KR20030035581A - Automatic Decision and Control Method of Amount of Loop as of Thickness of Material for Welder in Plating Factory - Google Patents

Abstract

PURPOSE: A method for automatically calculating and controlling looper amount considering a preset and stored basic looper amount and compensation amount for looper descending by weight and elasticity according to thickness of material injected into the welder using inlet and outlet loopers is provided. CONSTITUTION: The method comprises first step of constructing basic database by setting error compensation range value (Kn) for driving motor using trial and error method and storing the set error compensation range value into welder PLC considering elasticity and weight of the material and characteristics of the welder in each of the regions after dividing the thickness range of a material used in welder into 'n' number regions in advance; second step in which the welder PLC stores the processed information by processing the information after receiving thickness information of the material from an upper level computer in performing actual welding operation afterwards; third step of obtaining an allowable error compensation value by correspondingly comparing the thickness information with the database, and calculating an imaginary looper amount (L3) by adding a target looper amount (L1) preset by mathematical expression 2 (L3=L1+Kn) to the allowable error compensation value (Kn); fourth step of performing automatic controlling for maintaining the looper amount by repeatedly impressing an increment looper amount (ΔL) by mathematical expression 3 (ΔL=L3-L4) after sensing rotation speed of pinch rolls using a speed detecting sensor and converting the sensed rotation speed of the pinch rolls into a lopper amount (L4) so that the converted looper amount is feed backed to the inverter controller again after driving the motor by converting the imaginary looper amount (L3) into control value (DATAn) so that the converted control value is impressed to an inverter controller; and fifth step of turning back to the second step again if thickness of the material that is an object of welding operation is changed.

Description

Automatic Decision and Control Method of Amount of Loop as of Thickness of Material for Welder in Plating Factory}

The present invention relates to a method for automatically determining and controlling looper amount by material thickness for a plating factory welder, and more particularly, according to the thickness of the material into which the entrance and exit loopers installed at the front and rear ends of the welder are introduced into the welder. The present invention relates to a method for automatically calculating and controlling an accurate looper amount in consideration of a preset looper amount, which is preset and stored, and a compensation amount for a loop fall due to weight and elasticity.

In general, as shown in FIG. 1, the pinch rolls 3 and 5 used to move the strip through the welder 4 and to form the loops 7 and 8 are installed at both front and rear ends of the welder 4. It is. That is, the strip wound on the pay-off reel 1 is loosened and bitten by the pair of entry pinch rolls 3, and then passed through the welder 4, and then bites again by the pair of exit pinch rolls 5. After that, it is transferred to a later step, and the required welding operation is performed by the welder 4.

At this time, the welding of the welder 4 has to be fixed accurately, so that the entry pinch roll 3 and the exit pinch roll 5 form the entrance loop 7 and the exit loop 8, respectively. . That is, the strip is first lifted by raising the exit loop roll 2 positioned between the pair of entrance pinch rolls 3 and the exit loop roll 6 positioned between the pair of exit pinch rolls 5 to a constant height. The looper amount must be kept constant by bending and then controlling the driving and deactivation of the entry pinch roll 3 and the exit pinch roll 5.

However, the looper amount gradually decreases due to the weight of the material and the elasticity of the material when a predetermined time passes after the entrance loop 7 and the exit loop 8 are formed. Therefore, it is necessary to control for the continuous maintenance of the set looper amount.

In order to control the looper amount, the amount of looper is controlled by adjusting a control amount applied to the motor which transmits power to both pinch rolls 3 and 5. At this time, the voltage, current, their application time, the number of applied pulses, etc. are the control quantities, all of which are values that must be calculated separately for each welder 4, and are also concepts that can be converted into different units. By driving the rolls 3 and 5, it is to determine how many mm the looper amount rises. Therefore, hereinafter, the unit of the looper amount will be described unified in length unit (mm) unless specifically mentioned.

In the related art, the following formula was used to calculate the amount of incremental looper required for the formation and maintenance control of the entry loop 7 and the exit loop 8.

Where ΔL is the incremental looper amount and the looper increase necessary to maintain the target looper amount, L ₁ is the looper set amount, the target looper amount, and L ₂ is the increase in the looper estimated by the motor voltage applied by the previous control. to be.

However, according to Equation 1, in the prior art, the mechanical influence of the material properties, that is, the strength, elasticity, thickness, and the like on weight and warpage, was not considered in controlling the looper amount. That is, only the L ₁ value, which is the looper set amount, was considered. For example, when this value was set to 1,500 mm, the looper control of the front end of the pinch rolls 3 and 5 was configured to maintain this value.

Here, if we first think about the thickness of the material, the material may be varied even in one welder (4), the thickness of the material that has the greatest influence on the properties of the various materials, such as 0.4 It may have a range of ~ 2.3 mm. In this case, the thin material bends well, so that the looper amount can be well formed and maintained even when the voltage applied to the motors driving the pinch rolls 3 and 5 is small. It is obvious that higher torque or higher voltage, more pulses, must be applied as a larger torque is required.

However, in the conventional Equation 1, there is no consideration at all, and according to the thickness of the material used for welding, there is a large difference in the amount of looper in which the loops 7 and 8 are actually formed.

In addition, in the maintenance control of the looper amount, the actual looper amount increased by the control of the previous step or the actual speed of the pinch rolls 3 and 5 that can be converted should be measured and used as a feedback value. The increase in the execution amount L ₂ of the looper in ss is simply used for controlling the speed or moving distance of the pinch rolls 3 and 5 estimated by the voltage, current or pulse applied to the motor. Therefore, accurate looper control was not possible.

Therefore, due to the above two factors, it is difficult to accurately control the front and rear ends of the most important materials during welding work, which makes the operation of the welder 4 impossible and delays the working time, and also allows the driver to loop by hand. There was a problem that was to be the main cause of poor precision of the product because it was forced to control.

The present invention has been made to solve the above problems, by controlling the pinch roll (3, 5), that is, the applied voltage according to the thickness, which is an important factor of the characteristics of each material in the looper configuration of the welder (4) Plating plant welder which enables the automatic operation of the equipment according to the seamless looper configuration and also executes the looper control more precisely by measuring and feeding back the driving speed of the actual pinch rolls 3 and 5 by the previous stage of control. It is to provide an automatic determination and control method of looper amount by material thickness for 4).

1 is a configuration diagram of a welding line of a general plating factory,

2 is a block diagram of a control device in which the method of the present invention is implemented;

3A-3D are block diagrams illustrating each step of the method of the present invention, respectively;

4 is an overall flow chart illustrating the operation of the method of the present invention.

<Description of Symbols for Major Parts of Drawings>

1: Pay Off Reel 2: Entry Loop Roll

3: entrance pinch roll 4: welder

5: exit pinch roll 6: exit loop roll

7: entrance loop 8: exit loop

9: SCC Computer 10: Welder PLC

11: VVVF AC Motor 12: Speed Detection Sensor

20: Inverter Controller

In order to achieve the above technical problem, as shown in FIG. 2, the method of the present invention includes an upper computer 9, a welder PLC 10, a motor 11, a speed detection sensor 12, and an inverter controller 20. It is implemented by a program and a database that is stored and loaded in the welder PLC 10 of the control device consisting of the device, the welder PLC 10 has its own storage device and the determination device, which includes (9) and the output of the speed detection sensor 12 are input, output to the inverter controller 20, the output of the speed detection sensor 12 is input to the inverter controller 20, and output to the motor 11 It is configured to.

According to the method of the present invention stored in the welder PLC 10, the thickness range of the material to be used in the welder 4 is divided into n areas in advance (15), and the elasticity and Considering the weight and the characteristics of the welder 4, the error compensation range value Kn for driving the motor 11 is set (16) by trial and error and stored in the welder PLC 10 to build a basic database. The first step,

Thereafter, in the actual welding operation, the second step in which the welder PLC 10 receives the thickness information of the material from the upper computer 9 (13), processes (14) and stores it,

Comparing the thickness information 14 with the database 17 (18) to obtain a tolerance compensation value Kn (17),

A third step of calculating a virtual looper amount L ₃ by adding a target looper amount L ₁ and a tolerance compensation value Kn set in advance by

After converting the virtual looper amount L ₃ into a control value DATAn (19) and applying it to the inverter controller 20 to drive the motor 11, the speed of rotation of the pinch rolls 3 and 5 is detected. Detected by the sensor 12 and converted into a looper amount (L ₄ ) and fed back to the inverter controller 20

A fourth step of performing automatic control for maintaining the looper amount by repeatedly applying the incremental looper amount? L by

The welder 4 is composed of a fifth step of returning to the second step when the thickness of the material to be worked is changed.

The operation of the method of the present invention as described above will be described in more detail with reference to the accompanying drawings.

First, the configuration of the apparatus for storing and executing the method of the present invention is as shown in FIG. The device uses a host computer (9), welder PLC (10), motor to control the voltage, current or pulse applied to the pinch rolls (3, 5) driven directly in contact with the strip to form and maintain the looper. (11), the speed detection sensor 12 and the inverter controller 20 are control devices.

The method of the present invention is implemented by a program and a database, which are stored and loaded in the welder PL 10. Therefore, the welder PLC 10 should have its own storage device and judgment device. The output of the host computer 9 and the speed detection sensor 12 is input to the welder PC 10, and is configured to output to the inverter controller 20.

On the other hand, the output of the speed detection sensor 12 is input to the inverter controller 20, and is configured to output to the motor 11.

The method of the present invention using such a control device, in particular stored and executed in the welder PLC 10, is implemented according to a four step procedure for one welder 4 as shown in FIG. In particular, the thickness of the material to be applied to the welder 4 is configured to repeat the procedure from the second step to the fourth step.

The first step is to be built separately for each welder (4). This is because each welder 4 has its own characteristics, and the thickness of the material that the welder 4 can process also differs.

First, a thickness range of a material to be used for one particular welder 4 is previously divided into n regions (15). Although the thickness range of the said raw material differs for each welder 4, the welder 4 which can use the raw material of thickness 0.4mm-2.3mm is demonstrated in the Example of this invention shown in FIG. 3A, The number of area divisions for the thickness range can be variously set according to the embodiment. However, according to the embodiment of the present invention shown in FIG. 3A, the number of area divisions is described as being divided into eight areas (TABLE1 to TABLE8).

Then, in each of these areas, an error compensation range value Kn for driving the motor 11 in consideration of the elasticity and weight according to the thickness of the material and the properties of the welder 4 is determined by a trial and error method. It sets by 16. The error compensation range Kn may be set to a small value for a thin material and to a large value for a thick material. Actually, the driving force of the pinch rolls 3 and 5 of each welder 4 and the elasticity of the material It is a value to be determined through several tests in consideration of weight and weight. Therefore, it is very difficult to obtain by proper mathematical formula, so it is obtained by trial and error method.

In the embodiment of the present invention, when the thickness of the material is 0.4 to 2.3 mm for a specific welder 4, the thickness corresponding to the first area TABLE1 is divided as shown in FIG. 3A. For the material of 0.4 to 1.0 mm, the error compensation range value K ₁ is determined to be 0 mm by the trial and error method. Illustrating the result of the embodiment of the error compensation range value Kn by the trial and error method determined for all regions in this manner,

For the first area TABLE1, the error compensation range value K ₁ is 0 mm,

For the second area TABLE2, the error compensation range value K ₂ is 5 mm,

For the third area TABLE3, the error compensation range value K ₃ is 10 mm,

For the fourth area (TABLE4), the error compensation range value K ₄ is 15 mm,

For the fifth area (TABLE5), the error compensation range value K ₅ is 20 mm,

For the sixth area (TABLE6), the error compensation range value K ₆ is 25 mm,

For the seventh area (TABLE7), the error compensation range value K ₇ is 30 mm,

For the eighth area (TABLE8), the error compensation range value (K ₈ ) is 35 mm

to be.

When the error compensation range values Kn are determined for all regions in this manner (16), if necessary, they are converted into comparable data types (WORD1 to WORD8) (17) and stored in the storage means of the welder PLC 10. The step of constructing a basic database of material-specific error compensation range values Kn for the particular welder 4 is completed.

Then, in the second step, the welding work of a specific material is actually performed in the specific welder 4, and as shown in FIG. 3B, the welder PLC 10 first starts the material from the upper computer 9 of the upper part. Receive the thickness information (TABLE21) of (13). In this case, if the data TABLE21 is ASCII data, as in the embodiment, it cannot be used for direct comparison, and thus, the data TABLE21 must be reprocessed (WORD10) in the form of comparable data (14) and stored. The thickness of the material should be included in the thickness range (for example, 0.4 ~ 2.3mm) to build a database in the first step.

Thereafter, a third step is executed, in which the thickness information WORD10, 14 is compared with the databases WORD1 to WORD8, 17 as shown in FIG. 3C (18). Thereby, the tolerance compensation value Kn shown in Fig. 3A can be obtained for this specific material (17).

After that, the following Equation 2

The virtual looper amount L ₃ is calculated by adding the target looper amount L ₁ and the tolerance compensation value Kn set in advance. The target looper amount L ₁ is the same value as the conventional target looper amount, which is the amount of looper required for the particular welder 4 for any material without considering the thickness of the material. It is to be set differently according to its characteristics for each welder 4, for example, it can be set to 1,500 mm.

For example, when the target looper amount L ₁ is 1,500 mm and the thickness of the material is 1.5 mm, the material corresponds to the fifth area TABLE4 of the database. Tolerance compensation value K ₄ is 15 mm. Therefore, the virtual looper amount L ₃ is 1,500 mm by adding 15 mm, which is the tolerance compensation value K ₄ , to 1,500 mm, which is the target looper amount L ₁ . That is, even if the control is aimed at this value, since the natural descent due to the weight or elasticity of the material is about 15 mm, the actual looper amount is 1,500 mm, and thus the target looper amount (L ₁ ) suitable for the characteristics of the welder (4). This is to be achieved.

In the fourth step, the virtual looper amount L ₃ is converted into a control value DATAn (19). The conversion content may vary depending on the specifications of the motor 11, the diameter of the pinch rolls 3 and 5, and the like. The control value DATAn is not limited to the voltage, but may be any physical quantity used to control the motor 11. For example, it can be converted into voltage, current, and the number of pulses to be applied.

Taking the voltage value as an example of the control value DATAn, 19,

For the first area TABLE1, the voltage value DATA1 is 1.2V,

For the second area TABLE2, the voltage value DATA2 is 2.4V,

For the third region TABLE3, the voltage value DATA3 is 3.6V,

For the fourth area TABLE4, the voltage value DATA4 is 4.8V,

For the fifth region TABLE5, the voltage value DATA5 is 6.0V,

For the sixth area (TABLE6), the voltage value DATA6 is 7.2V,

In the seventh area (TABLE7), the voltage value (DATA7) is 8.4V,

In the eighth area TABLE8, the voltage value DATA8 is 10.0V.

You can do

The control values DATAn and 19 are applied to the inverter controller 20 to drive the motor 11. Then, the pinch rolls 3 and 5 engaged with the motor 11 are rotated while being driven.

Thereafter, the actual rotation speed of the pinch rolls 3 and 5 is detected by the speed detection sensor 12. The rotational speed does not estimate the rotational speed of the pinch rolls 3 and 5 based on the voltage applied amount of the motor 11 as in the conventional art, but speeds up the rotational speed of the actual pinch rolls 3 and 5. It should be detected by the detection sensor 12.

Next, the rotation speed measurement value is converted into a looper amount L ₄ and fed back to the inverter controller 20. By using the actual rotation speed in this way, more accurate control is possible.

After that, the following Equation 3

By repeatedly applying the incremental looper amount? L, automatic control for holding the looper amount is performed. As described above, subtracting the measured looper amount L ₄ from the virtual looper amount L ₃ calculates the amount to drive the motor 11. In other words,

Becomes Therefore, in order to continuously achieve the virtual looper amount L ₃ , a process amount, for example, a voltage is applied, and the rotation speeds of the actual pinch rolls 3 and 5 are detected and compared, and then the voltage is applied again.

Thereafter, the work of the welder 4 on the material having the thickness is finished, and when the thickness of the material which is the work object of the welder 4 is changed again, the process returns to the second step.

As described above, although the present invention has been described by way of limited embodiments and drawings, the present invention is not limited thereto, and the technical idea of the present invention and the following by those skilled in the art to which the present invention pertains. Various modifications and variations are possible, of course, within the scope of equivalents of the claims to be described.

According to the present invention as described above by building a database in advance by the thickness of the material and automatically branching and control according to the thickness of the actual material, the workability is excellent, the production efficiency is improved, to prevent the occurrence of failure It can be, there is no problem of deterioration of precision by hand, minimizes the defect of the product, and has a very innovative effect that can facilitate the convenience of the operator.

Claims (1)

Programs and databases stored and loaded in the welder PLC 10 of at least the host computer 9, the welder PLC 10, the motor 11, the speed detection sensor 12, and the inverter controller 20. In the method for automatically determining and controlling the amount of looper by the thickness of the material for the welder (4) of the plating factory implemented by The welder PLC 10 has its own storage device and a judging device, and the outputs of the host computer 9 and the speed detection sensor 12 are input to the inverter controller 20 and output to the inverter controller 20. 20, the output of the speed detection sensor 12 is input, and configured to output to the motor 11, The method divides the thickness range of the material to be used in the welder 4 into n areas in advance (15), and in each area, the error of driving the motor 11 in consideration of the elasticity and weight of the material and the characteristics of the welder 4. A first step of establishing a basic database by setting (16) the compensation range value Kn by trial and error and storing it in the welder PLC 10; Thereafter, in the actual welding operation, the second step in which the welder PLC 10 receives the thickness information of the material from the upper computer 9 (13), processes (14) and stores it, Comparing the thickness information 14 with the database 17 (18), the tolerance compensation value Kn is obtained (17). A third step of calculating a virtual looper amount L ₃ by adding a target looper amount L ₁ and a tolerance compensation value Kn set in advance by After converting the virtual looper amount L ₃ into a control value DATAn (19) and applying it to the inverter controller 20 to drive the motor 11, the speed of rotation of the pinch rolls 3 and 5 is detected. Detected by the sensor 12 and converted to the looper amount (L ₄ ) and fed back to the inverter controller 20, Equation 3 A fourth step of performing automatic control for maintaining the looper amount by repeatedly applying the incremental looper amount? L by Welder (4) is characterized in that it consists of a fifth step to return to the second step if the thickness of the material to be worked is changed Automatic determination and control method of looper amount by material thickness for plating factory welder (4).