新型卷板机运动结构与控制系统设计
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摘要
卷板机是一种将金属板材弯卷成筒体、锥体、曲面体或其他形体的通用成型设备,现已广泛应用于锅炉、化工、造船、航空、铁路运输及建筑等行业。目前,市场上的卷板机在卷制板材过程中普遍存在效率低、精度低等缺陷,因此本课题意在设计一种高效、高精的集预弯与卷制于一体的新型卷板机。
本文主要从运动结构、液压传动和控制系统三个方面对卷板机的性能进行了改进和优化,并提出了新的方案。
首先,对卷板机的运动结构进行了改造,将油压机与卷板机组合,实现了在卷板机上利用冲压成型原理对板材的剩余直边进行快速、精确的预弯。并根据几何学对工作辊在预弯、卷制工艺中的工作位置进行数学建模,推导出了工作辊在各工艺中的几何位移量,然后通过上位机传到下位机实现对执行机构的精确控制。
其次,对卷板机的液压系统进行了改造,在原有液压系统的基础上特别针对工作辊的同步、翻倒装置的保压以及液压马达的制动问题设计了特定的液压回路,实现了卷板机卷制过程中液压缸的同步动作、翻倒油缸的安全运行以及液压马达的平稳换向。
最后,对卷板机的控制系统进行了改造,设计出了一套上下位机主从式控制系统。上位机控制及界面显示采用VC++软件开发,下位机使用西门子公司的S7-200PLC进行运动控制。控制程序采用模块化设计,将系统整体划分为若干子模块,然后对每个子模块的运动进行设计。
The plate bending machine is a molding equipment which can bend plate into column, cone, arc and so on, has been widely used in boiler, chemical, air, rail transport and architecture industries. At present, the various plate bending machines have some common shortcomings of low efficient and low precision. Therefore, this topic with a view to design a new plate bending machine, which has the function of prebending and bending of high efficient and high precision.
The paper proposes a new project, which design to improve and optimize the performance of the new plate bending machine from the kinematic structure, hydraulic transmission and control system:
First of all, reforming the kinematic structure of the plate bending machine, combine the hydraulic machine and plate bending machine, make use of stamping forming principle for the remaining straight edge of plate for fast and accurate prebending. The method of geometry was used to get the mathematical modeling of the operative rolls on prebending and bending process, and deduce the displacement of the operative rolls. Then get the precisely control of the actuators through communication.
Secondly, reforming the hydraulic system of the plate bending machine, especially for the problem of rolls’synchronization, tilting device’s pressure and hydraulic motor’s braking from the original hydraulic, and design the particular hydraulic loop to resolve them. And the result is get the synchronization of hydraulic cylinder, safe operation of tilting device and steady commutation of hydraulic motor.
Finally, reforming the control system of the plate bending machine, the paper proposes a kind of PC + PLC master-slave type control system. The control and interface of supervisory computer’s development based on vc++, the next place machine use SIEMENS S7-200PLC for operation control. The modularizing is adopted in design for control program, to divide the system to several modules, and then design the movement of each child module.
本文主要从运动结构、液压传动和控制系统三个方面对卷板机的性能进行了改进和优化,并提出了新的方案。
首先,对卷板机的运动结构进行了改造,将油压机与卷板机组合,实现了在卷板机上利用冲压成型原理对板材的剩余直边进行快速、精确的预弯。并根据几何学对工作辊在预弯、卷制工艺中的工作位置进行数学建模,推导出了工作辊在各工艺中的几何位移量,然后通过上位机传到下位机实现对执行机构的精确控制。
其次,对卷板机的液压系统进行了改造,在原有液压系统的基础上特别针对工作辊的同步、翻倒装置的保压以及液压马达的制动问题设计了特定的液压回路,实现了卷板机卷制过程中液压缸的同步动作、翻倒油缸的安全运行以及液压马达的平稳换向。
最后,对卷板机的控制系统进行了改造,设计出了一套上下位机主从式控制系统。上位机控制及界面显示采用VC++软件开发,下位机使用西门子公司的S7-200PLC进行运动控制。控制程序采用模块化设计,将系统整体划分为若干子模块,然后对每个子模块的运动进行设计。
The plate bending machine is a molding equipment which can bend plate into column, cone, arc and so on, has been widely used in boiler, chemical, air, rail transport and architecture industries. At present, the various plate bending machines have some common shortcomings of low efficient and low precision. Therefore, this topic with a view to design a new plate bending machine, which has the function of prebending and bending of high efficient and high precision.
The paper proposes a new project, which design to improve and optimize the performance of the new plate bending machine from the kinematic structure, hydraulic transmission and control system:
First of all, reforming the kinematic structure of the plate bending machine, combine the hydraulic machine and plate bending machine, make use of stamping forming principle for the remaining straight edge of plate for fast and accurate prebending. The method of geometry was used to get the mathematical modeling of the operative rolls on prebending and bending process, and deduce the displacement of the operative rolls. Then get the precisely control of the actuators through communication.
Secondly, reforming the hydraulic system of the plate bending machine, especially for the problem of rolls’synchronization, tilting device’s pressure and hydraulic motor’s braking from the original hydraulic, and design the particular hydraulic loop to resolve them. And the result is get the synchronization of hydraulic cylinder, safe operation of tilting device and steady commutation of hydraulic motor.
Finally, reforming the control system of the plate bending machine, the paper proposes a kind of PC + PLC master-slave type control system. The control and interface of supervisory computer’s development based on vc++, the next place machine use SIEMENS S7-200PLC for operation control. The modularizing is adopted in design for control program, to divide the system to several modules, and then design the movement of each child module.
引文
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[2]肖聚亮.基于PMAC的卷板设备数控系统研究与开发[D].天津:天津大学,2003.
[3]张绪荣.用于卷管预弯工艺的大型油压机[J].锻压机械,1997(3):15-17.
[4] M Hua, D H Sansome, K Baines. Mathematical modeling of the internal bending moment at the top roll contact in multi-pass four-roll thin-plate bending[J]. Journal of Materials Processing Technology,1995,52 :425-459.
[5]任育红.水平下调式三辊卷板机工艺及设备研究[D].天津:天津大学,200606.
[6] M. Hua,K. Baines and I.M. Cole. Bending Mechanisms, Experimental Techniques and Preliminary Tests for the Continuous Four-Roll Plate Bending Process[J]. Journal of Materials Processing Technology 48 (1995) 159-172
[7]邢伟荣.卷板机的现状与发展[J].锻压设备与制造技术,2010(2):10-16.
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[9] Weilong Hu,Z.R. Wang. Theoretical analysis and experimental study to support the development of a more valuable roll bending process[J]. International Journal of Machine Tools & Manufacture,2001,41:731-747.
[10] Y.H. Lin,M. Hua. Influence of strain hardening on continuous plate roll-bending process[J]. International Journal of Non-Linear Mechanics,2000,35:883-896.
[11]李延广.三辊卷板机卷筒体不留余头卷制技术[J].中西南十省区(市)焊接学会联合会第九届年会论文集:227-228.
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[16] M. Hua,Y.H. Lin. Effect of strain hardening on the continuous four-roll plate edge bending process[J]. Journal of Materials Processing Technology. 1999,89–90: 12–18.
[17]杜鹏,张德华,潘晓光.三辊对称卷板机参数的计算模型与运动仿真[J].太原科技大学学报. 2006,27(1): 15-19.
[18]孙胜.回弹前筒体内径的确定[J].锻压机械,1996, (3):72.
[19]李云云严思杰许璐璐.基于数模平台的四辊卷板机辊轮工艺位置的计算[J].锻压技术,2010,35(5):80-83.
[20] M. Hua, Y.H. Lin. Large deflection analysis of elastoplastic plate in steady continuous four-roll bending process[J]. International Journal of Mechanical Sciences 41 (1999) 1461-1483.
[21]成其谦,吴荣昌. W12四辊卷板机改造[J].机械设计与制造.1994,(1):29-32.
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[23]李松晶,丛大成,姜洪洲.液压系统原理图分析技巧[M].北京:化学工业出版社,2009.
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[26] Yu Yuesen, Dai Peng, Xu Yajun, et al. Research on electro-hydraulic control system for hydraulic support at coal mine[J]. Procedia Earth and Planetary Science. 2009, 1(1):1549-1553.
[27]陈愈等编著.液压阀[M].北京:中国铁道出版社,1982.
[28]宋亚林.三辊卷板机的液压同步回路改进[J].液压与气动,2009(10):74-75.
[29]张承谱,阎祥安,曹玉平.上辊万能式三辊卷板机机架翻倒装置液压系统[J].液压与气动,2002(10):20-21.
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[31]上海煤矿机械研究所编.液压传动设计手册[M].上海:上海科学技术出版社,1981.
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[33] Ramazan Bayindir,Yucel Cetinceviz. A water pumping control system with a programmable logic controller (PLC) and industrial wireless modules for industrial plants—An experimental setup[J]. ISA Transactions, 2010,3:23-48.
[34] A. Honda,F. Okano,K. Ooshima. Application of PLC to dynamic control system for liquid He cryogenic pumping facility on JT-60U NBI system[J]. Fusion Engineering and Design. 2008,83:276–279.
[35]林育兹,鲍平.可编程序控制器原理及逻辑控制[M].北京:机械工业出版社,2005.11.
[36]赵海忠,王建国.浅谈PLC的选型[J].应用交流,2010.6.03
[37]陈宏.可编程控制器(PLC)的选型[M].化工进展,2003. 22(12):1354-1356.
[38]西门子有限公司.深入浅出西门子S7-200PLC[M].北京:北京航空航天大学出版社,2007.
[39]柳平增.基于卷板机控制的多轴数控系统的研究及应用[D].山东:山东科技大学,2003.
[40]周恩涛,徐学新编.液压系统设计元器件选型手册[M].北京:机械工业出版社,2007.
[41]王守城,段俊勇主编.液压元件及选用[M].北京:化学工业出版社,2007.
[42]杨东海,翁新华,杨汝清.基于VC++和MFC的上位机与PLC的通讯系统[J].微机算机信息. 2003,19(3):10-12.
[43] Ramapriyan Singlachar, Bhaskar Mukherjee. An advanced PC-PLC-based SCADA system for a commercial medical cyclotron[J]. Nuclear Instruments and Methods in Physics Research. 1997(399):396-406.
[44]郭伟,金施群.基于VC++的S7-200和工控机的自由口通讯[J].信息化技术与控制. 2007,17(1):16-19.
[45]丸山修孝著;王庆译.通信协议技术[M].北京:科学出版社,2004.
[46]赵晓明,徐立,邵威,夏春林.基于VC++的上位机与西门子系列PLC通信的研究[J].机电工程. 2007,24(7):42-44.
[47]卫庆军,曾文火,曹传生,闫红蕾. VC++环境下Siemens PLC与PC的串行通信[J].计算机技术. 2007,7(17):4490-4492.
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[2]肖聚亮.基于PMAC的卷板设备数控系统研究与开发[D].天津:天津大学,2003.
[3]张绪荣.用于卷管预弯工艺的大型油压机[J].锻压机械,1997(3):15-17.
[4] M Hua, D H Sansome, K Baines. Mathematical modeling of the internal bending moment at the top roll contact in multi-pass four-roll thin-plate bending[J]. Journal of Materials Processing Technology,1995,52 :425-459.
[5]任育红.水平下调式三辊卷板机工艺及设备研究[D].天津:天津大学,200606.
[6] M. Hua,K. Baines and I.M. Cole. Bending Mechanisms, Experimental Techniques and Preliminary Tests for the Continuous Four-Roll Plate Bending Process[J]. Journal of Materials Processing Technology 48 (1995) 159-172
[7]邢伟荣.卷板机的现状与发展[J].锻压设备与制造技术,2010(2):10-16.
[8]卜锋斌,丁肖良,戴贇.水平下调式三辊卷板机卷板工艺的数学建模[J].机电设备,2008(3):3-5.
[9] Weilong Hu,Z.R. Wang. Theoretical analysis and experimental study to support the development of a more valuable roll bending process[J]. International Journal of Machine Tools & Manufacture,2001,41:731-747.
[10] Y.H. Lin,M. Hua. Influence of strain hardening on continuous plate roll-bending process[J]. International Journal of Non-Linear Mechanics,2000,35:883-896.
[11]李延广.三辊卷板机卷筒体不留余头卷制技术[J].中西南十省区(市)焊接学会联合会第九届年会论文集:227-228.
[12]许贤良,王传礼主编.液压传动[M].北京:国防工业出版社,2006.
[13]杨秩.工控计算机和PLC的现状及其发展. 2005第六届工业仪表与自动化学术会议论文集:37-40.
[14]钟毅芳,吴昌林,唐增宝.机械设计[M].武汉:华中科技大学出版社,200102.
[15] M. Hua,K. Baines,I.M. Cole. Continuous four-roll plate bending: a production process for the manufacture of single seamed tubes of large and medium diameters [J]. International Journal of Machine Tools & Manufacture. 1999,39:905–935.
[16] M. Hua,Y.H. Lin. Effect of strain hardening on the continuous four-roll plate edge bending process[J]. Journal of Materials Processing Technology. 1999,89–90: 12–18.
[17]杜鹏,张德华,潘晓光.三辊对称卷板机参数的计算模型与运动仿真[J].太原科技大学学报. 2006,27(1): 15-19.
[18]孙胜.回弹前筒体内径的确定[J].锻压机械,1996, (3):72.
[19]李云云严思杰许璐璐.基于数模平台的四辊卷板机辊轮工艺位置的计算[J].锻压技术,2010,35(5):80-83.
[20] M. Hua, Y.H. Lin. Large deflection analysis of elastoplastic plate in steady continuous four-roll bending process[J]. International Journal of Mechanical Sciences 41 (1999) 1461-1483.
[21]成其谦,吴荣昌. W12四辊卷板机改造[J].机械设计与制造.1994,(1):29-32.
[22]郑军海.注塑机液压伺服系统设计与实现[D].山东:山东大学,20090503.
[23]李松晶,丛大成,姜洪洲.液压系统原理图分析技巧[M].北京:化学工业出版社,2009.
[24]焦生杰.工程机械机电液一体化[M].北京:人民交通出版社,2000.
[25] Omer Keles, Yucel Ercan. Theoretical and experimental investigation of a pulse-width modulated digital hydraulic position control system[J]. Control Engineering Practice. 2002(10):645-654.
[26] Yu Yuesen, Dai Peng, Xu Yajun, et al. Research on electro-hydraulic control system for hydraulic support at coal mine[J]. Procedia Earth and Planetary Science. 2009, 1(1):1549-1553.
[27]陈愈等编著.液压阀[M].北京:中国铁道出版社,1982.
[28]宋亚林.三辊卷板机的液压同步回路改进[J].液压与气动,2009(10):74-75.
[29]张承谱,阎祥安,曹玉平.上辊万能式三辊卷板机机架翻倒装置液压系统[J].液压与气动,2002(10):20-21.
[30]吴振芳,厉军.平衡阀和液压阀的选用[J].建筑机械,2007.07:89-90.
[31]上海煤矿机械研究所编.液压传动设计手册[M].上海:上海科学技术出版社,1981.
[32]李艳杰,于艳秋,王卫红,渠丰沛等编著. S7-200PLC原理与实用开发指南[M].北京:机械工业出版社,2009.
[33] Ramazan Bayindir,Yucel Cetinceviz. A water pumping control system with a programmable logic controller (PLC) and industrial wireless modules for industrial plants—An experimental setup[J]. ISA Transactions, 2010,3:23-48.
[34] A. Honda,F. Okano,K. Ooshima. Application of PLC to dynamic control system for liquid He cryogenic pumping facility on JT-60U NBI system[J]. Fusion Engineering and Design. 2008,83:276–279.
[35]林育兹,鲍平.可编程序控制器原理及逻辑控制[M].北京:机械工业出版社,2005.11.
[36]赵海忠,王建国.浅谈PLC的选型[J].应用交流,2010.6.03
[37]陈宏.可编程控制器(PLC)的选型[M].化工进展,2003. 22(12):1354-1356.
[38]西门子有限公司.深入浅出西门子S7-200PLC[M].北京:北京航空航天大学出版社,2007.
[39]柳平增.基于卷板机控制的多轴数控系统的研究及应用[D].山东:山东科技大学,2003.
[40]周恩涛,徐学新编.液压系统设计元器件选型手册[M].北京:机械工业出版社,2007.
[41]王守城,段俊勇主编.液压元件及选用[M].北京:化学工业出版社,2007.
[42]杨东海,翁新华,杨汝清.基于VC++和MFC的上位机与PLC的通讯系统[J].微机算机信息. 2003,19(3):10-12.
[43] Ramapriyan Singlachar, Bhaskar Mukherjee. An advanced PC-PLC-based SCADA system for a commercial medical cyclotron[J]. Nuclear Instruments and Methods in Physics Research. 1997(399):396-406.
[44]郭伟,金施群.基于VC++的S7-200和工控机的自由口通讯[J].信息化技术与控制. 2007,17(1):16-19.
[45]丸山修孝著;王庆译.通信协议技术[M].北京:科学出版社,2004.
[46]赵晓明,徐立,邵威,夏春林.基于VC++的上位机与西门子系列PLC通信的研究[J].机电工程. 2007,24(7):42-44.
[47]卫庆军,曾文火,曹传生,闫红蕾. VC++环境下Siemens PLC与PC的串行通信[J].计算机技术. 2007,7(17):4490-4492.
[48](美)Michael JYoung. Visual C++从入门到精通[M].北京:电子工业出版社,1999.
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