Double-station independent tension control pneumatic winding system and use method thereof
Technical Field
The invention relates to the technical field of coiled material processing equipment, in particular to a double-station independent tension control pneumatic rolling system and a use method thereof.
Background
In the processing industry of coiled materials such as films, papers, non-woven fabrics, composite materials, lithium battery diaphragms and the like, winding is a key process for determining the quality of final products, and double-station winding machines are widely applied to production lines such as high-speed slitting, printing coating and the like because the double-station winding machines can realize continuous production without stopping the machine.
At present, the disclosed double-station winding technology mainly has the following types, but the problems of complete independent control of double stations and cooperative optimization of clamping force cannot be completely solved:
Firstly, some schemes adopt a mode of mechanically linking or sharing a power source, for example, some schemes switch stations through a rotary swing arm structure to realize independent driving, but the frame structure is complex, dynamic balance requirements are high, high-precision closed-loop tension control is not involved, and other schemes adopt a mode of sharing a main transmission shaft by two stations, noise is reduced through belt transmission, but the intrinsic coupling of the power source limits the capability of realizing high-precision independent tension control, more typically, a coaxial double-spindle winding device is provided with two winding drums side by side on the same shaft, and the tension of two yarns is synchronously regulated only through a set of connecting rod cylinder mechanism, the design leads to strong coupling of tension regulation of the two winding drums, independent and differential accurate control cannot be carried out according to material characteristics, and tension disturbance of the other winding drum is extremely easy to be caused when the winding drum is replaced or a roll material parameter fluctuates, so that winding quality is influenced.
Secondly, in the aspect of tension control technology, the existing schemes focus on a single path, for example, some patents integrate multiple functions into a single winding machine set, or an advanced motion controller is adopted to realize single-shaft high-precision tension control and winding diameter calculation, but the problems of double-station independent control are not solved, in addition, the technologies generally consider an inflatable shaft as a simple clamping tool, the inflation pressure of the inflatable shaft is usually set to be a fixed value, the optimal clamping force required is dynamically changed along with the increase of the winding diameter in the whole winding process, the slippage between a winding core and the shaft is caused due to insufficient clamping force, and the winding core or inner layer materials, especially sensitive materials such as a light film and an aluminum foil, are crushed due to excessive clamping force.
Therefore, the prior art lacks a double-station winding system which can realize complete physical and logical decoupling from a driving source and a control system to an actuating mechanism and can carry out intelligent collaborative closed-loop control on winding tension and a clamping force of an inflatable shaft, and the technical problem which is solved by the application is solved.
Disclosure of Invention
The invention provides a double-station independent tension control pneumatic rolling system and a use method thereof, which solve the problems of tension coupling, low roll changing efficiency and inconsistent roll quality of the traditional double-station rolling system and realize high-efficiency and high-quality double-roll synchronous or alternate production.
The scheme for solving the technical problems is as follows:
The first aspect is that the pneumatic rolling system with double-station independent tension control and the using method thereof comprise a frame, a first rolling station, a second rolling station, a pneumatic control unit and an electric control unit, wherein the first rolling station and the second rolling station are arranged on the frame side by side, the pneumatic control unit provides independent pneumatic for the two stations, and the electric control unit independently controls the rolling process of the two stations;
The first winding station and the second winding station comprise an inflatable shaft, a tension sensor and a deviation correcting mechanism, wherein the inflatable shaft is provided with a servo driving motor and is driven by the servo driving motor to wind materials, the tension sensor is arranged on a material path and is used for detecting the tension of coiled materials in real time, and the deviation correcting mechanism is used for keeping the edges of the coiled materials tidy;
The pneumatic control unit comprises two completely independent air paths, and each air path comprises an air source, a precise pressure regulating valve, a pressure sensor and an electromagnetic reversing valve which are sequentially connected, and is finally connected to an air expansion shaft of a corresponding station;
The electric control unit comprises a double-channel tension controller and a master control PLC, the double-channel tension controller receives signals from two tension sensors, and the master control PLC independently controls the running states of the servo driving motors of the two air expansion shafts, and the precise pressure regulating valve and the electromagnetic reversing valve corresponding to the air channels according to the set tension values and feedback signals.
On the basis of the technical scheme, the invention can be improved as follows.
Further, the air expansion shaft and the servo driving motor are directly connected through the planetary gear reducer to form an independent winding driving module, firstly, elasticity, slipping or gaps possibly existing in transmission modes such as a traditional belt and a chain are eliminated, torque control of the servo motor can be transmitted to the air expansion shaft without loss and hysteresis, the substantivity, rigidity and response speed of tension control are greatly improved, and secondly, a driving system of each station is completely self-contained in physical and functional aspects through modularized design, so that physical basis for realizing real mechanical decoupling and independent motion control of double stations is achieved, and reliability and maintenance convenience of the system are improved.
Furthermore, each winding station is further provided with an ultrasonic ranging sensor or encoder for detecting the diameter of the coiled material, and the electrical control unit is provided with a winding diameter calculation function and is used for realizing constant tension or taper tension control, so that the system can implement winding diameter feedforward compensation, namely, the motor torque is adjusted in advance before tension disturbance occurs due to winding diameter change, the hysteresis of pure feedback control is overcome, the system can automatically and smoothly reduce a target tension value along with the increase of the winding diameter according to a preset taper curve, and therefore, an ideal winding shape with consistent internal and external tightness is obtained, and the problems of material deformation or chrysanthemum pattern caused by overtightening and the like are prevented.
Furthermore, the two independent air paths share the same air source, but the independent stepless regulation of the pressure is realized through the precise pressure regulating valve, the regulation range covers 0.2 to 0.8MPa, and the two stations set and adjust completely different optimal clamping pressures in real time according to different characteristics (such as friction coefficient and weight) or different winding stages of the coiled material.
In a second aspect, a method for using a pneumatic winding system with double-station independent tension control includes the following steps:
S1, presetting parameters, namely setting target tension values, tension taper curves, initial reel air pressure and deviation correcting parameters for a first winding station and a second winding station in a human-computer interface of the electrical control unit;
S2, clamping and threading, namely respectively sleeving the hollow winding cores on two air inflation shafts, and starting the pneumatic control unit to enable the air inflation shafts to inflate the winding cores;
The material is pulled and respectively passes through the tension sensor and the deviation correcting mechanism of the two stations and is fixed on each winding core;
S3, independent tension control is started, a winding program is started, and the servo driving motors of the two stations operate according to respective set torque modes;
The double-channel tension controller compares the detection tension of each station with the set tension in real time, and forms closed-loop control by independently adjusting the output torque of the corresponding servo driving motor;
Simultaneously, according to the increase of the winding diameter, the clamping air pressure of the corresponding air channel is independently regulated;
S4, reel changing and alternation are carried out, when the coiled material of the first winding station reaches a set diameter, a system automatically or prompting an operator to cut off and transfer the material to a prepared winding core of the second winding station, uninterrupted winding is realized, and during the winding of the second winding station, the first winding station can finish full-reel unloading and empty-core loading, so that double-station alternating circulating operation is realized.
On the basis of the technical scheme, the invention can be improved as follows.
Further, in step S3, the clamping air pressure of the air expansion shaft is reduced in stages according to a preset curve along with the increase of the winding diameter, so as to ensure that the winding core does not slip and the inner layer material is not damaged, thereby realizing intelligent dynamic optimization of the clamping force, providing sufficient static friction force to prevent starting slip by adopting higher air pressure when the winding diameter is small and the required transmission torque is small at the initial stage of winding, increasing the required transmission torque along with the increase of the winding diameter, the increase of the material weight and inertia, but increasing the contact area and the wrapping angle of the winding material and the winding core, reducing the air pressure according to the curve at the moment, effectively homogenizing the radial pressure applied to the winding core (especially the paper core) and the inner layer material on the premise of ensuring the transmission of the required torque, avoiding crushing the winding core or generating indentation on the inner layer material, remarkably improving the winding quality of high-end sensitive material, and having better safety and application range.
The invention has the beneficial effects that the invention provides the double-station independent tension control pneumatic rolling system and the use method thereof, and the pneumatic rolling system has the following advantages:
1. the winding quality and consistency can be remarkably improved, the totally independent closed-loop tension control of the double channels ensures that the process fluctuation or the winding changing action of any station can not disturb the other station, thereby ensuring that the tension curve of each winding material can strictly follow a set value, the winding quality (such as tightness and flatness) can reach extremely high consistency, and the dynamic optimization algorithm of the clamping force of the air expansion shaft effectively avoids physical damages such as winding core slipping (tension runaway) or winding core crushing caused by improper pressure, indentation generated by inner layer materials and the like, and is particularly suitable for winding high-end sensitive materials such as optical films, battery diaphragms, aluminum foils and the like;
2. the system reliability and the production efficiency can be greatly improved, the slipping, the abrasion and the gap of the traditional transmission mode are eliminated through the modularized driving design of the direct connection of the planetary reducer and the air expansion shaft, the transmission rigidity is high, the response is quick, the service life of equipment is long, the maintenance is simple and convenient, the automation or semi-automation can be realized in the reel changing process by virtue of the complete independence of double stations, one station can realize the unloading and the material preparation after the reel is fully rolled, and the other station can realize the seamless continuous production, so that the non-stop continuous operation in the real sense is realized, the idle time of the equipment is greatly reduced, and the whole production efficiency is improved;
3. The process adaptability and the intellectualization are enhanced, the system allows two stations to run with completely different tension curves, taper modes and clamping pressures, the system has the powerful capability of processing coiled materials with different materials, widths and specifications, the production arrangement is extremely flexible, the coil diameter calculation and taper control functions are integrated, the advanced control strategy from constant tension to any taper tension is realized, the feedforward compensation can be carried out through the coil diameter change, the control response is quicker and more stable, the centralized parameterization setting and management are carried out through a human-computer interface, the complex cooperative control of tension and air pressure is automatically completed by the system, the dependence on experience of operators is reduced, and the repeatability and standardization level of the process are improved.
The foregoing description is only an overview of the present invention, and is intended to provide a better understanding of the present invention, as it is embodied in the following description, with reference to the preferred embodiments of the present invention and the accompanying drawings. Specific embodiments of the present invention are given in detail by the following examples and the accompanying drawings.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the application and do not constitute a limitation on the application. In the drawings:
FIG. 1 is a flow chart of a dual-station independent tension controlled pneumatic winding system and a method for using the same according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a pneumatic rolling system with dual-station independent tension control and a method for using the same according to an embodiment of the present invention.
Detailed Description
The principles and features of the present invention are described below with reference to fig. 1-2, the examples being provided for illustration only and not for limitation of the scope of the invention. The invention is more particularly described by way of example in the following paragraphs with reference to the drawings. The advantages and features of the present invention will become more apparent from the following description. It should be noted that the drawings are in a very simplified form and are all to a non-precise scale, merely for convenience and clarity in aiding in the description of embodiments of the invention.
It will be understood that when an element is referred to as being "fixed to" another element, it can be directly on the other element or intervening elements may also be present. When a component is considered to be "connected" to another component, it can be directly connected to the other component or intervening components may also be present. When an element is referred to as being "disposed on" another element, it can be directly on the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like are used herein for illustrative purposes only.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and/or" as used herein includes any and all combinations of one or more of the associated listed items.
As shown in FIG. 2, the invention provides a double-station independent tension control pneumatic rolling system and a use method thereof, wherein the pneumatic rolling system comprises a frame structure, a pneumatic control unit and an electric control unit;
the frame structure main body is a rigidly welded frame and is used for bearing all functional components, and a first rolling station and a second rolling station which are completely identical in structure are arranged on the frame side by side;
taking a first winding station as an example, the core of the winding station is an air expansion shaft, and a convex key type air expansion shaft is preferably adopted to ensure the uniform expansion of a winding core, the air expansion shaft is directly connected with the output end of a planetary gear reducer through a coupler, the input end of the planetary gear reducer is directly connected with the output shaft of a servo driving motor, and the rigid direct connection module of the servo motor-the planetary reducer-the air expansion shaft forms a completely independent winding driving module, so that compared with the traditional belt or chain transmission, the design thoroughly eliminates the transmission elasticity, slipping and gap, and the torque command of the servo motor can be transmitted to a scroll in a lossless and high-rigidity manner, thereby being the basis for realizing high-precision and quick-response tension control;
a tension detection roller is arranged on a material path above the air expansion shaft in an inclined way, a high-precision torque type tension sensor is integrated in a bearing seat of the tension detection roller and is used for detecting the tension value of a material in operation in real time, and a correction mechanism consisting of a photoelectric sensor, a controller and a correction cylinder is arranged before the material enters a station and is used for detecting and correcting the transverse position of the material in real time so as to ensure that the winding edge is tidy;
each station is also provided with a coil diameter detection device, the embodiment adopts a non-contact ultrasonic ranging sensor which is aligned with the surface of the coiled material and used for measuring the outer diameter of the coiled material in real time, and also adopts a scheme of reading servo motor encoder pulse to perform indirect coil diameter calculation;
The pneumatic control unit is of a two-channel independent design, a system total air source is divided into two parallel and completely independent air paths after being processed by a triple piece formed by an air filter, a pressure reducing valve and an oil mist device, the first air path is sequentially connected with a first precise pressure regulating valve (an electric proportional valve is adopted in the embodiment), a first pressure sensor and a first two-position three-way electromagnetic reversing valve, and finally is connected to an air expansion shaft of a first station through a rotary joint, the second air path structure is completely symmetrical with the first air path, the pneumatic control unit comprises a second precise pressure regulating valve, a second pressure sensor and a second two-position three-way electromagnetic reversing valve, and is connected to the air expansion shaft of the second station, the precise pressure regulating valve can realize stepless regulation of pressure in the range of 0.2-0.8 MPa by receiving electric signals, and the pressure sensor is used for feeding back real-time air pressure to form a pressure closed loop;
The electric control unit is specifically configured by taking an industrial human-machine interface (HMI) and a main control Programmable Logic Controller (PLC) as cores, wherein the HMI is used for parameter setting, state monitoring and manual operation, the PLC is connected with all I/O signals of a system through an expansion module of the HMI, an analog input module of the HMI is connected with signals of two tension sensors, two pressure sensors and an ultrasonic sensor, an analog output module of the HMI is connected with two precise pressure regulating valves, a digital output module controls an electromagnetic reversing valve and a deviation correcting mechanism, servo drivers of the two stations are communicated with the PLC through a high-speed field bus (such as EtherCAT) to receive torque or speed instructions and drive respective servo motors, and a dual-channel tension control algorithm, a coil diameter calculation module (processing encoder or ultrasonic signal) and an air pressure self-adaptive control algorithm are integrated in the PLC.
As shown in fig. 1, the specific working principle and the using method of the invention are as follows:
Step S1, parameter presetting, wherein an operator creates or calls a process formula for a product to be produced on an HMI, and different process parameters are independently set for a first station and a second station respectively;
The device specifically comprises a target initial tension value (such as a station A:150N, a station B: 130N), a tension taper curve (such as a linear taper of 10%), an initial clamping air pressure of an inflatable shaft (such as a station A:0.5MPa, a station B:0.45 MPa), and a reference position of a deviation correcting sensor, wherein the parameters are stored in a PLC;
Step S2, clamping and threading, namely respectively sleeving two empty winding cores on air-expanding shafts of two stations, triggering a station inflation command through an HMI, controlling an electromagnetic reversing valve to act by a PLC, controlling a precise pressure regulating valve to output set initial air pressure, expanding the air-expanding shafts to tightly wind the winding cores, then dragging a sheet from a previous process (such as a splitting machine), sequentially passing through tension detection rollers and deviation correcting mechanisms of the two stations, and flatly pasting the end parts of the material on the winding cores;
step S3, starting and running the independent tension control, starting an automatic winding program, switching the servo motors of the two stations to a torque control mode for running according to the instruction sent by the PLC, and starting the core closed-loop control of the system to work:
The tension closed loop comprises a double-channel tension controller (integrated in PLC software) for acquiring signals T_feedback of two tension sensors in real time, comparing the signals T_feedback with a current target tension T_set_current dynamically calculated according to a taper curve to obtain a deviation e (T), and performing independent PID operation on the e (T) by the controller to output an adjusted torque instruction to a corresponding servo driver in real time so as to form a rapid and accurate independent tension closed loop;
Simultaneously, the PLC calculates the current coil diameter D_current in real time according to the feedback of an ultrasonic sensor or the pulse number of a servo motor encoder and the formula
T_set_current=T_initial-(T_initial-T_final)*(D_current-D_core)/(D_full-D_core);
Dynamically updating target tension to realize taper control;
The air pressure self-adaptive closed loop is that in the rolling process, the air pressure is not fixed, and the PLC dynamically calculates the target clamping air pressure P_set according to a preset rolling diameter-air pressure curve according to the real-time rolling diameter D_current;
For example, when D_current exceeds the core diameter by a factor of 2, the air pressure decay is initiated:
P_set=P_initial*[1-0.3*(D_current-2*D_core)/(D_full-2*D_core)];
the PLC controls the precise pressure regulating valve through analog output, so that the feedback value P_feedback of the pressure sensor tracks P_set, intelligent dynamic optimization of the clamping force is realized, and the winding core and the inner layer material are protected on the premise of ensuring no slip;
Step S4, reel changing and alternate operation are carried out, and when the diameter D_current of the coiled material at the first station reaches a preset reel changing diameter (such as 98% of the full reel diameter), a system alarms and prompts;
the preparation is that a servo motor of the second station is accelerated to be synchronous with the linear speed of the host machine in advance under the control of the PLC;
the PLC triggers the pneumatic cutting knife arranged between the two stations to act, cuts off the sheet, simultaneously, the auxiliary pressing roller of the second station presses down, and the new material head is quickly adsorbed on the winding core to be used by utilizing air flow or contact;
The tension switching, namely, at the moment of material attachment, the second station servo motor immediately switches a rotary moment mode from a speed mode, takes the current target tension value of the first station as an initial set value to take over tension control, and the first station servo motor is stopped stably;
and (3) circulating operation, namely continuously and independently winding the material by a second station in the process of fully winding and unloading the material at the first station, reloading the empty winding core and pre-inflating the material, and switching the material back to the first station which is ready when the second station is about to be fully wound, so that the continuous production is realized.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. What is not described in detail in this specification is prior art known to those skilled in the art.
The foregoing description is only a preferred embodiment of the present invention, and is not intended to limit the invention in any way, and those skilled in the art may easily implement the present invention as shown in the drawings and described above, but many modifications, adaptations and variations of the present invention using the above disclosed technical matters without departing from the scope of the present invention, and meanwhile, any equivalent modifications, adaptations and variations of the above embodiments according to the essential technology of the present invention are within the scope of the technical matters of the present invention.