The equipment body is composed of a body frame, an aluminum frame back plate, an automatic material receiving device, a stepper feeding mechanism, a bending mechanism, an automatic material cutting mechanism, an electrical control system, a power control system, a control box, and a touch screen human-machine interface.

鋁條全自動(dòng)折彎?rùn)C(jī)設(shè)備組成圖

Equipment composition diagram of aluminum bar fully automatic bending machine

自動(dòng)接料裝置：由接頭定位部件和鋁條定位部件組成，當(dāng)鋁條尾部到達(dá)信號(hào)發(fā)出時(shí)，接料系統(tǒng)會(huì)自動(dòng)定位鋁條尾部，等待下一條鋁條的自動(dòng)續(xù)接。

Automatic material receiving device: composed of joint positioning components and aluminum strip positioning components. When the aluminum strip tail reaches the signal, the material receiving system will automatically locate the aluminum strip tail and wait for the automatic continuation of the next aluminum strip.

步進(jìn)給料機(jī)構(gòu)：當(dāng)控制系統(tǒng)發(fā)出步進(jìn)長(zhǎng)度信號(hào)時(shí)，由該系統(tǒng)執(zhí)行給料。

Step feeding mechanism: When the control system sends a step length signal, the system executes feeding.

折彎?rùn)C(jī)構(gòu)：折彎?rùn)C(jī)構(gòu)的折彎角度可以精確調(diào)節(jié)和控制。

Bending mechanism: The bending angle of the bending mechanism can be accurately adjusted and controlled.

自動(dòng)斷料機(jī)構(gòu)：當(dāng)初始上料或一個(gè)框折彎完成時(shí)，斷料機(jī)構(gòu)會(huì)自動(dòng)切斷鋁條。

Automatic cutting mechanism: When the initial feeding or bending of a frame is completed, the cutting mechanism will automatically cut the aluminum strip.

電氣控制系統(tǒng)：電氣控制系統(tǒng)是整個(gè)設(shè)備的核心部分，設(shè)備的控制軟件安裝在MC運(yùn)動(dòng)控制器中。所有的控制指令、運(yùn)算工作、輸入輸出信號(hào)、系統(tǒng)狀態(tài)監(jiān)視，以及與操作人員的信息交流均由該部分完成。

Electrical control system: the electrical control system is the core part of the whole equipment, and the control software of the equipment is installed in the MC motion controller. All control instructions, calculation work, input and output signals, system status monitoring, and information exchange with operators are completed by this section.

該系統(tǒng)采用松下支持RTEX總線的A6N伺服及電機(jī)。RTEX具有極高的性價(jià)比，采用RTEX總線控制系統(tǒng)后，客戶在不增加電機(jī)成本的情況下，大幅降低了配線安裝工作。100M的網(wǎng)絡(luò)帶寬和RTEX優(yōu)異的穩(wěn)定特性，確保了MC1002R與系統(tǒng)各個(gè)A6N伺服驅(qū)動(dòng)器之間的控制周期能夠達(dá)到0.5ms，從而大幅提高了客戶機(jī)器的控制精度。

The system adopts Panasonic's A6N servo and motor that supports RTEX bus. RTEX has a very high cost-effectiveness. By adopting the RTEX bus control system, customers can significantly reduce wiring installation work without increasing motor costs. The 100M network bandwidth and excellent stability characteristics of RTEX ensure that the control cycle between MC1002R and various A6N servo drivers in the system can reach 0.5ms, greatly improving the control accuracy of the customer's machine.

動(dòng)力控制系統(tǒng)：由數(shù)個(gè)氣動(dòng)電磁閥、相應(yīng)氣路、眾多氣動(dòng)元件，以及控制信號(hào)回路組成氣動(dòng)動(dòng)力系統(tǒng)，負(fù)責(zé)完成設(shè)備復(fù)雜的程控動(dòng)作。

Power control system: composed of several pneumatic solenoid valves, corresponding air circuits, numerous pneumatic components, and control signal circuits, the pneumatic power system is responsible for completing complex program control actions of the equipment.

觸摸屏軟件界面：操作人員對(duì)設(shè)備的使用、所需要的大量的數(shù)據(jù)輸入，以及操作人員需要了解的設(shè)備運(yùn)行的信息，均通過觸摸屏來完成。

Touch screen software interface: The operator's use of the device, the large amount of data input required, and the information that the operator needs to know about the device's operation are all completed through the touch screen.

鋁條折彎的工藝流程

The process flow of aluminum bar bending

設(shè)備上電后，通過觸摸屏輸入鋁框圖形參數(shù)，踩下腳踏開關(guān)設(shè)備開始運(yùn)行，控制系統(tǒng)通過判斷原料位置選擇自動(dòng)上料流程還是直接進(jìn)入自動(dòng)折彎流程，并自動(dòng)判斷當(dāng)前原料的余料接頭位置是否出現(xiàn)在禁折區(qū)。步進(jìn)給料系統(tǒng)將由控制系統(tǒng)計(jì)算后的料長(zhǎng)精確的給進(jìn)至折彎刀頭，由折彎系統(tǒng)完成需要的折彎形狀。

After the device is powered on, input the aluminum frame graphic parameters through the touch screen, press the foot switch, and the device starts running. The control system selects the automatic feeding process or directly enters the automatic bending process by judging the position of the raw materials, and automatically determines whether the remaining material joint position of the current raw materials is out of the current folding zone. The stepper feed system will accurately feed the material length calculated by the control system to the bending tool head, and the bending system will complete the required bending shape.

重復(fù)以上兩步，直至完成整個(gè)鋁框成形流程。

Repeat the above two steps until the entire aluminum frame forming process is completed.

在鋁框折彎過程中，隨時(shí)會(huì)出現(xiàn)當(dāng)前加工的鋁條即將用完的情況，通過系統(tǒng)自動(dòng)判斷可使后續(xù)鋁條自動(dòng)續(xù)接至當(dāng)前鋁條尾部，不中斷當(dāng)前鋁條的成形工作。

During the bending process of the aluminum frame, there may be situations where the currently processed aluminum bars are about to be used up. Through automatic judgment by the system, subsequent aluminum bars can be automatically connected to the tail of the current aluminum bar without interrupting the forming work of the current aluminum bar.

控制方案

Control plan

控制器選用和利時(shí)MC1002R，是專用于運(yùn)動(dòng)控制的可編程控制器，一般用作單臺(tái)復(fù)雜運(yùn)動(dòng)機(jī)械設(shè)備的控制核心。MC1002R支持RTEX總線控制系統(tǒng)，可以連接多達(dá)32軸的松下A6N伺服。

The controller uses Hollysys MC1002R, which is a programmable controller specifically designed for motion control and is generally used as the control core of a single complex motion mechanical device. MC1002R supports RTEX bus control system and can connect up to 32 axis Panasonic A6N servo.

具有高精度64位運(yùn)動(dòng)解算，雙核ARM Cortex-A9 CPU，667M主頻控制器采用ARM Cortex-A9 CPU、667M主頻；運(yùn)算采用64位雙精度浮點(diǎn)數(shù)進(jìn)行運(yùn)算，確保運(yùn)算精度。

Equipped with high-precision 64 bit motion calculation, dual core ARM Cortex-A9 CPU, 667M main frequency controller using ARM Cortex-A9 CPU and 667M main frequency; 64 bit double precision floating point number is used for operation to ensure the accuracy of operation.

運(yùn)動(dòng)控制器

Motion controller

設(shè)備由觸摸屏、MC運(yùn)動(dòng)控制器和伺服系統(tǒng)組合成一個(gè)開放式運(yùn)動(dòng)控制系統(tǒng)，根據(jù)折彎工藝要求由MC運(yùn)動(dòng)控制器對(duì)各個(gè)輸出點(diǎn)、伺服單元進(jìn)行控制，送料伺服單元收到命令后驅(qū)動(dòng)伺服電機(jī)進(jìn)行送料，實(shí)現(xiàn)鋁條折彎?rùn)C(jī)的運(yùn)動(dòng)控制和邏輯控制?？刂屏鞒倘缦聢D：

The equipment is composed of touch screen, MC motion controller and servo system to form an open motion control system. According to the bending process requirements, MC motion controller controls each output point and servo unit. After receiving the command, the feeding servo unit drives the servo motor to feed, realizing the motion control and logic control of the aluminum bar bending machine. The control process is shown in the following figure:

控制流程圖

Control flowchart

實(shí)現(xiàn)的功能及效果

Implemented functions and effects

經(jīng)過實(shí)際運(yùn)行效果得出，此控制系統(tǒng)實(shí)現(xiàn)的功能如下：

After actual operation, it can be concluded that the functions implemented by this control system are as follows:

彎角速度自動(dòng)調(diào)節(jié)

Automatic adjustment of bending speed

鋁條自動(dòng)連接，矩形框接頭智能避讓

Automatic connection of aluminum strips, intelligent avoidance of rectangular frame joints

有獨(dú)特的自動(dòng)接料裝置，接料工作穩(wěn)定，對(duì)連續(xù)工作無任何影響；

Equipped with a unique automatic material receiving device, the material receiving work is stable and has no impact on continuous operation;

自動(dòng)斷料，斷口毛刺微小且易清除，不影響下道工序和美觀

Automatic cutting, small and easy to remove burrs on the fracture surface, without affecting the next process and aesthetics

加熱功能，可以用于暖邊條折彎，且暖邊折彎每個(gè)折彎角部采用獨(dú)立的加熱控制，保證折彎質(zhì)量；

The heating function can be used for bending the warm edge strip, and each bending corner of the warm edge bending adopts independent heating control to ensure the bending quality;

打孔功能，打孔配置可在折彎時(shí)在間隔框上加工充氣孔,用以中空玻璃加工完畢后人工充氬氣工作；

Punching function, punching configuration can process filling holes on the spacing frame during bending, used for manual argon filling work after the processing of hollow glass is completed;