Application of Programmable Controller in a Rail Welding Machine

An innovation is conducted on a K190πK rail auto welding machine because of its poor stability in quality of welding joints. A new control system based on a programmable controller is designed to replace the old one. The new control system is of higher accuracy in controlling sequence and good ability in anti disturbance, and is convenient to operate. The comparison tests are carried out. The experimental results show that the quality of welded joints is greatly increased by the improved welding mechine.

The Designed Operation of the Machine Control System on HL-2A Tokamak

The Ethernet and field-bus communications are used in the machine control system （MCS） of HL-2A. The control net, with a programmable logic controller （PLC） as its logic control master, an engineering control management station as its net server, and a timing control PC connected to a number of terminals, flexibly and freely transfers information among the nodes on it with the Ethernet transmission techniques. The PLC masters the field bus, which carries small pieces of information between PLC and the field sites reliably and quickly. The control net is connected into the data net, where Internet access and sharing of more experimental data are enabled. The communication in the MCS guarantees the digitalization, automation and centralization. Also provided are a satisfactory degree of safety, reliability, stability, expandability and flexibility for maintenance.

Research on key control technologies of all-position automatic welding machine

The pipeline all-position automatic welding machine system is a special welding system for automatically welding circumferential joint of pipeline on site, which has been widely used to the long-distance pipeline construction projects due to the advantages of automatic control for welding parameters at all-position, moving speed of bugs and operating. In this paper, the key control technologies of PAWM all-position automatic welding machine （ developed by Pipeline Research Institute of CNPC） such us the automatic control system, control software, personal digital assistant （PDA） software and complex programmable logic device （ CPLD ） program as well us the control method of welding parameter have been described detailedly. With the higher welding quality, higher welding effwiency and lower labor intensity, PA WM all-position automatic welding machine has been successfully applied in many famous pipeline construction projects.

Implementation of a new PC based controller for a PUMA robot

This paper describes the replacement of a controller for a programmable universal machine for assembly (PUMA) 512 robot with a newly designed PC based (open architecture) controller employing a real-time direct control of six joints. The original structure of the PUMA robot is retained. The hardware of the new controller includes such in-house designed parts as pulse width modulation (PWM) amplifiers, digital and analog controllers, I/O cards, signal conditioner cards, and 16-bit A/D and D/A boards. An Intel Pentium IV industrial computer is used as the central controller. The control software is implemented using VC++ programming language. The trajectory tracking performance of all six joints is tested at varying velocities. Experimental results show that it is feasible to implement the suggested open architecture platform for PUMA 500 series robots through the software routines running on a PC. By assembling controller from off-the-shell hardware and software components, the benefits of reduced and improved robustness have been realized.

Development of a Reconfigurable Platform for Manufacturing Equipment Control

In modern manufacturing equipment control area,controller is required to deliver higher computing capability for adopting advanced algorithms to meet speed and accuracy requirements,and reconfigurabilities for changing or(and)adding features or functions.This paper presents a methodology in design and implementation of a high performance and reconfigurable platform for manufacturing equipment control.This methodology is in virtue of system on a programmable chip(SoPC)technolo- gy but replacing the on-chip processor by an external high performance,floating-point digital signal processor(DSP).The appli- cation of the DSP is designed as a multi-threaded framework,which has more flexibilities than a traditional single-loop one.Fur- thermore,the field programmable gate array(FPGA)system can be reconfigured easily and quickly to meet a new requirement by dragging and dropping pre-built components in a SoPC building environment.As a result,the controller platform is more recon- figurable in terms of algorithms and functions.This platform is implemented in a 3-axis milling machine control and the result indicates that the design and implementation presented in this paper is feasible.

Industry 4.0 Application in Manufacturing for Real-Time Monitoring and Control

Modern manufacturing aims to reduce downtime and track process anomalies to make profitable business decisions.This ideology is strengthened by Industry 4.0,which aims to continuously monitor high-value manufacturing assets.This article builds upon the Industry 4.0 concept to improve the efficiency of manufacturing systems.The major contribution is a framework for continuous monitoring and feedback-based control in the friction stir welding(FSW)process.It consists of a CNC manufacturing machine,sensors,edge,cloud systems,and deep neural networks,all working cohesively in real time.The edge device,located near the FSW machine,consists of a neural network that receives sensory information and predicts weld quality in real time.It addresses time-critical manufacturing decisions.Cloud receives the sensory data if weld quality is poor,and a second neural network predicts the new set of welding parameters that are sent as feedback to the welding machine.Several experiments are conducted for training the neural networks.The framework successfully tracks process quality and improves the welding by controlling it in real time.The system enables faster monitoring and control achieved in less than 1 s.The framework is validated through several experiments.

造纸机分布传动可编程控制器PCC系统的应用

PCC可编程控制器以其强大的数据处理能力、高运算速度和可靠网络连接等优势,在在造纸工业中得到广泛应用,充分发挥其优势有助于推进造纸机的智能化发展、提升造纸机的技术水平。对此,简述了PCC系统控制原理,设计了以PCC B&R 2005为主控制器、操作面板为人机界面、PROFIBUS现场总线为通信方式的造纸机分布传动控制系统,对系统中主要硬件选型与配置、系统通信方式、下位机软件设计等进行了详细说明,并基于组态王与PCC进行造纸机分布传动上位机监控界面的设计,以期提高造纸机分布传动控制系统的控制精度、实时性和稳定性。

基于可编程控制器的槟榔包装控制系统设计

为解决槟榔自动包装机封口装置存在封口不牢固、包材烧穿等问题,设计了一种基于可编程控制器(programmable logic controller, PLC)技术的槟榔自动包装机封口装置控制系统,以实现槟榔包装的稳定性。介绍封口装置工艺以及控制系统结构,包括PLC、温度传感器、位置传感器、温度控制模块、伺服电机等。封口装置中温度为主要研究对象,同时为弥补传统PID(proportional-integral-differential)控制的不足,改善传统LADRC(linear active disturbance rejection control)控制参数整定困难等问题,提出一种粒子群(particle swarm optimization, PSO)优化改进型线性自抗扰温度控制器,以提高封口装置温度控制的鲁棒性和抗扰性。最后进行仿真和实验研究。结果表明:与传统PID以及自抗扰(active disturbance rejection control, ADRC)控制器相比,加入粒子群(particle swarm optimization, PSO)算法优化后的改进型LADRC方法,可以使系统输出响应、快速性增强,调节时间变短,封口装置实际包装温度误差<0.4℃。可见所述封口装置系统有效提高温度控制精度,一定程度上提升了槟榔自动包装机的生产效率。

基于PMC控制的数控车削实训安全防护装置设计

数控车削实训可以提升学生的实践动手能力,激发学生的实践创新能力。由于数控车削实训涉及教学内容较多,且要求学生独立操作数控设备,具有一定的安全隐患。该文通过分析传统教学安全措施,并梳理数控车削常见安全隐患及其发生原因,结合数控车削实训实际情况,提出了基于可编程机床控制器(production material control, PMC)控制的数控车削实训安全防护装置。使用数控机床自带的PMC实时监控实训工量器具,设置一定的逻辑关系控制主轴的启动,以实现安全防护目的;通过“指纹授权+逻辑关系”协助实训指导教师进行管理,达到规范管理目的。实践证明:该安全防护装置能有效减少实训安全事故的发生,提升学生职业素养,降低实训指导教师的劳动强度。

基于PLC的自动测流机器人系统设计

针对当前河道测流存在的效率和自动化程度较低、测量模式单一等问题,提出了一套基于可编程逻辑控制器(PLC)的河道自动测流机器人系统设计与实现方案。该机器人系统由运动系统、采集系统、人机交互以及远程通信四大模块组成。首先,设计了自动测流机器人系统的硬件结构,实现了自动测流机器人在河流轨道上运动、铅鱼收放等功能。然后,开发了基于PLC的测控系统,设计了PLC梯形图和硬件连接方案,实现了自动测流机器人运动控制。最后,自动测流机器人系统通过RS-485通信协议将多传感器采集的数据传输到操控屏,结合4G远程技术,实现了采集数据和操作指令的远程传输。通过现场模拟的采集测试,该机器人系统可实现自动测流、远程操控、故障自检等功能,并提供多种测量模式,满足河道测流的使用需求。该系统的设计为开展智能化河流数据采集的研究奠定了基础。

6工位熔管自动压装设备的设计研究

针对传统熔管压装效率低、人力成本高、质量不稳定等问题,笔者在研究传统熔管压装工艺基础上,提出了集装夹、压装、钻孔、压销钉为一体的自动化压装设备。设计了回转台实现工位的转换,工作台上均布6个工位,每个工位相隔60°;运用SolidWorks软件对整个设备机械结构进行了设计,对其关键机构的核心受力部件液压缸座进行了受力分析,并通过ANSYS Workbench软件进行了有限元强度校核;对压销钉机构气缸进行了计算选型;最后,完成PLC(Programmable Logic Croller)控制系统与人机界面的设计,实现了设备的自动化运行以及各工位运行状态的监控。工厂应用结果表明:该设备能够稳定运行,熔管压装效率提高了100%,工人数量减少了67%,满足企业自动化生产需求。

基于TIA Portal的HMI+PLC虚拟仿真探究

文章提出一种在TIA Portal软件上集成人机界面(Human Machine Interface,HMI)和可编程逻辑控制器(ProgrammableLogicController,PLC)进行虚拟仿真的方法。该方法能够在现有的硬件条件下,使学生不受时间、地点等的限制,只需要在计算机上安装TIA PORTAL软件就可以进行虚拟学习,构建控制系统,进行硬件组态、编程、控件组态、仿真运行和程序调试等。最后,以十字路口的交通灯为例,采用基于实际物理设备和基于TIAPORTAL软件虚拟仿真两种方式搭建控制系统,完成项目的设计、组态、编程、调试和运行测试。主要任务是寻找方法构建虚拟网络,将虚拟运行的PLC与HMI设备联系起来,实现虚拟设备之间和软件之间的数据传输,达到与使用实际物理设备效果相同的目的。

一种新型高层建筑外立面瓷砖检测装置的设计

针对瓷砖掉落的风险设计了一台基于红外热成像技术集成无人机来检测瓷砖空鼓现象。该设备采用人机交互的方式对设备进行控制操作,当操控者输入地点方位坐标无人机启动,到指定位置对目标进行检测,将检测数据传回终端进行图片分析与处理。在SolidWorks上建立设备三维建模运用仿真软件模拟检测过程。设备由无人机、红外相机、图传系统模块、数据储存模块、移动电源大部分组成,可编程逻辑控制器(单片机)为控制系统,设计了该控制系统的框架,确立了控制系统的硬件组成,基于C语言编写了无人机的控制系统包括无人机自动巡检、精准定位等程序,无人机的检测控制可汇集于一台手机。研究结果表明,所设计的装置结构合理、功能完善、性能稳定,降低了检测过程的危险性,提高了检测的工作效率。

基于机器视觉与力控的发动机弯管焊缝自动化打磨系统研究

某系列尺寸不一的弯管由2部分在中间对焊而成,目前多采用人工方式进行弯管内壁焊缝的打磨,存在打磨质量与标准不一、效率低和劳动强度大等问题。为此,设计并实现了一种基于机器视觉技术和力控的发动机弯管焊缝自动化打磨系统。利用工业相机模组正对弯管两侧端面并拍摄图像,经图像处理算法处理计算得到弯管两侧端面焊缝起始位置坐标。机械臂根据该坐标调整打磨轨迹并搭载浮动主轴,保持打磨力的恒定并对焊缝不规则区域进行补偿,实现基于位置控制和力控的打磨自适应调整。试验结果表明,系统整体打磨合格率为96.03%,相比人工打磨效率提升95.90%。系统可以在较少人工的参与和干预下完成弯管焊缝的自动化打磨,具有良好的稳定性和使用柔性,并且允许弯管存在一定的变形。

压力机结构件常见焊接问题及控制

为了全面提高压力机结构件焊接质量,降低压力机结构件的返修率,延长压力机的使用寿命,提升企业的生产能力和竞争力,本文对压力机结构件常见焊接问题及控制方法进行了探讨。根据实践研究以及总结过往经验,文章梳理了压力机结构件焊接变形和焊接缺陷类型,分析了引发变形和缺陷的原因,并采取合理和有效的措施,以实现压力机结构件焊接问题的科学控制。

减震器缸筒自动化加工单元构建与实现

为满足减震器缸筒零件自动化加工需求,设计了J43508型减震器缸筒自动化加工单元。出于对减震器缸筒较高的表面加工精度要求和工序排布便捷性的考虑,选取1台数控双头车床一次装夹,完成对工件两端的同时加工;基于自研桁架系统的自动化上下料输送装置实现工件自动化物料输送;选用信捷XD5-60T-E可编程控制器设计自动化加工单元控制系统;通过可触摸屏示教器对自动化加工单元进行实时生产监控。调试结果显示,该自动化加工单元配置布局有效,功能可靠,完全能够胜任工件自动化生产加工及上下料的工作。

Profibus-DP总线在印染拉幅定形机电气控制系统上的应用

对印染拉幅定形机的电气控制系统进行概述。该系统采用先进的西门子Profibus-DP总线通信技术,配备丹佛斯FC302变频器构成速度闭环控制方式。通过信号级联输出方式,实现各传动单元之间的速度同步,提高速度信号的实时性和精确度。此外,介绍了风机变频器和温控表所采用的Modbus总线通信方式,该通信方式实现了更好的设备数据整合与数据交换。

埋件钢筋热镦机自动化控制系统的设计

针对埋件钢筋热镦机在不确定性和噪声干扰下的稳定运行需求,设计了一种自动化控制系统。该系统通过位置与温度传感器采集实时运行状态数据,利用微处理器和现场可编程门阵列实现数据的预处理,并结合模糊PID控制算法计算出自动化控制量。实验结果表明,该系统能有效控制加热温度和钢筋位置,使二者迅速达到预设值。在噪声干扰条件下,系统仍能保持顶镦杆速度和砧子速度的稳定,并实现了顶镦杆速度和砧子速度不同程度的精度提升,显著提高了埋件钢筋的加工质量。

可编程控制器在石油焦化装置中联锁系统的应用与设计分析

随着科技和国民经济的快速发展,机械自动化和可编程控制成为时代的潮流。目前,很多设备需满足高效率、高自动化的要求,为满足高效率、高自动化要求,组合机床常常被用来加工特殊的设备和特殊的工件。可编程序控制PLC的出现成功地解决了安装复杂、维修率高的问题,且其程序编制方便、不易受外界干扰、操作灵活,大大提高了机床的灵敏度,降低了运行管理成本、保证了产品质量。