零速接纸机电控系统设计
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摘要
零速接纸机是一种可与多种软包装机械设备配套使用的通用辅助设备。为实现生产过程的连续化,在要求主机不停机的同时保证整个生产过程中张力满足工艺要求,零速接纸机应运而生了。零速接纸机,顾名思义,指的是在接纸过程中,接纸部位保持零速,而主机可以根据设定的速度运行。能做到这一点的主要原因是它较普通塔架式接纸机构增加了一套储纸机构。接纸过程中,主机生产所需纸张由储料架暂时供应,使接纸部位纸张不动,即为“零速”。这样既保证了相当高的接纸成功率和对接时的准确性,又可以保证生产过程无中断。提高产品质量的同时,提升了生产效率。另外,由于接纸可靠性的增强,接头较高速驳接变短,也增加了原料的利用率。本课题研究的零速接纸机着眼应用于印刷机、涂布机、制袋机等软包装机械,具有接纸成功率高、应用范围广、安装操作简单安全性能好的特点。
本文首先通过对国内外零速接纸机发展现状的调查,了解了其发展现阶段取得的成绩和依然存在的技术壁垒。针对现阶段零速接纸机在实际应用中对速度和张力的要求,提出了电控系统设计的主要性能指标。由此,针对性地进行硬件的选型和软件设计。主要研究了放卷电机、传感器、制动电阻等硬件选型时需要考虑的要素以及机器运行过程中对薄膜张力的控制的方法,并提出一个初步张力控制方案:闭环PID控制。然后用MATLAB/SIMULINK建立了系统的数学模型,利用该模型分析系统的稳定性和鲁棒性以及其阶跃响应的动态和稳态性能指标。最后,将基于西门子S7-200控制器的零速接纸机的控制程序按照软件特征和控制要求进行编写,并作最后调试。经论证,能够符合接纸过程中张力平稳、速度过渡平滑和安全系数达标的要求。
Zero-speed splice machine is a kind of universally used accessorial equipment which can match up with multiplicate soft packaging machine. To carry out“produce without pause”, the mainframe should not pause while the tension can meet the requirement set by users during all the process of manufacture, the zero-speed splice machine comes into being. Zero-speed splice machine can keep the splice unit stationary while the mainframe could run according to the set speed. How can it perform? It is depend on a unit of film tank which is not existed in the commonly used equipment of turret splicing unit. During the splice process, the film used by the mainframe is supplied by the film tank while the film in the splice unit is held still. In this way, not only both the rate of successfully splice and the veracity is enhanced, but also“produce without pause”is ensured. Both the quality and productivity is improved greatly. In addition, as the rate of successfully splice is raised and the tie-in is shorten, the rate of material utilization is raised. This paper research focuses on making the zero-speed splice machine an accessorial equipment for print machine, coating machine and bag-making machine etc, which is of high rate of successfully splice rate, widely used, easy to mount and operate and of good security.
Firstly, by investigating the status quo of the zero-speed splice machine from both home and abroad, the achievements and the problems still existing are known, to meet the requirements on speed and tension in zero-speed splicer machine, the key performance target of the control system is brought forward. With this, the next is to choose hardware and design the software for the control system accordingly. Mainly this paper researched the problem of how the unwind motor, the sensor and the break resistance should be chosen and how the tension during the flow is controlled. The control stratagem of PID control is used here. With the help of the math model set up by the software of MATLAB/SIMULINK, the system stability, robusticity and its dynamic and stable index is analyzed. Lastly, the control program is written on the platform of the S7-200 controller from Siemens according to the feature of the software and the requirements of the control system. It is proved that the designed control system can meet the requirements: stable tension in the manufacture process, smoothly transition in velocity and good security.
本文首先通过对国内外零速接纸机发展现状的调查,了解了其发展现阶段取得的成绩和依然存在的技术壁垒。针对现阶段零速接纸机在实际应用中对速度和张力的要求,提出了电控系统设计的主要性能指标。由此,针对性地进行硬件的选型和软件设计。主要研究了放卷电机、传感器、制动电阻等硬件选型时需要考虑的要素以及机器运行过程中对薄膜张力的控制的方法,并提出一个初步张力控制方案:闭环PID控制。然后用MATLAB/SIMULINK建立了系统的数学模型,利用该模型分析系统的稳定性和鲁棒性以及其阶跃响应的动态和稳态性能指标。最后,将基于西门子S7-200控制器的零速接纸机的控制程序按照软件特征和控制要求进行编写,并作最后调试。经论证,能够符合接纸过程中张力平稳、速度过渡平滑和安全系数达标的要求。
Zero-speed splice machine is a kind of universally used accessorial equipment which can match up with multiplicate soft packaging machine. To carry out“produce without pause”, the mainframe should not pause while the tension can meet the requirement set by users during all the process of manufacture, the zero-speed splice machine comes into being. Zero-speed splice machine can keep the splice unit stationary while the mainframe could run according to the set speed. How can it perform? It is depend on a unit of film tank which is not existed in the commonly used equipment of turret splicing unit. During the splice process, the film used by the mainframe is supplied by the film tank while the film in the splice unit is held still. In this way, not only both the rate of successfully splice and the veracity is enhanced, but also“produce without pause”is ensured. Both the quality and productivity is improved greatly. In addition, as the rate of successfully splice is raised and the tie-in is shorten, the rate of material utilization is raised. This paper research focuses on making the zero-speed splice machine an accessorial equipment for print machine, coating machine and bag-making machine etc, which is of high rate of successfully splice rate, widely used, easy to mount and operate and of good security.
Firstly, by investigating the status quo of the zero-speed splice machine from both home and abroad, the achievements and the problems still existing are known, to meet the requirements on speed and tension in zero-speed splicer machine, the key performance target of the control system is brought forward. With this, the next is to choose hardware and design the software for the control system accordingly. Mainly this paper researched the problem of how the unwind motor, the sensor and the break resistance should be chosen and how the tension during the flow is controlled. The control stratagem of PID control is used here. With the help of the math model set up by the software of MATLAB/SIMULINK, the system stability, robusticity and its dynamic and stable index is analyzed. Lastly, the control program is written on the platform of the S7-200 controller from Siemens according to the feature of the software and the requirements of the control system. It is proved that the designed control system can meet the requirements: stable tension in the manufacture process, smoothly transition in velocity and good security.
引文
【1】电机及其拖动基础第3版顾绳谷机械工业出版社P173(电机功率的选择)
【2】株式会社安川电机Varispeed G7使用说明书
【3】长春霍斯特光电有限公司增量型光电编码器使用说明书2004版
【4】反馈控制系统设计与分析——MATLAB语言应用薛定宇清华大学出版社
【5】自动控制原理胡寿松科学出版社
【6】包装印刷金银河化学工业出版社
【7】工业控制电子学——设备、系统与应用(第2版) Terry Bartelt清华大学出版社
【8】不停机接纸机构西安黑牛机械有限公司李玉龙印刷世界2003.11
【9】凹印机收放卷张力控制系统研究季铜钊浙江大学硕士学位论文
【10】卷绕张力控制系统的建模及张力控制器的设计禹恒洲鲁五一郭爱红计算机测量与控制2007.15(9)
【11】印刷机张力与速度解耦控制许建中鲁五一胡亚伟谢兵计算机测量与控制2008.16(4)
【12】测径及张力控制陈立秋染整技术第29卷第12期
【13】卷绕张力控制器的三种设计方法及性能分析李艳邵月祥邵世煌中国纺织大学学报第23卷第3期(1997)
【14】开卷机的恒张力控制崔红陈殿青辽宁科技学院学报第8卷1008-3723(2006)04-0024-02
【15】Adaptive fuzzy tension control system for winding process of the film materials Kuo-Ho Su Tzu-Hsung Chen Proceedings of Asia display 2007 volume 2.2127
【16】转动惯量实时补偿在复卷机纸幅张力控制中的应用孙标张金平中华纸业第28卷第10期2007.10
【17】无张力反馈的开卷机张力控制李训铭张乐宁河海大学常州分校学报第20卷第2期2006.6
【18】Electro-hydraulic compound control method and characteristic of control for tension system with high inertia loads Zhong tianyu Wang qingfeng Li yanmin Chinese journal of mechanical engineering vol.19 no.3,2006
【19】Development of PLC-based tension control system Ren sheng-le,Lu Hua,wang yongzhang, Fu hongya Chinese journal of Aeronautic 20(2007)266-277
【20】SIEMENS全集成自动化产品在高速涂布机上的应用戚志华轻工机械第28卷第1期2010.2
【21】The design of PLC-based furniture coating pipeline tension control system Xiaolian Pu, Jianjun Li, Shilong Xue
【22】Research of tension robust control based on mixed sensitivity He Jinbao, He Yongyi,Guo Shuai, Fang Minglun
【23】浅谈凹版印刷中对张力控制原理的理解和运用韩建国中国包装报2003.5.26
【24】用PC机实现卷径检测高建特钢技术1997年第3期
【25】张力控制在纸机传动中的应用陈景文孟彦京王红艳China pulp & paper vol.26,no.4 2007
【26】卷带包装材料连续供送恒张力控制系统的设计孙智慧岳亚东刘晔中国农业机械学会2006年学术年会论文集
【27】Tension control of a two-drum winder using paper trension estimation Rodrigo Carrasco and M. Aníbal Valenzuela, IEEE Transactions on industry applications, Vol. 42, No. 2, March/April 2006
【28】Model reference adaptive tension control of web packaging material Baosheng Wang, Jianmin Zuo, Mulan Wang, Hongyan Hao 2008 International Conference on Intelligent Computation Technology and Automation
【29】卷筒纸印刷机张力控制研究孙玉秋包装工程vol.29,no.3 2008.3
【30】凹版印刷中张力变化的因素及控制方法葛小森巩建敏printing field 2009.11
【31】卷筒纸凹印机技术讲座——张力控制系统第九讲印刷世界2010.2
【32】S7-200 PLC编程及应用廖常初p131
【2】株式会社安川电机Varispeed G7使用说明书
【3】长春霍斯特光电有限公司增量型光电编码器使用说明书2004版
【4】反馈控制系统设计与分析——MATLAB语言应用薛定宇清华大学出版社
【5】自动控制原理胡寿松科学出版社
【6】包装印刷金银河化学工业出版社
【7】工业控制电子学——设备、系统与应用(第2版) Terry Bartelt清华大学出版社
【8】不停机接纸机构西安黑牛机械有限公司李玉龙印刷世界2003.11
【9】凹印机收放卷张力控制系统研究季铜钊浙江大学硕士学位论文
【10】卷绕张力控制系统的建模及张力控制器的设计禹恒洲鲁五一郭爱红计算机测量与控制2007.15(9)
【11】印刷机张力与速度解耦控制许建中鲁五一胡亚伟谢兵计算机测量与控制2008.16(4)
【12】测径及张力控制陈立秋染整技术第29卷第12期
【13】卷绕张力控制器的三种设计方法及性能分析李艳邵月祥邵世煌中国纺织大学学报第23卷第3期(1997)
【14】开卷机的恒张力控制崔红陈殿青辽宁科技学院学报第8卷1008-3723(2006)04-0024-02
【15】Adaptive fuzzy tension control system for winding process of the film materials Kuo-Ho Su Tzu-Hsung Chen Proceedings of Asia display 2007 volume 2.2127
【16】转动惯量实时补偿在复卷机纸幅张力控制中的应用孙标张金平中华纸业第28卷第10期2007.10
【17】无张力反馈的开卷机张力控制李训铭张乐宁河海大学常州分校学报第20卷第2期2006.6
【18】Electro-hydraulic compound control method and characteristic of control for tension system with high inertia loads Zhong tianyu Wang qingfeng Li yanmin Chinese journal of mechanical engineering vol.19 no.3,2006
【19】Development of PLC-based tension control system Ren sheng-le,Lu Hua,wang yongzhang, Fu hongya Chinese journal of Aeronautic 20(2007)266-277
【20】SIEMENS全集成自动化产品在高速涂布机上的应用戚志华轻工机械第28卷第1期2010.2
【21】The design of PLC-based furniture coating pipeline tension control system Xiaolian Pu, Jianjun Li, Shilong Xue
【22】Research of tension robust control based on mixed sensitivity He Jinbao, He Yongyi,Guo Shuai, Fang Minglun
【23】浅谈凹版印刷中对张力控制原理的理解和运用韩建国中国包装报2003.5.26
【24】用PC机实现卷径检测高建特钢技术1997年第3期
【25】张力控制在纸机传动中的应用陈景文孟彦京王红艳China pulp & paper vol.26,no.4 2007
【26】卷带包装材料连续供送恒张力控制系统的设计孙智慧岳亚东刘晔中国农业机械学会2006年学术年会论文集
【27】Tension control of a two-drum winder using paper trension estimation Rodrigo Carrasco and M. Aníbal Valenzuela, IEEE Transactions on industry applications, Vol. 42, No. 2, March/April 2006
【28】Model reference adaptive tension control of web packaging material Baosheng Wang, Jianmin Zuo, Mulan Wang, Hongyan Hao 2008 International Conference on Intelligent Computation Technology and Automation
【29】卷筒纸印刷机张力控制研究孙玉秋包装工程vol.29,no.3 2008.3
【30】凹版印刷中张力变化的因素及控制方法葛小森巩建敏printing field 2009.11
【31】卷筒纸凹印机技术讲座——张力控制系统第九讲印刷世界2010.2
【32】S7-200 PLC编程及应用廖常初p131