铜材自动定尺飞锯机控制系统的研究
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摘要
目前连续挤压出来的铜线、铜扁线、铜管等铜材大多通过收线机卷曲成盘,若得到定长的铜材则需要工人按照要求的尺寸手工锯切.这种手工锯切的方法落后,生产效率低下,在科技和生产竞争日益激烈的今天早已不能满足生产的需求.作者针对TLJ630连续挤压生产线特点,结合冶金行业应用的飞锯/飞剪,设计了一套适合铜扁线,铜杆,异型截面铜材切割的飞锯控制系统.该飞锯控制系统采用先进的伺服控制,实现快速、高精度的在线切割。
本文对飞锯机锯车的运动过程进行了详细的分析,从而提出了以三菱PLC为控制核心,以三菱伺服控制器和伺服电机为驱动的先进可靠的伺服控制方案。给出了整个锯车运动控制的原理图、流程图和关键参数的计算,并对整个控制系统的硬件逐一进行分析和介绍。其中,对伺服电机的功率计算和校验进行了详细的说明。在PLC与上位机通讯过程中采用了VB和PLC的串行通信,介绍了串行通信协议、VB软件里面的控件使用、Aceess数据库和ODBC数据源的建立及采集数据的存储。借助于PLC和上位机的通信,论文对整个飞锯机控制系统进行了实验法建立数学模型。该方法简单实用,为SIMULINK仿真提供了可靠的数据。本文阐述了模糊PID控制的基本原理及设计方法,并通过SIMULINK仿真对该控制系统的性能进行了分析和预测,同时进行了锯切小车运行速度和位移的检测实验。
通过仿真结果和实验测试数据都充分说明了本文所设计的飞锯控制系统达到了预定的控制性能指标,使锯切小车的位置控制和速度控制都能达到生产要求。
At present,most of copper products extruded by continous extrusion machine,such as wire,copper flat wire,copper pipe and others are all curled by Take-up machine. People usually cut copper products into short length by hand. This measure is very slow and inefficicent.nowadasy, science and technology have great progress, hand sawing can not meet requirements.So, author apply to TLJ630 extusion production line design a flying saw control system,that adopt to advanced servo control technology .This kind of flying saw can saw any cross-section shape of copper fast and accurately.
This paper analysis flying saw’s vehicles movement in details, and then point out a new, advanced and reliable control method, which including the Mitsubishi PLC,servo controller and motor.PLC is the core part of control system, and the servo controller and motor are the drivers. The whole vehicle motion control schematics, flowcharts and some key parameters’calculation are discussed.Hardware of control system is also introduced in detail.Especailly, the calculation and check of servo motor power is very clearly. The communication between PC and PLC using VB software and MELsoft in serial communication. The serial communication protocol format, MSComm of VB, Access database,ODBC data sources and acquisition data storage are all introduced. By the communication between PLC and PC, the math model of the whole flying saw control system has been established by experiment. This way of establish math model is very easy and simple, that can supply some reliable data for simulink. Fuzzy PID controller’s basic principle and design method has been described, and then analysis and forecast the flying saw control system’s performance by the simulink. Moreover, vehicle’s velocity and displacement test experiments are completed.
The simulation results and experimental test data are all fully indicate that this flying saw control system’s performance has achieve the scheduled objective, so that make sawing vehicle position control and speed control achieve the production requirements.
本文对飞锯机锯车的运动过程进行了详细的分析,从而提出了以三菱PLC为控制核心,以三菱伺服控制器和伺服电机为驱动的先进可靠的伺服控制方案。给出了整个锯车运动控制的原理图、流程图和关键参数的计算,并对整个控制系统的硬件逐一进行分析和介绍。其中,对伺服电机的功率计算和校验进行了详细的说明。在PLC与上位机通讯过程中采用了VB和PLC的串行通信,介绍了串行通信协议、VB软件里面的控件使用、Aceess数据库和ODBC数据源的建立及采集数据的存储。借助于PLC和上位机的通信,论文对整个飞锯机控制系统进行了实验法建立数学模型。该方法简单实用,为SIMULINK仿真提供了可靠的数据。本文阐述了模糊PID控制的基本原理及设计方法,并通过SIMULINK仿真对该控制系统的性能进行了分析和预测,同时进行了锯切小车运行速度和位移的检测实验。
通过仿真结果和实验测试数据都充分说明了本文所设计的飞锯控制系统达到了预定的控制性能指标,使锯切小车的位置控制和速度控制都能达到生产要求。
At present,most of copper products extruded by continous extrusion machine,such as wire,copper flat wire,copper pipe and others are all curled by Take-up machine. People usually cut copper products into short length by hand. This measure is very slow and inefficicent.nowadasy, science and technology have great progress, hand sawing can not meet requirements.So, author apply to TLJ630 extusion production line design a flying saw control system,that adopt to advanced servo control technology .This kind of flying saw can saw any cross-section shape of copper fast and accurately.
This paper analysis flying saw’s vehicles movement in details, and then point out a new, advanced and reliable control method, which including the Mitsubishi PLC,servo controller and motor.PLC is the core part of control system, and the servo controller and motor are the drivers. The whole vehicle motion control schematics, flowcharts and some key parameters’calculation are discussed.Hardware of control system is also introduced in detail.Especailly, the calculation and check of servo motor power is very clearly. The communication between PC and PLC using VB software and MELsoft in serial communication. The serial communication protocol format, MSComm of VB, Access database,ODBC data sources and acquisition data storage are all introduced. By the communication between PLC and PC, the math model of the whole flying saw control system has been established by experiment. This way of establish math model is very easy and simple, that can supply some reliable data for simulink. Fuzzy PID controller’s basic principle and design method has been described, and then analysis and forecast the flying saw control system’s performance by the simulink. Moreover, vehicle’s velocity and displacement test experiments are completed.
The simulation results and experimental test data are all fully indicate that this flying saw control system’s performance has achieve the scheduled objective, so that make sawing vehicle position control and speed control achieve the production requirements.
引文
[1]李平,杨晓明,牛骁.飞锯机的控制方案解析.重型机械科技. 2006,(2):37-39
[2]童自惠,甘永兴,沈启飙.半闭环、全闭环兼容的位置控制数控飞锯系统.电气传动.2003,(5):34-37
[3]刘元文,宋宝韫.铜扁线连续挤压技术.锻压技术.2004,(4):49-50
[4]柴晓艳,张玉华.伺服飞锯机的控制系统和运动分析[J].制造业自动化,2004,26(3):48-50
[5]三菱通用交流伺服系统手册.三菱电子有限公司,2007
[6]BRADSHAWM.An introduction to software agents [A].In:Brashaw Med,software Agents[C],Menlo Park,CA:AAAI Press,1997.74~79
[7]INGHMP.Ulti agent System: a Theoretical Framework for Intention[M].Know2How,and Communication.Berlin:Springer2Ver2 lag,1994.146~168
[8]WOOLD RIDGE M J,JENNINGS N R. Intelligent Agents:Theory and practice[J].Knowledge Engineering Reviw,1995,10(2):115~152
[9]三菱通用AC伺服放大器使用手册.菱电自动化(上海)有限公司,2003
[10]钟肇新,范建东.可编程控制器原理及应用.广州:华南理工大学出版社,2003:242
[11]童自惠,甘永兴,沈启飙.S7-200CN在数控飞锯中的应用[J].制造业自动化. 2006,28(10):93-98
[12]崔增柱,刘元开,项占琴.基于PLC的钢管测长定尺飞锯控制系统的设计[J].机电工程. 2004,21(3):31-33
[13]韦德成,施春雷,崔岩.计算机与PLC串行通信的实现.黑龙江水专学报.2002,29(2) :111-112
[14]求是科技,仵浩,齐燕杰,宋文超.Visual Basic串口通信工程开发实例导航[M].北京:人民邮电出版社,2003.1
[15]时文飞,侯世英.PLC与计算机的串口通信程序设计[J].机床电器,2005.4
[16]明日科技,高春艳,李艳,谷伟东.Visual Basic数据库开发关键技术与实例应用.北京:人民邮电出版.2004.5
[17]杨平,翁思义,郭平.自动控制原理.北京:中国电力出版社.2009.2
[18]胡寿松.自动控制原理.北京:国防工业出版社.2002:64-69
[19]廖常初.FX系列PLC编程及应用.北京:机械工业出版社.2005:195-196
[20]孙增沂,张再兴,邓志东.智能控制理论与技术〔M」.北京:清华大学出版社,1997.52~54
[21]韦巍.智能控制技术阿].北京:机械工业出版社,2001.
[22]李士勇.模糊控制.神经控制和智能控制论〔M」.哈尔滨:哈尔滨工业大学出版社,1990.274~276.
[23]杜爱月.基于模糊控制的交通信号控制系统及仿真研究[DJ.西安:长安大学,2004.
[24]景占荣.基于遗传算法的模糊控制器设计及应用〔D].西安:西北工业大学,2006.
[25]刘曙光,王志宏,费佩燕.模糊控制的发展与展望[J].机电工程,2000,17(l):9~11.
[26]刘向杰,周孝信,柴天佑.模糊控制研究的现状与新发展[J].信息与控制,1999,4:283~292.
[27]程仁洪,涂奉生.基于模糊逻辑的混合型电机速度控制器[JJ.电机与控制学报,1998,9:145~148.
[28]ZadehLA.FuzzySet[Jl.InformatControl,1965,8:338一353.
[29]ZadehLA.FuzzyAlgoeithin[J].InformatControl,1968,12:94-102.
[30]伍义. 400型连续挤压机的PLC控制系统研究.大连交通大学.2007:55～60
[31]李媛.XSP800收排线机控制系统的研究.大连交通大学.2009: 59～63
[32]罗光明,黄晓宇,朱建林.基于MATLAB的模糊自整定PID参数控制器计算机仿真.机械与电子.2001,(2) :23-26
[33]章卫国,杨向忠.模糊控制理论与应用.西安:西北工业大学出版社,2004.7
[34]张国良等.模糊控制及其MATLAB应用.西安:西安交通大学出版社,2002.11
[35] Qin S J,Hu B G,Gosine R G.Fuzzy PID Controller Structures,IEEE 1997 Canadian Conference on Electrial and Computer Engineering,1997,(2):788-790
[2]童自惠,甘永兴,沈启飙.半闭环、全闭环兼容的位置控制数控飞锯系统.电气传动.2003,(5):34-37
[3]刘元文,宋宝韫.铜扁线连续挤压技术.锻压技术.2004,(4):49-50
[4]柴晓艳,张玉华.伺服飞锯机的控制系统和运动分析[J].制造业自动化,2004,26(3):48-50
[5]三菱通用交流伺服系统手册.三菱电子有限公司,2007
[6]BRADSHAWM.An introduction to software agents [A].In:Brashaw Med,software Agents[C],Menlo Park,CA:AAAI Press,1997.74~79
[7]INGHMP.Ulti agent System: a Theoretical Framework for Intention[M].Know2How,and Communication.Berlin:Springer2Ver2 lag,1994.146~168
[8]WOOLD RIDGE M J,JENNINGS N R. Intelligent Agents:Theory and practice[J].Knowledge Engineering Reviw,1995,10(2):115~152
[9]三菱通用AC伺服放大器使用手册.菱电自动化(上海)有限公司,2003
[10]钟肇新,范建东.可编程控制器原理及应用.广州:华南理工大学出版社,2003:242
[11]童自惠,甘永兴,沈启飙.S7-200CN在数控飞锯中的应用[J].制造业自动化. 2006,28(10):93-98
[12]崔增柱,刘元开,项占琴.基于PLC的钢管测长定尺飞锯控制系统的设计[J].机电工程. 2004,21(3):31-33
[13]韦德成,施春雷,崔岩.计算机与PLC串行通信的实现.黑龙江水专学报.2002,29(2) :111-112
[14]求是科技,仵浩,齐燕杰,宋文超.Visual Basic串口通信工程开发实例导航[M].北京:人民邮电出版社,2003.1
[15]时文飞,侯世英.PLC与计算机的串口通信程序设计[J].机床电器,2005.4
[16]明日科技,高春艳,李艳,谷伟东.Visual Basic数据库开发关键技术与实例应用.北京:人民邮电出版.2004.5
[17]杨平,翁思义,郭平.自动控制原理.北京:中国电力出版社.2009.2
[18]胡寿松.自动控制原理.北京:国防工业出版社.2002:64-69
[19]廖常初.FX系列PLC编程及应用.北京:机械工业出版社.2005:195-196
[20]孙增沂,张再兴,邓志东.智能控制理论与技术〔M」.北京:清华大学出版社,1997.52~54
[21]韦巍.智能控制技术阿].北京:机械工业出版社,2001.
[22]李士勇.模糊控制.神经控制和智能控制论〔M」.哈尔滨:哈尔滨工业大学出版社,1990.274~276.
[23]杜爱月.基于模糊控制的交通信号控制系统及仿真研究[DJ.西安:长安大学,2004.
[24]景占荣.基于遗传算法的模糊控制器设计及应用〔D].西安:西北工业大学,2006.
[25]刘曙光,王志宏,费佩燕.模糊控制的发展与展望[J].机电工程,2000,17(l):9~11.
[26]刘向杰,周孝信,柴天佑.模糊控制研究的现状与新发展[J].信息与控制,1999,4:283~292.
[27]程仁洪,涂奉生.基于模糊逻辑的混合型电机速度控制器[JJ.电机与控制学报,1998,9:145~148.
[28]ZadehLA.FuzzySet[Jl.InformatControl,1965,8:338一353.
[29]ZadehLA.FuzzyAlgoeithin[J].InformatControl,1968,12:94-102.
[30]伍义. 400型连续挤压机的PLC控制系统研究.大连交通大学.2007:55～60
[31]李媛.XSP800收排线机控制系统的研究.大连交通大学.2009: 59～63
[32]罗光明,黄晓宇,朱建林.基于MATLAB的模糊自整定PID参数控制器计算机仿真.机械与电子.2001,(2) :23-26
[33]章卫国,杨向忠.模糊控制理论与应用.西安:西北工业大学出版社,2004.7
[34]张国良等.模糊控制及其MATLAB应用.西安:西安交通大学出版社,2002.11
[35] Qin S J,Hu B G,Gosine R G.Fuzzy PID Controller Structures,IEEE 1997 Canadian Conference on Electrial and Computer Engineering,1997,(2):788-790