of the present utility model;

Fig. 5 is a control curve diagram used in the control method of the utility model.

In the figure, 1. Uncoiling mechanism; 2. Leveling mechanism; 3. Tension control mechanism; 4. Tension detection mechanism; 5. Winding mechanism; 301, fuselage; 302, clamping oil cylinder; ; 305, lower pressing plate; 401, frame; 402, upper drum bracket; 403, upper drum; 404, lower drum; 405, lower drum bracket, 406, pressure sensor; 407, bearing group; 408, guide Column; 501, frame; 502, motor reduction unit; 503, coupling; 504, main shaft; 505, bearing group; 506, chuck.

Detailed ways

Below in conjunction with accompanying drawing and embodiment the utility model is described further.

A kind of variable tension steel strip winding device that is used for prestressed mold manufacture, as shown in Figure 1, comprises uncoiling mechanism 1, leveling mechanism 2, tension control mechanism 3, tension detection mechanism 4, winding mechanism 5 connected successively, and Automatic automatic control system, etc. The main structure and function of each part are as follows:

Uncoiling mechanism 1 is used to support steel strip coil, and it is made up of uncoil frame and the mandrel etc. on it, and uncoil frame is fixed on the ground, without power drive, and steel strip coil can rotate freely around mandrel.

The leveling mechanism 2 is used to guide the moving direction of the steel belt and level the surface of the steel belt. It is composed of a leveling frame, a guide wheel, and a leveling roller group. The leveling frame is fixed on the ground and has no power. drive. The guide rollers accommodate changes in the strip entry angle due to the reduced coil diameter in order to maintain a constant strip entry level. The leveling roller group is provided with a plurality of steel rollers in the upper and lower layers interlacedly distributed, and the steel strip passes through the leveling roller group in the leveling mechanism 2 under the tension of the winding tension, resulting in plastic deformation and surface leveling. The number of steel rollers in the upper layer is greater than 2, the steel roller in the lower layer is one more than the upper layer, and the steel rollers can rotate around their respective axes.

The tension control mechanism 3 is shown in Fig. 2 and Fig. 2a, it is used to control the numerical value of the winding tension, and consists of two parts: a tension rough adjustment device and a tension fine adjustment device. The tension coarse adjustment device and the tension fine adjustment device have the same mechanical structure, and are installed on the same fuselage 301, and the fuselage 301 adopts a closed structure with good rigidity. The tension coarse adjustment device is located upstream of the tension fine adjustment device, that is, on the side close to the leveling mechanism 2, and their structure includes a piston-type clamping cylinder 302, a guide rail 303, an upper pressing plate 304, a lower pressing plate 305, and the like. The cylinder body of the clamping oil cylinder 302 is fixed on the fuselage 301 by bolts, the end of the piston rod is connected with the upper pressing plate 304, the upper pressing plate 304 cooperates with the guide rail 303, and can move up and down, and the lower pressing plate (305) is installed on the fuselage (301 )superior. The guide rail 303 is fixed on the right column of the fuselage 301, and can withstand the horizontal force from the upper platen 304 along the moving direction of the steel belt, so as to avoid the harmful influence of the bending moment on the piston rod. When oil is fed into the upper chamber of the clamping oil cylinder 302, the oil pressure acts on the upper pressing plate 304 through the piston rod, and the steel strip is clamped on the lower pressing plate 305 to generate frictional force on the upper and lower surfaces of the steel strip. The total winding tension is equal to the sum of the steel belt friction resistance produced by the tension coarse adjustment device and the tension fine adjustment device. The clamping force value output by the coarse adjustment clamping cylinder is divided into several fixed gears, which can be changed in steps. The oil pressure maintains a constant value, that is, the clamping force remains unchanged; the clamping force output by the tension fine adjustment device can be continuously changed, and the oil pressure of the fine adjustment clamping cylinder can be adjusted in real time through the proportional control electro-hydraulic servo system, which can be changed The values of the clamping force and the frictional force make the winding tension conform to the preset theoretical curve.

Tension detection mechanism 4 is shown in Fig. 3, Fig. 3 a, and it is used for real-time detection steel strip tension in winding process, and signal is sent to automatic automatic control system, and it is made up of frame 401, upper drum support 402, upper rotating Drum 403, lower drum 404, lower drum bracket 405, pressure sensor 406, bearing group 407, guide post 408, etc. The upper drum bracket 402 is placed in the middle of the frame 401, and the two sets of lower drum brackets 405 are symmetrically arranged on both sides of the upper drum bracket 402. When the steel belt passes through the upper drum 403 and the lower drum 404, its movement The direction should be parallel to the axis of the pressure sensor 406 . The upper drum 403 and the lower drum 404 are installed on the upper drum bracket 402 and the lower drum bracket 405 respectively through bearing sets, and can freely rotate around their respective axes. The pressure sensor 406 is installed at the lower middle position of the upper drum bracket 402, and the upper drum bracket 402 is guided by two sets of guide columns 408 fixed on the frame 401 to avoid tilting. Neglecting the influence of friction, the pressure acting on the pressure sensor 406 is equal to twice the value of the winding tension of the steel strip, and the winding tension of the steel strip can be obtained indirectly by measuring the pressure acting on the upper drum support in real time.

The winding mechanism 5 is composed of a frame 501, a motor reduction unit 502, a shaft coupling 503, a main shaft 504, a bearing group 505, a chuck 506, an encoder, a direct torque controller, and the like. The mold to be wound is fixed on the chuck 506, and the motor reduction unit 502 is connected with the main shaft 504 through a coupling 503 to drive the chuck 506. The encoder is installed on the main shaft (504), and is used to obtain the data of winding layers in real time and convert it into the radius of the mould.

The automatic control method of the variable tension steel strip winding device will be further described below in conjunction with the schematic diagram of the control method shown in FIG. 5 .

1) Before starting the mold winding process, input the known winding tension theoretical curve T and the number of winding layers into the automatic control system. The winding tension in the winding process comes from the torque of the winding mechanism 5 motor and the frictional resistance generated by the clamping cylinder of the tension control mechanism 3. The control object of the system is the torque M of the winding mechanism 5 motor; the tension control mechanism 3 roughly adjusts the clamping The oil pressure p ₁ of the oil cylinder; the oil pressure p ₂ of the fine adjustment clamping oil cylinder. According to the theoretical curve T of winding tension and the input design data such as the number of winding layers, the automatic control system automatically generates the theoretical control curves for coarse oil pressure p ₁ , fine oil pressure p ₂ and motor torque M shown in the diagram;

2) The winding process is divided into three stages of tension establishment, stable winding and winding end, which correspond to the three stages of the time coordinate axis t: 0-t _s is tension establishment stage I, t _s -t _m stable winding stage II, t _m -t _n ends winding phase III. In the stable winding stage (t _s -t _m ), the oil pressure p ₁ of the coarse clamping cylinder remains constant, and the theoretical winding tension T decreases as the number of winding layers (or time t) increases, so the oil pressure of the fine clamping cylinder The theoretical curves of pressure p ₂ and motor torque M show a downward trend. At any moment in the mold winding process, there is a definite correspondence between the winding tension T, the coarse oil pressure p ₁ , the fine oil pressure p ₂ and the motor torque M;

3) During the winding process, use the tension detection mechanism 4 to obtain the pressure acting on the pressure sensor 406 in real time, and the actual winding tension in the steel strip is half of the pressure value. The number of winding layers of the mold can be obtained in real time by the encoder of the winding mechanism 5, and the actual radius of the mold can be obtained by multiplying the number of winding layers by the thickness of the steel strip and adding the outer radius of the mold core. The actual torque output by the motor reduction unit 502 is equal to the product of the winding tension of the steel strip and the radius of the mold;

4) The automatic automatic control system compares the detected value with the theoretical value of the steel strip winding tension shown in Figure 5 in real time, and outputs a control signal, so as to continuously adjust and fine-tune the oil pressure _p2 of the clamping cylinder and the torque M of the motor to achieve variable tension. Closed-loop control under tension conditions.

The working process of the present utility model is:

According to the design data of the winding prestressed mold, determine the steel strip coil for winding. Select high-strength spring steel material, the thickness of the steel strip is less than 0.2mm, the width is determined according to the actual axial length of the mold to be wound, and the total length should meet the amount of material used for winding a pair of molds. Before the equipment is powered on, the steel strip coil is placed on the mandrel of the uncoiling mechanism 1, and the steel strip coil can rotate freely around the axis of the mandrel. Manually unfold the steel belt, pass through the guide wheel of the leveling mechanism 2, the leveling roller group, the tension coarse adjustment device and the tension fine adjustment device of the tension control mechanism 3, the drum group of the tension detection mechanism 4, and cut off a certain length The end of the steel strip is flattened, and then the steel strip is fixed on the outer cylindrical surface of the mold by welding or other methods.

After the equipment is powered on and before the automatic winding program is started, the known design data such as the theoretical curve of winding tension and the number of winding layers are first input into the automatic control system, and the two clamping cylinders are automatically generated by the automatic control system according to the hydraulic pressure and motor torque. The theoretical control curve forms a closed-loop control program. Then, start the automatic winding work mode. The winding process is divided into three stages: establishing tension, stabilizing winding and ending winding. The corresponding winding process and control method are as follows:

1) In the stage of establishing tension, firstly, the oil pressures of the coarse adjustment clamping cylinder and the fine adjustment clamping cylinder respectively reach their maximum setting values, and the steel belt is clamped so that it cannot move. After a period of time lag, the motor starts and the output torque increases continuously. During this process, the pressure sensor continuously measures the increase of the tension of the steel strip. After reaching the set value of the initial tension, the oil pressure of the coarse clamping cylinder remains constant, and its clamping force remains unchanged. The oil pressure of the oil cylinder gradually decreases according to the theoretical curve until the steel belt slides between the upper and lower splints, thus starting the second stage of mold winding.

2) The stable winding stage is a very time-consuming process. During this period, as the number of winding layers increases, the clamping force of the coarse-adjustment clamping cylinder remains unchanged, and the oil pressure and motor torque of the fine-adjustment clamping cylinder follow the Theoretical curve changes. The tension detection mechanism continuously feeds back the tension signal to the automatic control system, and the encoder continuously feeds back the actual number of winding layers. The automatic control system analyzes and calculates the above-mentioned measured results, and compares them with the preset winding tension theoretical curve to generate The error control signal is sent to the electro-hydraulic servo system of the clamping cylinder and the AC frequency conversion motor to adjust the oil pressure in the clamping cylinder of the tension fine adjustment device and the output torque of the motor, so as to realize the continuous variable tension winding process.

3) When the number of detected winding layers reaches the set value, the winding process enters the end winding stage. At this time, keep the output torque of the motor unchanged, and properly increase the clamping force of the clamping oil cylinder of the tension fine adjustment device, so that the steel belt cannot move and the motor stops rotating. Keep this state for a period of time, and fix the outer steel strip of the mold by welding or other methods. Then the equipment is powered off, the excess steel strip is cut off at the welding point, and the winding mold is removed from the chuck. So far, the manufacturing process of a pair of steel strip winding prestressing dies is over.

Claims (6)

1. A variable tension steel strip winding device for prestressed mold manufacturing, characterized in that: it includes sequentially connected uncoiling mechanism (1), leveling mechanism (2), tension control mechanism (3), tension detection mechanism (4), winding mechanism (5), tension control mechanism is made up of two parts of tension coarse adjustment device, tension fine adjustment device, and pressure sensor (406) is installed in tension detection mechanism (4), is installed in winding mechanism (5) There is an encoder, the pressure sensor (406) and the encoder input the data of winding tension and winding layers obtained in real time into the automatic control system, and the automatic control system is connected with the tension control mechanism (3) and the winding mechanism (5) to form a variable tension condition Under the closed-loop automatic control system. 2. The variable tension steel strip winding device for prestressed mold manufacturing according to claim 1, characterized in that: the uncoiling mechanism (1) includes an uncoiling frame, on which a mandrel is installed, and the steel strip coil Place on the mandrel. 3. The variable tension steel strip winding device for prestressed mold manufacturing according to claim 1, characterized in that: the leveling mechanism (2) includes a leveling frame, on which guide wheels and leveling rollers are installed The set of leveling rollers consists of two sets of leveling rollers arranged staggered up and down, wherein there are at least two upper leveling rollers, and at least one more lower leveling roller than the upper leveling roller. 4. The variable tension steel strip winding device for prestressed mold manufacturing according to claim 1, characterized in that: the tension control mechanism (3) is composed of two parts: a tension rough adjustment device and a tension fine adjustment device, and they Installed on the same fuselage (301); the tension coarse adjustment device is located on the side close to the leveling mechanism (2); the tension coarse adjustment device and the tension fine adjustment device have the same structure, both of which include piston-type clamping cylinders (302 ), the end of the piston rod is connected to the upper platen (304), while the upper platen (304) matches the guide rail (303), and the lower platen (305) is installed on the fuselage (301); the tension control mechanism (3) is also equipped with a proportional The controlled electro-hydraulic servo system can adjust the oil pressure and clamping force of the two clamping oil cylinders (302) respectively, and the electro-hydraulic servo system is connected with the automatic control system. 5. The variable tension steel strip winding device for prestressed mold manufacturing according to claim 1, characterized in that: the tension detection mechanism (4) includes a frame (401), in the middle of the frame (401) It is the upper drum support (402), on which the upper drum (403) is installed; the lower drum bracket (405) is arranged symmetrically on both sides of the upper drum bracket (402), on which the lower drum (404) is installed, A pressure sensor (406) is provided at the middle position below the upper drum support (402), and the pressure sensor (406) is connected with the automatic control system. 6. The variable tension steel strip winding device for prestressed mold manufacturing according to claim 1, characterized in that: the winding mechanism (5) includes a winding frame (501), on which a motor reduction unit (502 ), it is connected with the main shaft (504) through the shaft coupling (503), the main shaft (504) is connected with the chuck (506) through the bearing group (505), the encoder is arranged on the main shaft (504), and the motor reduction unit (502 ) and the encoder are connected with the automatic control system.

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