Research And Design Of Forging Manipulator Control System

With the continuous promotion of "Made in China 2025",China’s demand for high-quality and high-precision large forgings in nuclear power,aerospace,rail transportation and other industries is increasing,putting forward more stringent requirements on forging processing efficiency and forging precision.The forging manipulator is an indispensable piece of forging equipment in the forging production line.It works inline with the forging press to achieve different forging processes and plays a key role in effectively improving the automation of forging production and the quality of forged parts.Based on the background of a forging factory,aiming for low control accuracy and relatively backward automation level of the traditional forging manipulator control system,the control system of 5T forging manipulator is researched and designed.Firstly,this thesis describes the structure and process flow of the forging manipulator control system,analyzes the principle of the hydraulic system of the forging manipulator,and determines the control scheme of controlled objects;Aiming at the characteristics of the forging manipulator with many control objects and long distance,the distributed I/O control scheme based on PROFINET field bus is adopted,and the overall architecture of the forging manipulator control system consisting of monitoring layer,control layer,and equipment layer is designed.Secondly,in order to solve the problem of the large inertia of the forging manipulator and the existence of phase lag in the electro-hydraulic servo system,which leads to its low accuracy of axial feeding and positioning,the corresponding mathematical model is established by analyzing the large carriage travel mechanism of the forging manipulator,and the control strategy based on RBF neural network to adjust the PID parameters is determined.And the control algorithm based on RBF-PID is built by MATLAB and analyzed with the established transfer function of the large carriage travel mechanism of the forging manipulator.The results show that the control method has certain advantages in reducing overshoot,adjustment time,and oscillation mitigation,and improves the robustness and control accuracy of the system.Thirdly,the lower computer design is based on the overall architecture of the forging manipulator control system.Through the comprehensive analysis of the forging manipulator control system,the hardware part selected S7-1200 series PLC as the master controller and ET200 SP as the distributed slave station,and used the PROFINET field bus to communicate with each layer to realize the data interaction of the whole system,and completes the selection of field equipment and the electrical design of the system;According to the system control requirements,the software part used TIA Portal platform for hardware configuration and program design of the system.Finally,the system upper computer monitoring function is analyzed,and the upper computer of the forging manipulator control system is designed using TIA Portal WINCC,and the process interface including system conditions and hydraulic system monitoring is designed to realize the real-time monitoring of the process;Through the field debugging of the forging manipulator control system functions and communication,thus verifying that the system can meet the design requirements and realize the intelligent control of the forging manipulator control system.