| The fan blade is a core component of household electrical appliance industry air supply system, which is made of plastic. With the industrial production becomes evermore large-scale, sophisticated and efficiency-oriented, the plastic welding equipment develops from artificial to full automation and digitalization. Thanks to its advantages including high efficiency, no filler material and easy automation, ultrasonic plastic welding is widely applied in processing thermoplastic plastics and composites materials. The aim of this research is focus on the control system in cross-flow fan blades full automation ultrasonic welding production line, which combines the mechanical device with the electric control device by related hardware and software, through the ultrasonic plastic welding technology.Starting with automation of the plastic welding production line, this paper analyzed the main quality affecting factors and the processing characteristics of welding forming. Based on the requirement of the above research and the design idea of macaronis system, the full automation welding equipment is divided into four subsystems, including parts automatic feeding subsystem, parts welding feeding subsystem, ultrasonic plastic welding subsystem and the finished products automatic moving subsystem.The parts automatic feeding subsystem orderly moves a lot of parts to the specified location in right form.The parts welding feeding subsystem deliveries the work-pieces to welding position according to the welding order. The ultrasonic plastic welding subsystem automatically welds the parts, and the finished products automatic removing subsystem takes out the finished product to the specified location or the next station through conveyor belt. The programmable logical controller is the core of the direct digital control system, it receives the sensor signal, feedback signal, and manual-input signal. After that, it outputs computed signal in order to control the running of system. In addition, to ensure all sub-systems work in order, it separately compiles all function module programs in the FWIN platform by modular design thinking.The above research made it into reality that the welding processing of cross-flow fan blades working automatically. And it is a breakthrough that changes the ultrasonic welding technology from semi-automatically to full automatically and improves labor productivity and product quality and reduces production costs. First, in this research, the weld formation took an average of 2 minutes and 40 seconds. The product qualification rate increased 4.5% reaching 96%. Second, one can operate a plurality of automatic welding equipment at the same time, making the labor cost reduced by 2/3. Moreover, by changing the program of control system and the corresponding mechanical structure, the production line can be applied to other types of fan blade welding in this field. |
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