1 Introduction 7 80 years, the rapid development of China s industrial economy early. Pressing the development of industries and infrastructure construction in full swing manner. Plant, equipment, transport facilities, a sharp increase in demand, the demand for all kinds of metal pipe can not meet the many demands of metal pipe constantly complicated shape, which gave birth to bender system design and development. As the domestic technology level of the backward bending equipment development were designed many remain at the initial stage, relay Shi s electrical control system of production out of product quality and Chan Liang Du Mei You Dadaorenmen right Gezhong metal tube technology aspirations. After 90 years, the rapid development of China s economic level and rising, and the PC technology is widely used in industry, two-dimensional type of bending machine has been unable to meet the needs of complex industries. Three-dimensional pipe bending machine is in this context the gradual development of shape, and programmable logic controller (PLC) control system in the pipe to play an important role, to the complex requirements of the pipe system provides an important technical assurance.
Automatic three-dimensional pipe bending machine system requires three pulse input, two sets of pulse signal output, powerful file function. Yonghong PLC is due to a single CPU can handle four meter high-speed hardware device, while four sets of output pulses, practical FUN160 file function, to meet the three-dimensional pipe bending machine control system complexity requirements, widely used in pipe machine industry.
2 System Overview (1) system structure automatic three-dimensional pipe bending machine control system consists of programmable logic controller (PLC), rotary encoders, stepper motor, man-machine interface (HMI) and the composition of hydraulic pumps. Rotary encoders are used to measure the angle and length control, stepping motor rotation is mainly used to achieve control and drive the length of car control, solenoid valve with the hydraulic pumps used to achieve elbow power.
(2) system function A, manual, semi-automatic, automatic and other operations, and may satisfy the mandrel and without mandrel, single point and multi-angle, two-dimensional and three-dimensional angle angle selection control requirements of different occasions specific needs.
B, can store hundreds of product models, each model can be set bending angle of 20 parameters and 20 rotation parameters, which can meet a variety of complex, multi-angle, different space requirements, and can work in real time the progress of monitoring display. Shown in Figure 1;
C, can be adjusted to set "clamping time", "folder back time", "into the core time" to meet the requirements of real process and prevent delays caused by mechanical action on the defective;
D, test machine mode option, for mechanical adjustments, consistent with administrator privileges people choose to try native mode, different users different operations to ensure system security. Shown in Figure 2;
E, can be set to limit the use of machinery in line with administrator privileges on the machine s use of personnel can be set time limit;
F, complete alarm system, improper operation or mechanical failure to make prompt on the screen, and stop and alarm. Shown in Figure 3.
(3) System I / O distribution systems use one platform FBs-24MCT host, 1 FBs-8EA input-output expansion module, and 1 unit FBs-8EY output expansion module. Distribution of input and output terminals as shown below.
Input:
X0 X1 elbow bend Encoder Encoder A-phase B-phase encoder A car with X2 X3 X4 car Encoder B-phase phase X5 rotary encoder A rotary encoder B-phase signal X7 X6 origin back to the sensor signal X8 auxiliary core push before the induction signal after the sensor signal X9 X10 auxiliary pushed into the car care materials into the auxiliary sensing area X11 push pedal signal interference X12 X13 X14 safety switch back, tube bending test signal X15-X17 systems allow the output signal:
Y0 Y1 stepper motor stepper motor 1A Phase 1B Phase Y2 Y3 action clip feed stepper motor 2A 2B-phase stepper motors with Y4 Y5 Y6 electromagnet core left behind back into the core Y7 Y8 Y9 vice folder main folder back back back bending Y10 folder material back Y12 Y11 Y13 core auxiliary push back retirement relief valve Y16 Y14 Y15 bend slow slow slow bend back the core Y17 Y19 Y18 Deputy folder into the main folder into the bending motion Y21 Y20 3 system software and hardware to achieve oil pump system is mainly the work of steps to have the main pipe clamping vice folder, there are core into the core and the timing, pipe, auxiliary push bend, bend to slow, main folder folder back, stepping motor rotating movement, back bending movement, return the core completion. The main work flow shown in Figure 4.
(1) file system management design in accordanceThe actual needs of different users need to product diversity, bend angle parameters of the characteristics of a flexible variable, three-dimensional pipe bending machine system design requirements in the PLC with powerful file processing. In system design, using FUN160 function instruction, shown in Figure 5. When M1 = OFF, M0 by the 0 ????? 1, the register R0 from the beginning, the length of the data registers R101 to write to the file starting blocks F0 register (index register data for the F0 of R100 the first N blocks); when M1 = ON time, M0 from the 0 ????? 1, the data register from the beginning of the first N F0 blocks (index registers R100 of data N) in the register data are stored in register data register R0 start area (area length of R101 data).
(2) the angle of the design system can be set up for each part bending angles of 20 and 20 space rotation. Because each part of the bend angle can not all set, when a number of parts bend angle less than 20 (that is, other angles are 0), CPU will continue to scan until the 20th point of all is finished, This is largely a waste of not only the CPU s scan time, but also reduces the system efficiency. Therefore, in the design process, using parameters to find ways to 0, program design shown in Figure 6, when the 20 parameters of the first N-register to 0, M2 = ON, then R4 data for the first N- parameter register, and inform the CPU execution to the command when the end of the implementation of the elbow.
(3) the length of the measurement system design and spatial angle measurement system, the length and angle of a stepping motor control space.
Stepper motor driven carts to achieve the length measurement function, and the pulses back to the CPU processing. The previous space angle control using artificial rotation, when the encoder count to the electromagnet when the driver moves, but because of the delay action time electromagnet, causing a lack of precision pipe.
To improve the system instead of manual rotation by a stepping motor, rotary encoder to detect and feedback signals, which not only meet the requirements of the system control precision, but also greatly improves production efficiency and automation.
(4) vibration interference processing in the system s working process, due to electrical shock and occasionally bending force is too small or too large produces some of the interference caused by the encoder s error in the count, reducing the accuracy of elbow . Therefore, addition of the auxiliary system, and slow back bend, reducing the vibration caused by large error factor.
4 Conclusion automatic pipe bending machine from the successful design has been revised and improved several times by many, has a large number of production applications. The control system in all respects as compared with the previous pipe system has great advantages: Parts up to hundreds of parameters, bend angle can be increased to as many as 20, processing of products from solid to hollow section steel metal pipes, furniture, handicrafts to industrial chemicals from travel equipment such as metal pipe; elbow length and angle of rotation control automation, the accuracy is greatly improved, allowing the error value is controlled within 0.2 ???, a person can achieve operation, greatly reduces labor costs, greatly improve the yield; operating system easy, man - machine dialogue easy to understand, the training can be realized by simple safe operation; sound alarm system and procedures reasonably designed to system maintenance and commissioning personnel has brought great convenience, reducing the amount of debugging time.
Running through the year proves that the system technology has reached the advanced level, and used in transportation, petrochemical and production life, and good economic and social benefits, is worthy of wide dissemination and use of equipment.