JPH11268154A - Adaptation control method and device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To avoide the shortcomings of an existing setup technique by continuously monitoring and actually measuring a dead band value during operating a mechanical device and updating the dead band value continuously based on the measuring bead band value. SOLUTION: In order to compensate for a dead band, a control device 44 calculates a command position by subtracting an initial dead band value from a desired position. Next, the control device 44 actuates air motors 22 and 24, and sends signals for actuating leadscrews 32, 36 to control valves 46, 48, and side guide systems 16, 18 are shifted based on the calculated command position.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a control apparatus and method for accurately positioning a shaft or a movable member in an apparatus, and more particularly, to a method for automatically setting up a shaft of a waveform shaping apparatus and / or a box making apparatus. And an apparatus.

[0002]

BACKGROUND OF THE INVENTION Mechanical devices such as corrugating devices and / or box making devices typically include corrugating rolls,
It consists of a number of rolls, such as printing rolls, pressure rolls, slitter / grooving rolls, side guides and other components to be precisely aligned and positioned. Each roll rotates about a central axis. In order for the machine to operate properly, all axes must be properly aligned with each other and with the rest of the machine. At present, axis alignment or "setup"
Is performed using a computer controller. Typically, the axis of each roll used is positioned using a setup signal that drives an air motor and a lead screw. As would be expected, motors, lead screws and other mechanical components cannot always be stopped at the very moment that each axis is accurately positioned at a preselected position, thus leading to overshoot or "dead bands". Occur. Currently, this dead band is compensated using a "brute force" approach. The setup routine is executed periodically to measure overshoot or deadband values and to subtract this from the setup signal, which requires stopping the machinery for a period of a week. Shutting down the machinery will result in a loss of revenue and the operator of the equipment will disturb the setup routine, thus causing the equipment to become relatively inconsistent relatively quickly.

[0003]

SUMMARY OF THE INVENTION An existing setup is provided by continuously monitoring and measuring a dead band value during operation of a mechanical device and continuously updating the dead band value based on the measured dead band value. It is an object of the present invention to provide an adaptive control method and control device which avoids the disadvantages of the technique.

[0004]

According to the present invention, there is provided a control device for adaptively controlling the movement of a member or a shaft, for example a roll or guide of a mechanical device such as a corrugating device, to a desired position. You. The control device calculates the command position by subtracting the dead band value selected in advance from the desired position. The control device issues a signal to move the components of the device to this commanded position. A sensor determines the actual position of the member. The controller updates the deadband value by subtracting the actual position from the commanded position, and controls the subsequent movement of the member as a function of the updated deadband value. The controller can be programmed to average the updated deadband value over a preselected number of movements of the member. Once the average value of the dead band values has been calculated, the subsequent movement of the member is determined as a function of the updated average value of the dead band values. A sensor such as an encoder can be used to determine the actual position of the member. The control device is operative to determine the updated deadband value during operational movements, i.e., during normal setup movements, collimation movements, and specific setup movements of the machine during operation. Is possible.

[0005]

FIG. 1 shows an adaptive control device 10 according to the present invention. Although the adaptive control device 10 (hereinafter simply referred to as the device 10) is shown in combination with the movable lateral guide system of the flexo folder gluer device, the adaptive control device 10 is adapted to be movable, such as a roll or a guide. The present invention can be applied to any mechanical device having a member or a shaft. The side guide mechanism 11 includes a shaft 12 attached to a frame 14. A pair of side guides 16 and 18 are slidably disposed on each side of the shaft 12. Displacement device 20 is side guide system 1
6 and 18 to the shaft 12 as shown by the arrows in the figure.
To move along the side. In the illustrated embodiment, the displacement device 20 includes a pair of air motors 22, 24 and a gearbox 26. The lead screw can be driven by many types of AC or DC motors controlled by a contractor instead of a valve.

[0006] The air motor 22 is connected to the side guide system 1.
The lead screw 32 operatively connected to 6 is driven. A support member 34 is attached to the center position of the shaft 12.
The distal end 33 of the lead screw 32 is rotatably mounted on a bearing 35 positioned at the center of the support member 34. Similarly, air motor 24 drives lead screw 36 operatively coupled to side guide system 18. The lead screw 36 is mounted on the bearing 3 at the center of the support member 34.
7 so as to be rotatable. The distal end 39 of the lead screw 36 is rotatably attached to the bearing 35 of the frame 14. Air motors 22 and 24 have lead screw 3
2 and 36 respectively drive the side guide system 16
And 18 move laterally along shaft 12. Position sensors, such as encoders 40 and 42, are associated with air motors 22 and 24 and determine the correct position of side guide systems 16 and 18 on shaft 12.
From the encoders 40 and 42, the side guide system 16
And a signal proportional to the distance traveled on 18 is sent to a controller 44, which may be a microprocessor or a programmable logic controller or the like.

Controller 44 processes the signals received from encoders 40 and 42 and then sends command signals to a pair of control valves 46 and 48. Control valves 46 and 48
Controls the operation of the air motors 22 and 24 so that the side guide systems 16 and 18 are positioned at desired positions. Overshoot or "deadband" always occurs because motors, lead screws and other mechanical components cannot stop the side guide system at the desired location. The adaptive controller 10 continuously monitors and measures this dead band during operation of the machine.

Referring to FIG. 2, during manufacture of the mechanical device, an initial dead band value is stored in the controller memory. This initial deadband value is determined from historical data for similar machinery. In operation, the operator enters the desired travel distance of the side guide systems 16 and 18 or the computer displays, for example, 30 inches (about 7 inches).
The desired position is calculated based on order setup conditions such as a distance of 6.2 cm). If the initial "dead band value" is determined to be 0.1 inch (approximately 0.25 cm), the side guide systems 16 and 18 will typically have the desired effect due to valve and motor response delays and lost lead screw movement. Exceed the position by 0.1 inches.

In order to compensate for the dead band, the control unit 44 calculates a command position by subtracting an initial dead band value from a desired position. Next, the control device 44 operates the air motors 22 and 24 and sends signals for operating the lead screws 32 and 36 to the control valves 46 and 48, and based on the calculated command position, the side guide system 16
And 18 are biased. For example, if the desired position is 30 inches (approximately 76.2 cm) and the initial dead band value is 0.1 inches (approximately 0.25 cm), the command position is 29.9 (approximately 75.9 cm).
m). In other words, the control unit determines that the measurement position is 29.9
When it reaches (approximately 75.9 cm), the side guide system is actually stopped. The lateral guide system actually stops at approximately 30 inches due to unavoidable overshoot.

After the side guide systems 16 and 18 have been moved to the commanded position, encoders 40 and 42 measure the actual position of the side guide systems. This measured value is stored in the memory of the controller 44. A counter increments the number of movements of the side guide system. The controller then calculates an average deadband value based on the new position data received from the encoder. The dead band value is determined by subtracting the actual position from the command position, and the determined dead band value is added to the "axis position difference" register. Next, the average dead band value is obtained by dividing the axis position error difference by the increment count value N. The calculation result is stored as a new dead band value. This new average dead band value can also be calculated using any conventional average value calculation routine. At this point, iterations
The count value is compared to a preselected maximum limit number to determine whether the number has reached the maximum number.

For example, when the preset maximum number of times is 10
When the side guide system moves for the next ten times, the control device individually calculates the dead band value for each movement and obtains an average value of these ten times. When the limit number is reached, the old or initial dead band value is replaced with the calculated new dead band value. Thus, the new commanded position to which side guide systems 16 and 18 next move will be equal to the updated deadband value minus the new desired position.

The deadband routine is executed on a continuous basis to compensate for wear or environmental changes caused by the system. The adaptive control device 10 does not need to stop the mechanical device when obtaining a new dead band value. The adaptive controller can also handle any axis movement, including normal computerized setup movements, manual collimation movements, and specific movements to determine new deadbands. the system,
Environmental changes can be compensated, for example, by using sensors to compensate for changes in factory temperature or air pressure. In addition, instead of an air motor,
For example, by using an electric actuator, fluctuations in voltage or current can be compensated. A major advantage of the present system is that it does not require any separate dead band routines that result in lost production time. The system always uses the optimal deadband value and the operator does not need to remember to perform another routine. Although the present invention has been described with reference to the embodiments, it should be understood that various modifications can be made within the present invention.

[0013]

By continuously monitoring and measuring the dead band value during the operation of the mechanical device and continuously updating the dead band value based on the measured dead band value, the disadvantages of the existing setup technique are eliminated. An adaptive control method and control device to avoid are provided.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of an adaptive control device of the present invention for use with a movable lateral guide system of a flexo folder gluer device.

FIG. 2 is a flowchart for operating the adaptive control device.

[Explanation of symbols]

 Reference Signs List 10 Adaptive control device 11 Side guide mechanism 12 Shaft 14 Frame 16, 18 Side guide 20 Displacement device 22, 24 Air motor 26 Gear box 34 Support member 32, 36 Lead screw 35, 37 Bearing 40, 42 Encoder 44 Control device 46, 48 Control valve

Claims (16)

[Claims] 1. A method for adaptively controlling movement of a member of a device to a desired position, wherein a command position is calculated by subtracting a preselected dead band value from a desired position. Generating a signal to move to the commanded position, determining the actual position of the member, calculating the updated deadband value by subtracting the actual position from the commanded position, Controlling the movement as a function of the updated dead band value. A method for adaptively controlling movement of a member of a device to a desired position. 2. The method of claim 1, further comprising averaging the updated dead band value with respect to the movement of the member a preselected number of times, wherein controlling subsequent movement of the member as a function of the updated dead band value. 2. The apparatus of claim 1 wherein controlling includes controlling subsequent movement of the member as a function of an average of said updated deadband values. 3. The apparatus of claim 1, wherein determining the actual position of the member includes determining an actual position of the shaft using the sensor. 4. The apparatus of claim 1, including using an encoder as the sensor. 5. The apparatus of claim 1, wherein generating a signal for moving a component of the apparatus to a commanded position is performed during an operational movement of the apparatus during operation of the apparatus. 6. The apparatus of claim 1, wherein the member comprises including a roll, roll nip or guide of a corrugating device. 7. Controlling the subsequent movement of the member as a function of the updated dead band value controls the subsequent movement of the member as a function of the updated dead band value and ambient conditions. The apparatus of claim 1, comprising: 8. The apparatus of claim 7, wherein the ambient conditions include temperature. 9. A device for adaptively controlling the movement of a member of a waveform shaping device to a desired position, comprising: means for calculating a commanded position by subtracting a preselected dead band value from the desired position; Means for generating a signal for moving a member of the waveform shaping device to the commanded position; means for determining the actual position of the member; and a dead band updated by subtracting the actual position from the commanded position. Moving the member of the waveform shaping device to a desired position, comprising: means for calculating a value; and a controller for controlling subsequent movement of the member as a function of the updated deadband value. For adaptive control of 10. The apparatus further comprising means for averaging the updated dead band value with respect to the movement of the member at a pre-washed number of times, wherein the control unit updates the subsequent movement of the member with the updated dead band value. 10. The apparatus of claim 9, wherein the control is performed as a function of the average value of. 11. The apparatus of claim 9, wherein the means for determining the actual position of the member includes a sensor for determining the actual position of the member. 12. The sensor according to claim 11, wherein the sensor is an encoder.
Equipment. 13. The means for generating a signal for moving a member of a waveform shaping device to a commanded position is operative during an operational movement of the waveform shaping device during operation of the waveform shaping device. 9 devices. 14. The apparatus of claim 9, wherein the member comprises a roll or guide of a corrugating device. 15. Detecting ambient conditions and sending a signal representative of the ambient conditions to a controller, which causes the subsequent movement of the member to be based on the average of the updated dead band values and the ambient The apparatus of claim 9 further comprising a sensor for controlling as a function of the condition. 16. The apparatus of claim 15, wherein the ambient condition is temperature.