More Than 10,000 Tons Forging Hydraulic Press Manufacturing Operations Self-learning Control Systems

With the constant development of the spaceflight project and the requirement of the modernization of national defense, the higher precision and larger tonnage hydraulic press machine of our country have been put forward higher to the control level. The ten-thousand-ton multi-ram die-forging water press machine is a key machine to machining kinds of spaceflight equipments and military establishments. While the rebuilding of the operating and controlling system of the ten-thousand-ton multi-ram die-forging water press machine, a stable and reliable unmanned automatic control system is necessary to be designed, which can keep operators from doing the same thing all the time, make sure higher product quality and meet the practical production requirements. So the research meaning of the unmanned automatic control system is very enormous.The network structure including an industrial control computer, a programmable logic controller (PLC) and some field instrumentations is the base of this paper. The target of this paper is to achieve unmanned automatic control of the ten-thousand-ton multi-ram die-forging water press machine production process and finally improve the yield and quality of products though adopting appropriate control strategies and control algorithm. The main research contents are as following:1. The structural components of the ten-thousand-ton multi-ram die-forging water press machine control system are studied. The working principle of the ten-thousand-ton multi-ram die-forging water press machine and the control mechanism of the distributors are clarified. The control signals of the ten-thousand-ton multi-ram die-forging water press machine are analyzed carefully in this paper.2. The programme of the production operation self-learning control system for the ten-thousand-ton multi-ram die-forging water press machine is discussed in this paper. According to the hardware, software and the actual production process of the water press machine, the self-learning method that by extracting operating characteristics to accurately describe the practical production process of the ten-thousand-ton multi-ram die-forging water press machine is determined. The way to realize unmanned automatic production is given as well.3. The operating characteristics of the ten-thousand-ton multi-ram die-forging water press machine production process are accurately extracted by modular programming under the configuration software STEP7 V5.2 development environment.4. Under the configuration software WinCC 6.0 development environment, the processing algorithms of the operating characteristics, the function of extracting operational knowledge accurately and the data communication between the upper computer and PLC during the process of unmanned automatic production are realized by software design in the upper computer. In order to help operators finish the self-learning process, to get the correct operational knowledge and to realize the unmanned automatic operation of the ten-thousand-ton multi-ram die-forging water press machine, the friendly HMI screen is designed.