CN103074474B - Control system for rolling and strengthening torsion shaft of heavy armored vehicle - Google Patents

Abstract

The invention provides a control system for rolling and strengthening the torsion shaft of a heavy-duty armored vehicle. The system includes a rolling motion control subsystem, a rolling head hydraulic control subsystem, and a measurement and data acquisition and processing subsystem; wherein the rolling motion The control subsystem and the rolling head hydraulic control subsystem are respectively connected with the measurement and data acquisition and processing subsystem. The rolling motion control subsystem is mainly composed of two photoelectric encoders, a motion control unit, a Z-axis servo motor, and a spindle servo motor; the hydraulic control subsystem includes a PID control unit, a hydraulic pump station, an electro-hydraulic flow servo valve, and a pressure sensor; And the data acquisition subsystem is mainly composed of laser displacement sensor, high-resolution photoelectric code and data processing module. The invention can realize processing, measurement and intelligent control of the hydraulic system, has a high degree of automation, is easy to expand the system, realizes the intelligent control of torsion shaft parts, and improves the efficiency of rolling processing.

Description

Control system for rolling hardened torsion shafts of heavy armored vehicles

technical field

The invention relates to a control system of a rolling machine tool, in particular to a control system for rolling and strengthening the torsion shaft of a heavy armored vehicle.

Background technique

Under normal conditions, the driving conditions of heavy armored vehicles are harsh, and the torsion shaft for transmission needs to work frequently under heavy load conditions. The torsion shaft of a heavy-duty armored vehicle is an important transmission part for the vehicle engine to transmit power to the wheel hub. It is subjected to large torsion and rolling loads during the working process. The torsion shaft plays an important role in generating surface cracks under repeated, high-strength conditions.

Through the rolling finishing and strengthening processing of the torsion shaft, especially the surface processing of the torsion shaft journal, wheel seat, etc., it has played a great role in improving the surface quality and fatigue strength of the axle. Although the rolling finishing and strengthening processing of axles has a long history, the Ministry of Railways has been widely used in the surface processing of axles, but the equipment currently used is generally ordinary lathes. This processing method has the problems of high labor intensity, low processing efficiency, and long workpiece replacement cycle. In addition, due to the need for manual oil mist lubrication during the processing process, there are also problems such as poor environmental protection, low oil utilization rate, and environmental pollution.

Contents of the invention

The object of the present invention is to provide a control system for rolling and strengthening the torsion shaft of a heavy armored vehicle, which can realize fully automatic control of machine tool processing.

Realize the technical scheme of the present invention as follows:

A control system for rolling the torsion shaft of a heavy armored vehicle, the system includes a rolling motion control subsystem, a rolling head hydraulic control subsystem, and a measurement and data acquisition and processing subsystem; the rolling motion control subsystem It is connected with the hydraulic control subsystem of the rolling head and the measurement and data acquisition and processing subsystem respectively;

The rolling motion control subsystem is mainly composed of two photoelectric encoders, a motion control unit, a Z-axis servo motor and a spindle servo motor; The motors rotate synchronously; the motion control unit is connected to the photoelectric encoder, the Z-axis servo motor and the spindle servo motor respectively; the Z-axis servo motor is connected to the machine tool table, and the spindle servo motor is connected to the machine tool spindle;

The photoelectric encoder is used to detect the angular velocity and rotation angle of the servo motor connected to it, and transmit the detected angle information to the motion control unit;

The motion control unit controls the Z-axis servo motor to drive the machine table to move along the Z-axis according to the angle information transmitted by the photoelectric encoder connected to the Z-axis servo motor, and the angle information transmitted by the photoelectric encoder connected to the spindle servo motor and The tooth root position transmitted by the measurement and data acquisition and processing subsystem is processed, and a control signal is generated to control the spindle servo motor to drive the spindle to rotate;

The hydraulic control subsystem includes a PID control unit, a hydraulic pump station, an electro-hydraulic flow servo valve, and a pressure sensor; the output pipeline of the hydraulic pump station is connected to the oil inlet of the electro-hydraulic flow servo valve, and the pressure sensor is located in the oil outlet pipe of the electro-hydraulic flow servo valve. The oil outlet pipeline of the electro-hydraulic flow servo valve is connected to the hydraulic cylinder of the rolling head on the machine tool, and the PID control unit is connected to the pressure sensor and the control end of the electro-hydraulic flow servo valve respectively;

The PID control unit uses the PID algorithm to control the control end of the electro-hydraulic flow servo valve according to the pressure value collected by the pressure sensor;

The measurement and data acquisition subsystem is mainly composed of laser displacement sensors, photoelectric encoding and data processing modules; the laser displacement sensors are installed on the machine tool slide box and move with the machine tool slide box, and the photoelectric encoder is located in the machine tool spindle box and synchronized The pulley is connected to the tail of the main shaft, and the data processing module is respectively connected to the laser displacement sensor and the photoelectric code;

The laser displacement sensor is used to detect the radius R of the torsion shaft and transmit it to the data processing module;

The photoelectric encoder is used to detect the rotation angle θ of the main shaft and transmit it to the data processing module.

The data processing device calculates the received rotation angle θ and the radius R of the torsion shaft, obtains the dedendum position of the torsion shaft, and transmits it to the rolling motion control subsystem.

Further, the PID algorithm of the present invention is: according to the pressure value V(K) collected by the pressure sensor at the current Kth sampling time, control the oil pressure output (K) of the oil outlet of the electro-hydraulic flow servo valve; where

e(K)=C-V(K);

Among them, C is the control value set according to the oil pressure required by the oil outlet of the electro-hydraulic flow servo valve, and e(K) is the error value between the output value of the servo end and the set value at the Kth sampling time;

Then the output increment △ output is:

△output=Kp×(e(K)-e(K-1))+Ki×e(K)+Kd(e(K-2)×e(K-1)+e(K-2)); Among them, e(K-1) is the error value input by the server at the (K-1)th sampling moment, e(K-2) is the error value input by the server at the (K-2)th sampling moment, output ( K-1) is the output of the control unit at the (K-1)th sampling time; Kp=100 is the integral coefficient of the servo end, Ki=50 is the proportional coefficient of the servo end, Kd=700 is the differential coefficient of the servo end, then the output (K) is:

output (K) = output (K-1) + △ output.

Further, the specific method for calculating the root position of the torsion shaft in the present invention is as follows: select a group (θ, R) corresponding to the tooth profile section of the torsion shaft, and divide the submaximum and subminimum of R in the selected (θ, R) respectively Denote it as R _max and R _min , select (θ, R) according to θ from small to large, compare the R corresponding to θ with R _max and R _min in turn, and put the first one within R _min ±0.3mm The point of the range is marked as S, starting from S, find the first point that falls within the range of R _min ±0.3mm and mark it as A, find the first point that exceeds the range of R _min ±0.3mm and mark it as B; then the dedendum The coordinates of the position are (θ _c , R _c ), where θ _c = (θ _A + θ _B )/2, where θ _A is the angle corresponding to point A, θ _B is the angle corresponding to point B, R _c for θ The corresponding distance; calculate the coordinates (θ _c , R _c ) of the dedendum position of the torsion axis.

Further, the rolling motion control subsystem of the present invention further includes a signal adapter board, which is a signal input and output port on the motion control unit.

Further, the rolling motion control subsystem of the present invention also includes two stroke switches installed on the base of the machine tool, and the two stroke switches are respectively located in the positive and negative directions of the machine tool movement; The limit control is performed on the position. When the machine tool moves to the position of the travel switch, the travel switch generates an in-position signal and transmits it to the motion control unit. When the motion control unit receives the in-position signal, it controls the spindle servo motor to stop moving.

Further, the present invention also includes a PLC control subsystem for detecting and displaying the working state of the machine tool.

Further, the measurement and data acquisition subsystem of the present invention also includes a magnetostrictive sensor, which is installed in the hydraulic cylinder of the rolling head of the hydraulic control system to measure the actual position of the hydraulic cylinder during processing and transmitted to the outside for display.

Further, the present invention also includes a process database, which is used to store the information of the torsion shaft, and the information of the torsion shaft includes the batch number of the torsion shaft, the size after processing, the processing amount and the date of processing.

Beneficial effect

First, the control system of the present invention includes a rolling motion control subsystem, a rolling head hydraulic control subsystem, and a measurement and data acquisition and processing subsystem, thereby realizing processing, measurement, and intelligent control of the hydraulic system, with a high degree of automation and easy system installation. The expansion realizes the intelligent control of the torsion shaft and improves the efficiency of rolling processing.

Second, the present invention uses the PID algorithm to control the output hydraulic pressure of the hydraulic control subsystem of the rolling head, thereby realizing constant pressure output, ensuring the uniformity of rolling on each part of the torsion shaft, and improving the quality of the torsion shaft.

Third, compared with the existing manual rotation of the torsion shaft to find the dedendum position, the present invention uses an accurate algorithm to calculate the dedendum position of the torsion shaft, and the motion control unit controls the rotation of the main shaft servo motor according to the calculated results, which is very good The efficiency of processing is improved.

Description of drawings

Figure 1 is a schematic diagram of a rolling machine tool;

Figure 2 is a schematic diagram of the operation panel;

Fig. 3 is a schematic diagram of the control system of the present invention;

1-machine tool spindle 2-processing parts 3-control system 4-laser displacement sensor 5-rolling head 6-hydraulic tailstock 7-worktable.

Detailed ways

As shown in Figure 1, the rolling machine tool mainly includes a machine tool spindle 1, a control system 3, a hydraulic tailstock 6, and a workbench 7. The torsion shaft 2 that needs to be rolled is mounted on the main shaft 1, and the operator operates on the operation panel as shown in Figure 2.

As shown in Figure 3, the control system for rolling the torsion shaft of a heavy armored vehicle in the present invention includes a rolling motion control subsystem, a rolling head hydraulic control subsystem, and a measurement and data acquisition and processing subsystem; The rolling motion control subsystem and the rolling head hydraulic control subsystem are respectively connected with the measurement and data acquisition and processing subsystems.

The rolling motion control subsystem is mainly composed of two photoelectric encoders, a motion control unit, a Z-axis servo motor and a spindle servo motor; The motors rotate synchronously; the motion control unit is connected with the photoelectric encoder, the Z-axis servo motor and the spindle servo motor respectively; the Z-axis servo motor is connected with the machine tool table, and the spindle servo motor is connected with the machine tool spindle.

The photoelectric encoder is used to detect the angular velocity and rotation angle of the servo motor connected to it, and transmit the detected angle information to the motion control unit; the motion control unit transmits the angle information from the photoelectric encoder connected to the Z-axis servo motor, Control the Z-axis servo motor to drive the machine tool table to move along the Z-axis, process the angle information transmitted from the photoelectric encoder connected to the spindle servo motor and the tooth root position transmitted from the measurement and data acquisition and processing subsystem, and generate control signals for control The main shaft servo motor drives the main shaft to rotate.

The rolling motion control subsystem of the present invention is the core of the motion control of the rolling machine tool, which completes the driving of the machine tool table in the horizontal direction (that is, along the Z-axis direction), and controls the rotation of the main shaft (that is, around the C-axis) to realize Z, C two-axis linkage interpolation.

The hydraulic control subsystem includes a PID control unit, a hydraulic pump station, an electro-hydraulic flow servo valve, and a pressure sensor; the output pipeline of the hydraulic pump station is connected to the oil inlet of the electro-hydraulic flow servo valve, and the pressure sensor is located in the oil outlet pipe of the electro-hydraulic flow servo valve. The oil outlet pipeline of the electro-hydraulic flow servo valve is connected with the hydraulic cylinder of the rolling head on the machine tool, and the oil outlet pipeline of the electro-hydraulic flow servo valve is connected with the hydraulic cylinder of the rolling head on the machine tool. The PID control unit is connected with the pressure sensor and The control end of the electro-hydraulic flow servo valve is connected; the PID control unit uses the PID algorithm to realize the control of the control end of the electro-hydraulic flow servo valve according to the pressure value collected by the pressure sensor; The hydraulic cylinder provides hydraulic oil to achieve rolling.

The measurement and data acquisition subsystem is mainly composed of laser displacement sensors, photoelectric encoding and data processing modules; the laser displacement sensors are installed on the machine tool slide box and move with the machine tool slide box, and the photoelectric encoder is located in the machine tool spindle box and synchronized The pulley is connected to the tail of the main shaft, and the data processing module is connected to the laser displacement sensor and the photoelectric code; the laser displacement sensor is used to detect the radius of the torsion shaft and transmit it to the data processing module; the photoelectric encoder is used to detect the rotation angle of the main shaft, And transmit it to the data processing module; the data processing device calculates the received rotation angle θ and the radius R of the torsion shaft, obtains the dedendum position of the torsion shaft, and transmits it to the rolling motion control subsystem.

Due to the transmission rotation, there is a certain error between the rotation angle of the main shaft servo motor and the main shaft. The present invention sets a high-precision photoelectric encoder connected to the main shaft, and a photoelectric encoder connected to the main shaft motor. to precisely control the rotation of the spindle motor.

In order to ensure the uniformity of the rolling of each part of the torsion shaft and improve the quality of the torsion shaft, the present invention designs a PID algorithm to realize the control of the output hydraulic pressure. Pressure value V (K), the oil pressure output (K) controlling the oil outlet of the electro-hydraulic flow servo valve;

e(K)=C-V(K);

Among them, C is the control value set according to the oil pressure required by the oil outlet of the electro-hydraulic flow servo valve, and e(K) is the error value between the output value of the servo end and the set value at the Kth sampling time;

Then the output increment △ output is:

△output=Kp×(e(K)-e(K-1))+Ki×e(K)+Kd(e(K-2)×e(K-1)+e(K-2));

Among them, e(K-1) is the error value input by the server at the (K-1)th sampling moment, e(K-2) is the error value input by the server at the (K-2)th sampling moment, output ( K-1) is the output of the control unit at the (K-1)th sampling time; Kp=100 is the integral coefficient of the servo end, Ki=50 is the proportional coefficient of the servo end, Kd=700 is the differential coefficient of the servo end, then the output (K) is:

output (K) = output (K-1) + △ output.

In order to accurately obtain the dedendum position of the torsion shaft and automatically process the dedendum, the present invention designs a set of algorithms to calculate the dedendum position of the torsion shaft. ), record the second maximum and second minimum of R in the selected (θ,R) as R _max and R _min respectively, in the selected (θ,R) according to θ from small to large, and sequentially record the corresponding R is compared with R _max and R _min , and the first point falling in the range of R _min ±0.3mm is marked as S, starting from S, find the first point falling in the range of R _min ±0.3mm and marked as A, Find the first point that exceeds the range of R _min ±0.3mm and record it as B; then the coordinates of the dedendum position are (θ _c , R _c ), where θ _c = (θ _A + θ _B )/2, where θ _A is the angle corresponding to point A, θ _B is the angle corresponding to point B, and R _c is the distance corresponding to θ _c ; calculate the coordinates (θ _c , R _c ) of the dedendum position of the torsion axis.

In order to prevent the external strong electric signal from burning the motion control unit, the present invention also sets a signal adapter board on the rolling motion control subsystem as the signal input and output port on the motion control unit, which plays the role of bidirectional transmission of signals, and also has photoelectric isolation protection.

In order to prevent the rotational movement of the machine tool from exceeding its limit, the present invention also sets a travel switch on the rolling motion control subsystem for limit control of the position of the machine tool. When the machine tool moves to the position where the travel switch is located, the travel switch generates signal and transmit it to the motion control unit.

Since the machine tool may be abnormal during the working process, it is necessary to inform the external staff of the working state of the machine tool in real time. Therefore, the present invention designs a PLC control subsystem for detecting and displaying the working state of the machine tool. The PLC control system is mainly composed of CPU, memory, switch input/output module and analog input/output module; the CPU is used to perform logical operations on the input and output signals of the machine tool, and complete the internal timing, counting, arithmetic operations, and data processing of the PLC control system. Processing and transmission, communication, and various application instruction interpretation functions, etc. The data used in the CPU calculation process needs to be read from the storage, and the results of the data analysis and processing are also stored in the memory. The memory and the CPU are in a two-way data transmission relationship. The memory is used to store the digital signals transmitted from the digital input/output module and the analog input/output module, and transmit the data calculated by the CPU to the digital input/output module and the analog input/output module. The switch input/output module is used to collect the high and low level state signals of the machine tool, and convert the collected state signals into digital form and write them into the memory; the switch value input/output module reads the state signals in the memory, and It is converted into a mode output that can be recognized by the machine tool; the analog input/output module is used to collect the continuously changing analog signal generated during the working process of the machine tool, and convert it into digital form and write it into the memory; the analog input/output module Read the data processed by the CPU in the memory and convert it into an analog signal for use by the electrical system of the machine tool.

In order that the staff can see the pressure value output by the rolling head in real time, the present invention sets a magnetostrictive sensor in the hydraulic cylinder of the hydraulic control system rolling head, and the magnetostrictive sensor is used to measure the actual pressure of the hydraulic cylinder during the machining process. Position, the position change is transmitted and displayed through the RS485 protocol.

At the same time, the present invention also designs a process database, which is programmed in the ACCESS format and has information on part batch numbers, parts after processing, sizes after processing, processing quantities, and processing dates. After each processing is completed, it can be uploaded to a remote server for analysis and storage through the TCP/IP protocol.

To sum up, the above are only preferred embodiments of the present invention, and are not intended to limit the protection scope of the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included within the protection scope of the present invention.

Claims (6)

1. A control system for rolling the torsion shaft of a heavy armored vehicle, characterized in that the system includes a rolling motion control subsystem, a rolling head hydraulic control subsystem, and a measurement and data acquisition and processing subsystem; wherein The rolling motion control subsystem and the rolling head hydraulic control subsystem are respectively connected with the measurement and data acquisition and processing subsystem; The rolling motion control subsystem is mainly composed of two photoelectric encoders, a motion control unit, a Z-axis servo motor and a spindle servo motor; The motors rotate synchronously; the motion control unit is connected to the photoelectric encoder, the Z-axis servo motor and the spindle servo motor respectively; the Z-axis servo motor is connected to the machine tool table, and the spindle servo motor is connected to the machine tool spindle; The photoelectric encoder is used to detect the angular velocity and rotation angle of the servo motor connected to it, and transmit the detected angle information to the motion control unit; The motion control unit controls the Z-axis servo motor to drive the machine table to move along the Z-axis according to the angle information transmitted by the photoelectric encoder connected to the Z-axis servo motor, and the angle information transmitted by the photoelectric encoder connected to the spindle servo motor and The tooth root position transmitted by the measurement and data acquisition and processing subsystem is processed, and a control signal is generated to control the spindle servo motor to drive the spindle to rotate; The hydraulic control subsystem includes a PID control unit, a hydraulic pump station, an electro-hydraulic flow servo valve, and a pressure sensor; the output pipeline of the hydraulic pump station is connected to the oil inlet of the electro-hydraulic flow servo valve, and the pressure sensor is located in the oil outlet pipe of the electro-hydraulic flow servo valve. The oil outlet pipeline of the electro-hydraulic flow servo valve is connected to the hydraulic cylinder of the rolling head on the machine tool, and the PID control unit is connected to the pressure sensor and the control end of the electro-hydraulic flow servo valve respectively; The PID control unit uses the PID algorithm to control the control end of the electro-hydraulic flow servo valve according to the pressure value collected by the pressure sensor; The PID algorithm is: according to the pressure value V(K) collected by the pressure sensor at the current Kth sampling time, control the oil pressure output (K) of the oil outlet of the electro-hydraulic flow servo valve; where e(K)=C-V(K); Among them, C is the control value set according to the oil pressure required by the oil outlet of the electro-hydraulic flow servo valve, and e(K) is the error value between the output value of the servo end and the set value at the Kth sampling time; Then the output increment △ output is: △output=Kp×(e(K)-e(K-1))+Ki×e(K)+Kd(e(K-2)×e(K-1)+e(K-2)); Among them, e(K-1) is the error value input by the server at the (K-1)th sampling moment, e(K-2) is the error value input by the server at the (K-2)th sampling moment, output ( K-1) is the output of the control unit at the (K-1)th sampling time; Kp=100 is the integral coefficient of the servo end, Ki=50 is the proportional coefficient of the servo end, Kd=700 is the differential coefficient of the servo end, then the output (K) is: output (K) = output (K-1) + △ output; The measurement and data acquisition subsystem is mainly composed of laser displacement sensors, photoelectric encoding and data processing modules; the laser displacement sensors are installed on the machine tool slide box and move with the machine tool slide box, and the photoelectric encoder is located in the machine tool spindle box and synchronized The pulley is connected to the tail of the main shaft, and the data processing module is respectively connected to the laser displacement sensor and the photoelectric code; The laser displacement sensor is used to detect the radius R of the torsion shaft and transmit it to the data processing module; The photoelectric encoder is used to detect the rotation angle θ of the main shaft and transmit it to the data processing module; The data processing device calculates the received rotation angle θ and the radius R of the torsion shaft, obtains the dedendum position of the torsion shaft, and transmits it to the rolling motion control subsystem; The specific method for calculating the dedendum position of the torsion shaft is as follows: select a group (θ, R) corresponding to the tooth profile section of the torsion shaft, and record the second maximum and second minimum of R in the selected (θ, R) as R max and R _max respectively. R _min , according to the selected (θ, R) in order of θ from small to large, compare the R corresponding to θ with R _max and R _min in turn, and record the first point that falls within the range of R _min ±0.3mm as S, starting from S, find the first point that falls within the range of R _min ±0.3mm and record it as A, find the first point that exceeds the range of R _min ±0.3mm and record it as B; then the coordinates of the tooth root position are (θ _c , R _c ), where θ _c = (θ _A + θ _B )/2, where θ _A is the angle corresponding to point A, θ _B is the angle corresponding to point B, and R _c is the angle corresponding to θ _c The distance; calculate the coordinates (θ _c , R _c ) of the dedendum position of the torsion axis. 2. The control system for rolling and strengthening the torsion shaft of a heavy armored vehicle according to claim 1, wherein the rolling motion control subsystem also includes a signal adapter plate, and the signal adapter plate is a motion Signal input and output ports on the control unit. 3. The control system for rolling the torsion shaft of a heavy armored vehicle according to claim 1, wherein the rolling motion control subsystem also includes a two-stroke switch installed on the machine tool base, and the two-stroke The switches are respectively located in the positive and negative directions of the movement of the machine tool; the limit switch is used to limit the position of the machine tool. When the machine tool moves to the position of the limit switch, the limit switch generates an in-position signal and transmits it to the motion control unit. When the motion control unit receives the in-position signal, it controls the spindle servo motor to stop moving. 4. The control system for rolling the torsion shaft of the heavy armored vehicle according to claim 1, further comprising a PLC control subsystem for detecting and displaying the working state of the machine tool. 5. The control system for rolling the torsion shaft of a heavy armored vehicle according to claim 1, wherein the measurement and data acquisition subsystem also includes a magnetostrictive sensor, and the magnetostrictive sensor is installed on In the hydraulic cylinder of the rolling head of the hydraulic control system, it is used to measure the actual position of the hydraulic cylinder during processing and transmit it to the outside for display. 6. The control system for rolling and strengthening the torsion shaft of a heavy armored vehicle according to claim 1, further comprising a process database, the process database is used to store torsion shaft information, and the torsion shaft information includes torsion The batch number of the shaft, the size after processing, the amount of processing and the date of processing.

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