Design And Implementation Of Key Control Technology For HJ-400/2500A Core Cutting Line Of Transformer

Core cutting line of transformer is a special equipment for processing silicon steel sheet of transformer core, It is used for the production of transformer yoke piece, side column plate and post plate, The shearing quality will have a direct impact on the technical performance and economic index of the transformer. This project is entrusted by Zhejiang Senerge electronic equipment co., Ltd, aims to design the high efficiency automatic control system for the transformer core cutting line, based on the mechanical structure of the equipment. The control system of this production line is divided into uncoiling unit, feeding unit, punching and shearing unit, width adjusting unit, auxiliary feeding unit, separating and stacking unit, monitoring and alarm unit8parts, The control program for each unit is written as an independent module, each module called by the main program, together constitute the PLC control program.The main controller of the system is Mitsubishi FX3u-80MT/ES PLC, Siemens Smart Line1000IE industrial touch screen as human-machine interface, Both together to complete parameters setting, plate shear, operation monitoring and alarm processing and other production control tasks. The feeding, width adjustment and stacking units driven by the servo system, complete the precise feeding and positioning function. Pneumatic, hydraulic system control the action of cutting tools and material platform, complete shearing, stacking and other auxiliary actions.For the shear line, improve production efficiency and ensure cutting accuracy at the same time is a key point of the control system. Improve efficiency mainly adopts the following methods:improve the feeding speed, changing the feeding control algorithm, improve the efficiency of shearing action. Because PLC gets feedback on position information from the encoder, Substantial increase in speed, the frequency of encoder feedback pulse to PLC input port is increasing rapidly, may exceed its acceptable range, so the system is equipped with FX3u-4HSX-ADP high-speed adapter to extend the receiving frequency range of input port. Feeding device is one pair of rubber rollers with rubber surface. Lower is driving roller, driven by servo motor and precise planet reducer, upper is press roller, the press roller will be moved down owing to the pressure of a cylinder in order to ensure the smooth feeding. At the end of the fast feed, the lower roller driven by the servo motor can stop and lock, but the upper roller will have a relative motion due to inertia, so use the methods of error compensation and multi-speed to ensure the feeding accuracy.Energy conservation is an important development direction of transformer. Transformer core adopts the silicon steel sheets which with strong magnetic ability as raw materials, composed of a stacked manner, can reduce the transformer size, reduce the hysteresis loss and eddy current loss of the iron core. To further reduce no-load loss and noise of transformer core, the system adds the step iterative design (a ladder joint structure, also known as step), step laminated core laminations edge is not neatly arranged, but in a staggered step stacking arrangement, there are two step methods, namely longitudinal step and transverse step. The operator can finish the tasks of step function selection, step cycle and step size settings on the touch screen.In order to reduce the labor intensity of workers, the stacking unit also adopts servo control for precise positioning, not only can separate the different sheets, but also ensures the stacking sheets neatly.In addition, the process of the production line, the electrical structure, control programs and HMI configuration of the automatic control system are introduced. At the end of this paper, introduces debugging and commissioning processes of the control system and solutions of the problems encountered.