焊丝层绕机恒张力系统的研究
|
摘要
随着国内基本建设的快速发展,各种焊丝、绕组的需求量越来越大,这些制品的加工技术急需改进和提高。如焊丝的缠绕,需要精度高、自动化程度高的生产设备。加快基于恒张力控制的高精度缠绕技术的研究迫在眉睫。
焊丝经校直应达到标准规定的挺度和翘距。缠卷焊丝具有连续性的翘距和挺度能确保连续的电接触、平滑的电弧特征和更连贯的焊透,以确保在自动焊接设备上的无间断送丝。而基于角度排线及缠绕张力恒定是基础。研究的主要内容有:
基于网络的运动控制,运用现场总线技术将各检测机构和执行机构与控制中心建立通信联系;在深入分析焊丝层绕机的结构、特点以及在收线过程中影响焊丝张力因素的基础上,建立了张力控制系统数学模型,提出了浮动辊位置反馈以及矢量式变频传动控制方案,并设计了PID控制器,针对放线机卷径变化影响控制效果,提出了多模型的控制方案,设计了基于模糊切换规则的多模型控制器,通过MATLAB仿真实验证明能较好地满足预期控制要求。较好地解决了焊丝恒张力缠绕和焊丝主动导开的技术难题,提高了焊丝的层绕精度和设备的运行效率;提出了排线机构角度控制避免缠绕不紧密和叠绕现象的出现;对系统中各测控单元硬件以及软件进行设计。实际运行结果表明:系统综合性能指标符合工艺要求。
Along with the fast development of the local capital construction, the demand of various welding wire and winding is daily on the increase. But the improvement and exaltation of the processing technology of these products are needed urgently. For example, high accuracy equipments for winding welding wire are needed. Speeding the research on winding technology based on the high accuracy constant-tension control is staring us in the face.
The welding wire should attain the standard provision deflection and pitch by straightening. The continuous deflection and pitch of the welding wire can assure continuous electrical contact, smooth arc characteristic and coherently penetrative welding, and serve wire on the automation welding equipment continuously. The arranging wire based on angle and the constant intertwist tension are foundation.
The main contents of this research are about the movement control based on the network, to communicate every measurement equipment and actuator with control center by the fieldbus. On the basis of the thorough analysis of the structure, characteristic and the factors that effects the tensile force of the flux cored wire in the process of coiling, the models of tension control system are established in the view of engineering. Floating-roller's position feedback control scheme and vector type frequency inverter control scheme are proposed, and a type of PID regulator is designed according to the requirements of the tension control system. The variation of the winding-diameter of the wheel of pay-off influences control effect, a PID control strategy based on multi-model control is presented, and a multiple model controller using fuzzy switching regulation is designed. The simulation in MATLAB shows that the expected control performances are achieved. The technique problem of constant tension and initiative unwinding is worked out. The winding precision and the work efficiency of the equipment are promoted. Aiming at the machine structure characteristics, the arranging wire mechanism based on angle control is put forward to avoid emergence of unwinding and overlapping in this paper. Measurement and control units are designed from both aspects of software and hardware. The actual results show that performance targets meet technological requirements.
焊丝经校直应达到标准规定的挺度和翘距。缠卷焊丝具有连续性的翘距和挺度能确保连续的电接触、平滑的电弧特征和更连贯的焊透,以确保在自动焊接设备上的无间断送丝。而基于角度排线及缠绕张力恒定是基础。研究的主要内容有:
基于网络的运动控制,运用现场总线技术将各检测机构和执行机构与控制中心建立通信联系;在深入分析焊丝层绕机的结构、特点以及在收线过程中影响焊丝张力因素的基础上,建立了张力控制系统数学模型,提出了浮动辊位置反馈以及矢量式变频传动控制方案,并设计了PID控制器,针对放线机卷径变化影响控制效果,提出了多模型的控制方案,设计了基于模糊切换规则的多模型控制器,通过MATLAB仿真实验证明能较好地满足预期控制要求。较好地解决了焊丝恒张力缠绕和焊丝主动导开的技术难题,提高了焊丝的层绕精度和设备的运行效率;提出了排线机构角度控制避免缠绕不紧密和叠绕现象的出现;对系统中各测控单元硬件以及软件进行设计。实际运行结果表明:系统综合性能指标符合工艺要求。
Along with the fast development of the local capital construction, the demand of various welding wire and winding is daily on the increase. But the improvement and exaltation of the processing technology of these products are needed urgently. For example, high accuracy equipments for winding welding wire are needed. Speeding the research on winding technology based on the high accuracy constant-tension control is staring us in the face.
The welding wire should attain the standard provision deflection and pitch by straightening. The continuous deflection and pitch of the welding wire can assure continuous electrical contact, smooth arc characteristic and coherently penetrative welding, and serve wire on the automation welding equipment continuously. The arranging wire based on angle and the constant intertwist tension are foundation.
The main contents of this research are about the movement control based on the network, to communicate every measurement equipment and actuator with control center by the fieldbus. On the basis of the thorough analysis of the structure, characteristic and the factors that effects the tensile force of the flux cored wire in the process of coiling, the models of tension control system are established in the view of engineering. Floating-roller's position feedback control scheme and vector type frequency inverter control scheme are proposed, and a type of PID regulator is designed according to the requirements of the tension control system. The variation of the winding-diameter of the wheel of pay-off influences control effect, a PID control strategy based on multi-model control is presented, and a multiple model controller using fuzzy switching regulation is designed. The simulation in MATLAB shows that the expected control performances are achieved. The technique problem of constant tension and initiative unwinding is worked out. The winding precision and the work efficiency of the equipment are promoted. Aiming at the machine structure characteristics, the arranging wire mechanism based on angle control is put forward to avoid emergence of unwinding and overlapping in this paper. Measurement and control units are designed from both aspects of software and hardware. The actual results show that performance targets meet technological requirements.
引文
[1]郭帅.机电张力系统关键控制技术的研究及实践.上海大学博士学位论文,2006,15-17
[2]殷树言.焊接技术及应用.哈尔滨:哈尔滨工业大学出版社,1992.
[3]佳本.我国药芯焊丝的发展过程.上海机电进出口贸易,2004,2
[4]孙少凡.采用单片机控制CO2焊丝层绕机.信息技术,2003,27(5):44-48
[5]马国玺.PLC控制的埋弧焊丝层绕机排线器.金属制品,2004,30(6):26-28
[6]杨卫书,闻兴立.多功能埋弧焊丝层绕机的研制.金属制品,2004,30(5):33-34
[7]王军,关长勇,马昌.交流伺服电机在层绕机上的应用.金属制品,2004,30(5):31-32
[8]孙少华,穆伟然,胡春祚,贾惠义.自动焊丝层绕机控制系统.信息技术,2000,4:16-18
[9]席永平,OPGW设备笼绞机放线恒张力控制系统设计.同济大学硕士学位论文,2004,2-3
[10]汤旭晶,戴忠,俞忠明,江志凌.拉线放卷恒张力控制系统的研究.电气传动自动化,2006,28(1):34-35
[11]冯连强.一种全数字间接恒张力控制系统的设计及应用.重型机械,2006,2:24-27
[12]郭兆仁.基于网络的运动控制研究及在精绕机中的应用.北京化工大学硕士学位论文,2007,30-32
[13]于克龙.绕线机排线机构的运动分析与控制.机械制造与自动化,2005,34(3):102-103
[14]陶卫,浦昭邦,孙运斌.角度测量技术的发展.激光杂志,2002,23(2):5-7
[15]于晓东,胡大欣.旋转编码器在回转体回转角度测量中的应用.林业机械与木工设备,2005,(2):43-44
[16]李五田,韩大鹏,张丽华.层绕机排线及恒张力控制的设计[J].金属制品,2007,33(2):45-47
[17]D.Knittel,E.Laroche,H.Koc.Tension control for wingding systems with two degrees of freedom controller.Industry Applications Conference,2001,1:576-582
[18]Fang Lin Luo,Changyun.WenMultiple-Page mapping artificial neural network algorithm used for constant tension control,Expert Systems With Applications.1997,13(4):307-315
[19]罗雨,纪文刚.基于MODBUS-RTU的层绕机停车控制技术的研究.北京石油化工学院学报,2007,15(2):29-33
[20]蒋军.转速闭环变频调速系统的简易设计方法.兵工自动化,2007,1(26):66-67
[21]jean Pierre Thomesse.The Field Bus IFAC Intelligent Components and Instruments For Control Application[M].Amnecy,France,1997:32-35
[22]D.Lorenz,S.M.Yang.AC induction servo sizing for motion control Applications via loss minimizing real-time flux control,in Conf.Rec.IEEE-IAS Annu.Meeting,1989:612-616.
[23]张晖.收线机张力自动控制系统.金属制品,1995,21:12-17
[24]彭庆京.新型的放线恒张力控制系统.科园,2004,6:37
[25]邵联合.PID控制算法的仿真和研究[J].承德石油高等专科学校学报.2001,2(3):20-24.
[26]杨巨庆,黄健,段丽华.PID控制技术与应用[J].哈尔滨师范大学自然科学学报,2004,2(20):76-79
[27]代军,苏娅芳,张雪.PID算法及其演变[J].辽宁省交通高等专科学校学报,2003,3(5):43-45
[28]P.Cominos,N.Munro.PID controllers:recent tuning methods and design to specification[J].IEEE Control Theory Appllication.2002,1(49):46-53
[29]Kiam Heong Ang,Gregory Chong,YunLi.PID control system analysis,Design,and Technology[J].IEEE Transactions on contorl sysetms Tcehnology.2005,4(13):55-57
[30]JoseL.Tong,Jmaes.PBobis.A model for designing PID controllers.1992,IEEE:1157-1162
[31]陶永华,尹恰欣,葛芦生.新型PID控制及其应用.北京,机械工业出版社,1998,9:220-222
[32]陈沫然.Simulink4建模及动态仿真.北京,电子工业出版社,2002
[33]Wen-June Wang and Hwan-Rong Lin.Fuzzy control design for the trajectory tracking in phase plane,IEEE Trans.on Systems,Man,and Cybemetics,1998,28(5):710-719
[34]席裕庚,王凡.非线性系统预测控制的多模型方法.自动化学报,1996,2(4):456-460
[35]Johansen,T.A,Foss.B.A Multiple model approaches to modeling and control.J.Control.1999,72(7/8):575
[36]李晓理.多模型自适应控制方法的研究.东北大学博士论文,沈阳,1999
[37]A.Badr,Z.Binder D.Rey.Weighted multi-model control Int J.Syst.Sci.1992,23(1):145-149
[38]W.G.He,K.Howard,R.Rob.Multiple model adaptive control procedure for blood pressure control.IRRR Trans Biomed Rng,1986,1(33):10-19
[39]G.Aly,A.Badr,Z.Binder.Multiple model control of MIMO systems:location and control algorithms.Int.J Systems Sci,1988,1(19):1687-1698
[40]牟世忠.基于多模型的控制策略的研究.天津大学硕士学位论文,1997
[41]A.Badr,Z.Binder,D.Rey.Weighted multi-model control.Int.J Systems Sci,1992,23(1):145-149
[42]胡国亮.用MATLAB进行的模糊控制器的设计与仿真.基础自动化,2000,2:15-20
[43]彭月祥,王凤全.接近开关及其应用[J].电气开关,1998,5:36-38.
[44]上山直彦.现代交流调速(吴铁坚译).北京:水利电力出版社,1989,22-34
[45]韩安荣.通用变频器及其应用.北京:机械工业出版社,2003,133-136
[46]陶卫,浦昭邦,孙运斌.角度测量技术的发展.激光杂志,2002,23(2):5-7
[47]杨柳.精密绕线机的伺服系统控制.现代电子技术,2001,8
[48]张桂香.旋转电加工数控系统及伺服控制的研究.中国农业大学硕士学位论文,2001,2
[49]邱公伟.可编程控制器网络通信及应用.北京:清华大学出版社,2000,50
[50]虞日跃,史洪源.RS-485总线的理论与实践.电子技术应用,2001,11:55-57
[2]殷树言.焊接技术及应用.哈尔滨:哈尔滨工业大学出版社,1992.
[3]佳本.我国药芯焊丝的发展过程.上海机电进出口贸易,2004,2
[4]孙少凡.采用单片机控制CO2焊丝层绕机.信息技术,2003,27(5):44-48
[5]马国玺.PLC控制的埋弧焊丝层绕机排线器.金属制品,2004,30(6):26-28
[6]杨卫书,闻兴立.多功能埋弧焊丝层绕机的研制.金属制品,2004,30(5):33-34
[7]王军,关长勇,马昌.交流伺服电机在层绕机上的应用.金属制品,2004,30(5):31-32
[8]孙少华,穆伟然,胡春祚,贾惠义.自动焊丝层绕机控制系统.信息技术,2000,4:16-18
[9]席永平,OPGW设备笼绞机放线恒张力控制系统设计.同济大学硕士学位论文,2004,2-3
[10]汤旭晶,戴忠,俞忠明,江志凌.拉线放卷恒张力控制系统的研究.电气传动自动化,2006,28(1):34-35
[11]冯连强.一种全数字间接恒张力控制系统的设计及应用.重型机械,2006,2:24-27
[12]郭兆仁.基于网络的运动控制研究及在精绕机中的应用.北京化工大学硕士学位论文,2007,30-32
[13]于克龙.绕线机排线机构的运动分析与控制.机械制造与自动化,2005,34(3):102-103
[14]陶卫,浦昭邦,孙运斌.角度测量技术的发展.激光杂志,2002,23(2):5-7
[15]于晓东,胡大欣.旋转编码器在回转体回转角度测量中的应用.林业机械与木工设备,2005,(2):43-44
[16]李五田,韩大鹏,张丽华.层绕机排线及恒张力控制的设计[J].金属制品,2007,33(2):45-47
[17]D.Knittel,E.Laroche,H.Koc.Tension control for wingding systems with two degrees of freedom controller.Industry Applications Conference,2001,1:576-582
[18]Fang Lin Luo,Changyun.WenMultiple-Page mapping artificial neural network algorithm used for constant tension control,Expert Systems With Applications.1997,13(4):307-315
[19]罗雨,纪文刚.基于MODBUS-RTU的层绕机停车控制技术的研究.北京石油化工学院学报,2007,15(2):29-33
[20]蒋军.转速闭环变频调速系统的简易设计方法.兵工自动化,2007,1(26):66-67
[21]jean Pierre Thomesse.The Field Bus IFAC Intelligent Components and Instruments For Control Application[M].Amnecy,France,1997:32-35
[22]D.Lorenz,S.M.Yang.AC induction servo sizing for motion control Applications via loss minimizing real-time flux control,in Conf.Rec.IEEE-IAS Annu.Meeting,1989:612-616.
[23]张晖.收线机张力自动控制系统.金属制品,1995,21:12-17
[24]彭庆京.新型的放线恒张力控制系统.科园,2004,6:37
[25]邵联合.PID控制算法的仿真和研究[J].承德石油高等专科学校学报.2001,2(3):20-24.
[26]杨巨庆,黄健,段丽华.PID控制技术与应用[J].哈尔滨师范大学自然科学学报,2004,2(20):76-79
[27]代军,苏娅芳,张雪.PID算法及其演变[J].辽宁省交通高等专科学校学报,2003,3(5):43-45
[28]P.Cominos,N.Munro.PID controllers:recent tuning methods and design to specification[J].IEEE Control Theory Appllication.2002,1(49):46-53
[29]Kiam Heong Ang,Gregory Chong,YunLi.PID control system analysis,Design,and Technology[J].IEEE Transactions on contorl sysetms Tcehnology.2005,4(13):55-57
[30]JoseL.Tong,Jmaes.PBobis.A model for designing PID controllers.1992,IEEE:1157-1162
[31]陶永华,尹恰欣,葛芦生.新型PID控制及其应用.北京,机械工业出版社,1998,9:220-222
[32]陈沫然.Simulink4建模及动态仿真.北京,电子工业出版社,2002
[33]Wen-June Wang and Hwan-Rong Lin.Fuzzy control design for the trajectory tracking in phase plane,IEEE Trans.on Systems,Man,and Cybemetics,1998,28(5):710-719
[34]席裕庚,王凡.非线性系统预测控制的多模型方法.自动化学报,1996,2(4):456-460
[35]Johansen,T.A,Foss.B.A Multiple model approaches to modeling and control.J.Control.1999,72(7/8):575
[36]李晓理.多模型自适应控制方法的研究.东北大学博士论文,沈阳,1999
[37]A.Badr,Z.Binder D.Rey.Weighted multi-model control Int J.Syst.Sci.1992,23(1):145-149
[38]W.G.He,K.Howard,R.Rob.Multiple model adaptive control procedure for blood pressure control.IRRR Trans Biomed Rng,1986,1(33):10-19
[39]G.Aly,A.Badr,Z.Binder.Multiple model control of MIMO systems:location and control algorithms.Int.J Systems Sci,1988,1(19):1687-1698
[40]牟世忠.基于多模型的控制策略的研究.天津大学硕士学位论文,1997
[41]A.Badr,Z.Binder,D.Rey.Weighted multi-model control.Int.J Systems Sci,1992,23(1):145-149
[42]胡国亮.用MATLAB进行的模糊控制器的设计与仿真.基础自动化,2000,2:15-20
[43]彭月祥,王凤全.接近开关及其应用[J].电气开关,1998,5:36-38.
[44]上山直彦.现代交流调速(吴铁坚译).北京:水利电力出版社,1989,22-34
[45]韩安荣.通用变频器及其应用.北京:机械工业出版社,2003,133-136
[46]陶卫,浦昭邦,孙运斌.角度测量技术的发展.激光杂志,2002,23(2):5-7
[47]杨柳.精密绕线机的伺服系统控制.现代电子技术,2001,8
[48]张桂香.旋转电加工数控系统及伺服控制的研究.中国农业大学硕士学位论文,2001,2
[49]邱公伟.可编程控制器网络通信及应用.北京:清华大学出版社,2000,50
[50]虞日跃,史洪源.RS-485总线的理论与实践.电子技术应用,2001,11:55-57