全自动码坯机位置控制系统的设计及应用
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摘要
随着社会和科技的进步,各高新技术企业也在逐步改善员工工作环境、提高企业的科技含量。人们对自己周围的工作环境或者所从事的工作也有着更高的要求,正在逐步的由较繁重的体力劳动向较轻的体力劳动或者脑力劳动转变,企业的人力成本也由此在逐步上升。这对传统的制砖企业采用手工码坯用人多并且劳动强度大、生产效率低、砖坯码放质量不一致是一个严峻的挑战。现在制砖企业正逐步使用自动化设备去取代劳动力工作。过去的制砖企业通过采用手工将已生产成型的砖坯搬运和码放到窑车上,因砖坯生产线单位时间内砖产量高并且刚生产出来的砖坯湿且重,需要搬运和码放好,使得工人的劳动强度大、砖坯码放质量不一致、企业的人力成本高。为了解决人力成本的提高和劳动力的短缺为制砖企业带来的一系列问题,我们设计了一种位置控制器,让它去控制码坯机和分坯机,从而构成一种自动码砖的设备,全自动码坯机。
全自动码坯机位置控制系统的设计都是基于码坯机和分坯机这两个控制部件来进行设计的。其中关键的控制部件是三台控制行走的电机和码砖定位用的传感器。在熟悉控制关键的控制部件和码砖工序之后,对控制系统进行了详细的设计。详细设计分为硬件设计和软件设计。控制系统硬件部分由ARM+FPGA构成的主控模块以及模拟量和数字量模块的构成,其中ARM用于对整个系统进行控制,FGPA用于发出DDS正交频率去控制伺服电机,模拟量模块用于输出0-10V的模拟量给变频电机和电气比例阀,数字量模块输入部分采集传感器和按键等输入开关量的信号,数字量模块输出部分输出信号给电磁阀等输出开关量。软件部分主要由自动和手动控制程序,DDS正交频率程序,ARM与FPGA间双向高速数据通信程序构成。此外,还配有10寸触摸屏用于对整个系统进行操作,式样新颖,界面友好,在码坯运行遇到问题可以及时停止码坯运行,在线更改参数,方便可靠。通过硬件、软件再结合触摸屏控制实现了全自动码坯机位置控制系统的设计。全自动码坯机位置控制系统运行稳定,说明了整个设计的合理性,减少了制砖企业采用手工码坯的成本,提高了企业的劳动生产率,解决了人力成本的提高和劳动力的短缺给企业带来的问题。
Along with the society and the progress of science and technology, the high-tech enterprises are also gradually improve staff working environment, improve the content of science and technology[1]. People also have higher requirements to their surrounding work environment or work, which gradually shift by the more onerous physical labor to lighter physical or mental work, the manpower cost of the enterprise also is rising stage by stage. This is a grim challenge to the traditional brick enterprises, they adopt manual code billet with many people and great labor intensity, low production efficiency, brick stacking quality inconsistency.Modern brick making enterprises gradually use automation equipment to replace the labor work. The traditional brick making enterprises will have to carry and stack the molded brick from the blank cutting machine to the kiln car by using manpower. Because the brick production line can produce more brick per unit time.The brick is humidity and heavy,it need carry and stack which cause the high labor load the difference of the brick stacking quality and high labor cost[2].In order to solve the rise of the manpower cost and the labor shortage which brings a series of problems to the brick-making enterprises, we design a position controller, let it control the setting machine and the brick seperating machine, thereby forming an automatic stacking brick equipment, automatic setting machine[3].
The design of the automatic setting machine control system is based on the setting machine and the brick seperating machine.The mainly actuating mechanism t is the three motor and the sensors which determin position of the the brick stacking. In the familiar with the mainly actuating mechanism and the process of the brick stacking,we carefully design the control system.The detailed design divided into the hardware and software.The control system hardware part is composed by ARM+FPGA and analog and digital module. ARM is used for the control of the entire system, the FGPA produce a DDS orthogonal frequency to control the servo motor, the analog module is used for outputting0-1OV analog for variable frequency motor and the proportion-air valve, and the digital module is used for connect some sensors and key switchs. The software part is composed by automatic and manual control program and each state switching procedure. In addition, we also equipped with10Inch Touch screen for the entire system operation, the style is novel, the interface is friendly, when the brick stacking control encounter problems,we can stop setting operation in time,online change parameters,convenient and reliable. Through hardware, software combined with touch screen control to design the automatic setting machine control system.The position control system runs stably, indicates the rationality of the design, reduce the use of manpower brick stacking production cost,improves the production efficiency of the enterprise,solve the labor cost rise and the labor shortage which brings problems to the enterprise[1].
全自动码坯机位置控制系统的设计都是基于码坯机和分坯机这两个控制部件来进行设计的。其中关键的控制部件是三台控制行走的电机和码砖定位用的传感器。在熟悉控制关键的控制部件和码砖工序之后,对控制系统进行了详细的设计。详细设计分为硬件设计和软件设计。控制系统硬件部分由ARM+FPGA构成的主控模块以及模拟量和数字量模块的构成,其中ARM用于对整个系统进行控制,FGPA用于发出DDS正交频率去控制伺服电机,模拟量模块用于输出0-10V的模拟量给变频电机和电气比例阀,数字量模块输入部分采集传感器和按键等输入开关量的信号,数字量模块输出部分输出信号给电磁阀等输出开关量。软件部分主要由自动和手动控制程序,DDS正交频率程序,ARM与FPGA间双向高速数据通信程序构成。此外,还配有10寸触摸屏用于对整个系统进行操作,式样新颖,界面友好,在码坯运行遇到问题可以及时停止码坯运行,在线更改参数,方便可靠。通过硬件、软件再结合触摸屏控制实现了全自动码坯机位置控制系统的设计。全自动码坯机位置控制系统运行稳定,说明了整个设计的合理性,减少了制砖企业采用手工码坯的成本,提高了企业的劳动生产率,解决了人力成本的提高和劳动力的短缺给企业带来的问题。
Along with the society and the progress of science and technology, the high-tech enterprises are also gradually improve staff working environment, improve the content of science and technology[1]. People also have higher requirements to their surrounding work environment or work, which gradually shift by the more onerous physical labor to lighter physical or mental work, the manpower cost of the enterprise also is rising stage by stage. This is a grim challenge to the traditional brick enterprises, they adopt manual code billet with many people and great labor intensity, low production efficiency, brick stacking quality inconsistency.Modern brick making enterprises gradually use automation equipment to replace the labor work. The traditional brick making enterprises will have to carry and stack the molded brick from the blank cutting machine to the kiln car by using manpower. Because the brick production line can produce more brick per unit time.The brick is humidity and heavy,it need carry and stack which cause the high labor load the difference of the brick stacking quality and high labor cost[2].In order to solve the rise of the manpower cost and the labor shortage which brings a series of problems to the brick-making enterprises, we design a position controller, let it control the setting machine and the brick seperating machine, thereby forming an automatic stacking brick equipment, automatic setting machine[3].
The design of the automatic setting machine control system is based on the setting machine and the brick seperating machine.The mainly actuating mechanism t is the three motor and the sensors which determin position of the the brick stacking. In the familiar with the mainly actuating mechanism and the process of the brick stacking,we carefully design the control system.The detailed design divided into the hardware and software.The control system hardware part is composed by ARM+FPGA and analog and digital module. ARM is used for the control of the entire system, the FGPA produce a DDS orthogonal frequency to control the servo motor, the analog module is used for outputting0-1OV analog for variable frequency motor and the proportion-air valve, and the digital module is used for connect some sensors and key switchs. The software part is composed by automatic and manual control program and each state switching procedure. In addition, we also equipped with10Inch Touch screen for the entire system operation, the style is novel, the interface is friendly, when the brick stacking control encounter problems,we can stop setting operation in time,online change parameters,convenient and reliable. Through hardware, software combined with touch screen control to design the automatic setting machine control system.The position control system runs stably, indicates the rationality of the design, reduce the use of manpower brick stacking production cost,improves the production efficiency of the enterprise,solve the labor cost rise and the labor shortage which brings problems to the enterprise[1].
引文
[1]王海臣.自动码坯机在烧结砖厂的应用[J].砖瓦,2008,10：19-20.
[2]姚远,徐国平,江佩等.全自动码坯机控制系统设计[J].电子测量技术,2012,35(1)：28-30.
[3]贾相福.谈谈码坯方式的选抒[J].瓦砖,2010(3)：16-17.
[4]何长海.自动码坯机、智能机械手、自动卸砖机在砖瓦生产线上的应用[J].砖瓦世界,2010,10：16-18.
[5]靳聪,高宪庭,刘晓哲.自动码坯机在铁煤集团年产1.6亿块煤矸石烧结砖厂的应用[J]瓦砖世界,2011(1)：17-19.
[6]王陈滨,姚友康.液压码坯机的液压系统设计[J]瓦砖,2008(2)：24-25.
[7]姚友康.码坯机液压系统污染的防控[J].瓦砖,2009(7)：27-28.
[8]时洪文.动码坯机与机器人的选择[J].瓦砖,2012(1)：33-34.
[9]包燕燕,李华栋,樊冬梅.伺服系统和PLC控制在自动码坯机中的应用[J].砖瓦,2007,5：15-16.
[1O]Fadel M. Position control laws for electromechanical actuator[C].Proc of the eighth International Conference on Electrical Machines and Systems. Nanjing: IEEE Press, 2005,:1708-1713.
[11]闫飞,石春,吴刚,王俊.基于PLC和触摸屏的电动缸自动测试系统设计[J].伺服控制,2010,8：107-110.
[12]杨跃,田联房,王孝洪.基于ARM与Linux的排爆机器人控制系统设计[J].电子测量技术,2010,33(3)：79-82.
[13]吴明亮,汪小兵,余淑荣等.基于PLC的伺服驱动填充系统的设计[J].机床与液压,2011,39(12)：89-91.
[14]Chen.Chin-Sheng,Wang.Shih-Ming.Adaptive Digital Control Based on Reduced-order Parameter Identification and Disturbance Observer for Linear Motor.Proc. ASME Int. Manuf. Sci. Eng. Conf. MSEC. Jan.2007,:751-758.
[15]敖荣庆,袁坤.数字伺服控制系统与设计[M].北京：航空工业出版社,2006.
[16]熊权洪.基于CAN总线的独立运动控制器的设计与研究[D].武汉理工大学,2007.
[17]林涛.基于以太网方式的两轴运动控制系统的设计[D].武汉理工大学,2009.
[18]B.Paseal.Pressure Control of Pneumatie System with a Nonnegligible Connection Port Restriction.Control and Intelligent Systems,2005,33(2)111-118.
[19]郭一方.火焰切割机嵌入式数控系统[D].武汉理工大学硕士论文,2010.
[20]HACHIYA K,OHMAE T. Digital speed control system for a mo-tor using two speed detection methods of an incremental encoder[C].2007 European Power Electronics and Application,Sep-tember5-7,2007.2007,9:1-10.
[21]吴国荣,肖曦.基于自校正的伺服系统速度控制器[J].电气传动,2009,(10).
[22]J.C.Reli, C.M.Liao.A Study on the Speed Control Perormance of a servo-Pneurnatic Motor and the Application to Pneumatic Tools,2004,23(7-8):572-576.
[23]Hsu,Pau-Lo,Yeh,Syh-Shiuh. Precision control and compensation of servomotors and machine tools via the disturbance observer[J].Mechatomic/IEEE Transactions on Industrial Electronics,2010,57 (1):420-429.
[24]陶瑞超.位置/速率伺服系统的自适应鲁棒控制方法研究[D].哈尔滨工业大学,2011.
[25]吴国荣,肖曦.基于自校正的伺服系统速度控制器[J].电气传动,2009,(10).
[26]Younkin G W. Compensating Structural Dynamics for Ser-vo Driven Industrial Machines with Acceleration Feedback[C].Industry Applications Conference,Thirty-ninth IAS Annual Meeting,Conference Record of the 2004. IEEE,2004,:1881-1890.
[27]Mutasim Nour. Self-Tuning of PI Speed Controller Gains Using Fuzzy Logic Controller[J].Modern Applied Science,2008,2 (6):55-65.
[28]王建.低焓地热工程技术及其应用[D].中国地质大学(北京),2006.
[29]郑泽东,李永东,肖曦.基于状态观测和反馈的伺服系统位置控制器[J].清华大学学报.
[30]S.Maiti,C.Chakraborty,S Sengupta.Simulation Studies on Model Reference Adaptive Controller Based Speed Estimation Technique for the Vector Controlled Permanent Magnet Synchronous Motor Drive.Simulation Modelling Practice andTheory.2008:1～12.
[31]王雪,李强,叶敬春.双电伺服主传动轴电机控制软件的开发研究[J].锻压装备与制造技术2012,(01).
[32]Cetin Gencer,Aysun Coskun.A robust speed control of Pennanent Magnet Synchronous motors using adaptive neural fuzzy inference system controllers [C].Asian J. Inform. Technol,2005,4(10):918-919.
[33]李玉民.机械手柔性抓取切换控制系统设计与仿真分析[J].国外电子测量技术.2010,29(10)：30-33.
[34]Lu Lu,Zheng Chen, BinYao, Qingfeng Wang.Desired Compensation Adaptive Robust Control of a linear-Motor-Driven Precision Industrial Gantry With ImProved Cogging Force ComPensation[J]. Mechatronics,IEEE/ASMETranson,2008:617-624.
[35]孙诚,张艳红.基于EPP模式的数据传输方法研究[J].电子测量技术,2011,34(6)：95-96-109.
[36]温洁.数控火焰切割机虚拟测试系统的研究与设计[D].武汉理工大学硕士论文,2010.
[37]潘松,黄继业.EDA技术与VHDL(第2版)[M].2007.
[38]K.Sridharan,T.K.Priay.The design of a hardware accelerator for real-time complete visibility graph construction and efficient FPGA implementation[J].IEEE Trans.Ind. Electron, 2005(52):1185-1187.
[39]汤忠庆.一种正弦波信号发生器的设计[J].电子工程师,2006,32(9)：29-31.
[40]A Harmonic Signal Generator Based on DDS and SOPC[A]. Proceedings of 2010 Chinese Control and Decision Conference[C],2010.
[41]孙超,林占江.基于DDS的雷达任意波形信号源的研究[J].电子测量与仪器学报.2008,22(2)：31-36.
[42]N.P.Ligocki,A.Retterg.Towards a modular communication system for FPGAs[J].in Proc. Electron. Des.,2004:71-76.
[43]杨守良.利用Matlab/DSP Builder实现DDS的设计[J].微计算机信息,2006-07-20.
[2]姚远,徐国平,江佩等.全自动码坯机控制系统设计[J].电子测量技术,2012,35(1)：28-30.
[3]贾相福.谈谈码坯方式的选抒[J].瓦砖,2010(3)：16-17.
[4]何长海.自动码坯机、智能机械手、自动卸砖机在砖瓦生产线上的应用[J].砖瓦世界,2010,10：16-18.
[5]靳聪,高宪庭,刘晓哲.自动码坯机在铁煤集团年产1.6亿块煤矸石烧结砖厂的应用[J]瓦砖世界,2011(1)：17-19.
[6]王陈滨,姚友康.液压码坯机的液压系统设计[J]瓦砖,2008(2)：24-25.
[7]姚友康.码坯机液压系统污染的防控[J].瓦砖,2009(7)：27-28.
[8]时洪文.动码坯机与机器人的选择[J].瓦砖,2012(1)：33-34.
[9]包燕燕,李华栋,樊冬梅.伺服系统和PLC控制在自动码坯机中的应用[J].砖瓦,2007,5：15-16.
[1O]Fadel M. Position control laws for electromechanical actuator[C].Proc of the eighth International Conference on Electrical Machines and Systems. Nanjing: IEEE Press, 2005,:1708-1713.
[11]闫飞,石春,吴刚,王俊.基于PLC和触摸屏的电动缸自动测试系统设计[J].伺服控制,2010,8：107-110.
[12]杨跃,田联房,王孝洪.基于ARM与Linux的排爆机器人控制系统设计[J].电子测量技术,2010,33(3)：79-82.
[13]吴明亮,汪小兵,余淑荣等.基于PLC的伺服驱动填充系统的设计[J].机床与液压,2011,39(12)：89-91.
[14]Chen.Chin-Sheng,Wang.Shih-Ming.Adaptive Digital Control Based on Reduced-order Parameter Identification and Disturbance Observer for Linear Motor.Proc. ASME Int. Manuf. Sci. Eng. Conf. MSEC. Jan.2007,:751-758.
[15]敖荣庆,袁坤.数字伺服控制系统与设计[M].北京：航空工业出版社,2006.
[16]熊权洪.基于CAN总线的独立运动控制器的设计与研究[D].武汉理工大学,2007.
[17]林涛.基于以太网方式的两轴运动控制系统的设计[D].武汉理工大学,2009.
[18]B.Paseal.Pressure Control of Pneumatie System with a Nonnegligible Connection Port Restriction.Control and Intelligent Systems,2005,33(2)111-118.
[19]郭一方.火焰切割机嵌入式数控系统[D].武汉理工大学硕士论文,2010.
[20]HACHIYA K,OHMAE T. Digital speed control system for a mo-tor using two speed detection methods of an incremental encoder[C].2007 European Power Electronics and Application,Sep-tember5-7,2007.2007,9:1-10.
[21]吴国荣,肖曦.基于自校正的伺服系统速度控制器[J].电气传动,2009,(10).
[22]J.C.Reli, C.M.Liao.A Study on the Speed Control Perormance of a servo-Pneurnatic Motor and the Application to Pneumatic Tools,2004,23(7-8):572-576.
[23]Hsu,Pau-Lo,Yeh,Syh-Shiuh. Precision control and compensation of servomotors and machine tools via the disturbance observer[J].Mechatomic/IEEE Transactions on Industrial Electronics,2010,57 (1):420-429.
[24]陶瑞超.位置/速率伺服系统的自适应鲁棒控制方法研究[D].哈尔滨工业大学,2011.
[25]吴国荣,肖曦.基于自校正的伺服系统速度控制器[J].电气传动,2009,(10).
[26]Younkin G W. Compensating Structural Dynamics for Ser-vo Driven Industrial Machines with Acceleration Feedback[C].Industry Applications Conference,Thirty-ninth IAS Annual Meeting,Conference Record of the 2004. IEEE,2004,:1881-1890.
[27]Mutasim Nour. Self-Tuning of PI Speed Controller Gains Using Fuzzy Logic Controller[J].Modern Applied Science,2008,2 (6):55-65.
[28]王建.低焓地热工程技术及其应用[D].中国地质大学(北京),2006.
[29]郑泽东,李永东,肖曦.基于状态观测和反馈的伺服系统位置控制器[J].清华大学学报.
[30]S.Maiti,C.Chakraborty,S Sengupta.Simulation Studies on Model Reference Adaptive Controller Based Speed Estimation Technique for the Vector Controlled Permanent Magnet Synchronous Motor Drive.Simulation Modelling Practice andTheory.2008:1～12.
[31]王雪,李强,叶敬春.双电伺服主传动轴电机控制软件的开发研究[J].锻压装备与制造技术2012,(01).
[32]Cetin Gencer,Aysun Coskun.A robust speed control of Pennanent Magnet Synchronous motors using adaptive neural fuzzy inference system controllers [C].Asian J. Inform. Technol,2005,4(10):918-919.
[33]李玉民.机械手柔性抓取切换控制系统设计与仿真分析[J].国外电子测量技术.2010,29(10)：30-33.
[34]Lu Lu,Zheng Chen, BinYao, Qingfeng Wang.Desired Compensation Adaptive Robust Control of a linear-Motor-Driven Precision Industrial Gantry With ImProved Cogging Force ComPensation[J]. Mechatronics,IEEE/ASMETranson,2008:617-624.
[35]孙诚,张艳红.基于EPP模式的数据传输方法研究[J].电子测量技术,2011,34(6)：95-96-109.
[36]温洁.数控火焰切割机虚拟测试系统的研究与设计[D].武汉理工大学硕士论文,2010.
[37]潘松,黄继业.EDA技术与VHDL(第2版)[M].2007.
[38]K.Sridharan,T.K.Priay.The design of a hardware accelerator for real-time complete visibility graph construction and efficient FPGA implementation[J].IEEE Trans.Ind. Electron, 2005(52):1185-1187.
[39]汤忠庆.一种正弦波信号发生器的设计[J].电子工程师,2006,32(9)：29-31.
[40]A Harmonic Signal Generator Based on DDS and SOPC[A]. Proceedings of 2010 Chinese Control and Decision Conference[C],2010.
[41]孙超,林占江.基于DDS的雷达任意波形信号源的研究[J].电子测量与仪器学报.2008,22(2)：31-36.
[42]N.P.Ligocki,A.Retterg.Towards a modular communication system for FPGAs[J].in Proc. Electron. Des.,2004:71-76.
[43]杨守良.利用Matlab/DSP Builder实现DDS的设计[J].微计算机信息,2006-07-20.