Research On Cold Roll Forming System Of Color Metal Glazed Tile Based On Virtual Reality Technology

Due to its beautiful shape, compact structure, long lifespan and other advantages,color meatl glazed tile has been widely used in construction industry, glazed tile generally use cold roll forming method for production, which is energy saving, material saving and high efficiency. But cold roll forming laws has not yet fully been mastered,there are quality defects such as crack, spring-back during the cold roll forming. The control strategy of glazed tile forming is simple, and the dimensional accuracy of processed workpiece is low. The time of designing machine is long, and debugging and modification is tedious. Because of the above reasons, the promotion of glazed tile has been limited.In order to solve the problem mentioned above, virtual reality technology was used,the rolls forming system and control system were devised. The shape precision and dimensional precision of processed workpiece was increased and the design and debug time were reduced by virtual machine real electric simulation and verified through experiments. There is a great significance and application value whether to further understand the laws of cold roll forming and increase productivity, or to try the virtual reality new way to solve the cold roll forming problems.Firstly, the reason for quality defects such as crack, spring-back, including material strain exceeds the allowable strain, elastic plastic deformation and the severe changes of edge strain were analyzed. The effect of the passes, over bending angle and shaping angle distribution on the shape precision were studied based on the geometrical and material properties of glazed tile. According to reasons of the defects, the rolls mechanism and the punching mechanism were designed. The roll forming process and punching process simulation have been simulated by using Abaqus finite element software. Optimization methods such as adding importing rolls and enlarging excessive bending angle were made to increase the shape precision.Secondly, the factors that cause dimensional error were found, including motor acceleration and deceleration distance, accumulation of punching and cutting error and the distance between the punching mechanism and shearing mechanism. The two stage break strategy and the method of adjusting the distance between the punchingmechanism and shearing mechanism solutions were found to increased the dimensional accuracy of the glazed tile. According to the process of the glazed tile production, the control system of the glazed tile cold roll forming was set up. Based on the virtual reality technology, the virtual machine real electric module was built. The control system platform and the module of the glazed tile cold roll forming machine were built.The simulation of the control system platform controlling the virtual machine was made by joint debugging among Matlab/Simulink, ADAMS and PLC, the control system parameters were found, which increased the dimensional accuracy of the glazed tile.The debug scheme were determined, which reduced the debugging time of the real machine and improving the design efficiency.Finally, the verification experiments were implemented. Take the finite element simulation optimized rolls as the rolls of the real machine, the control system made by virtual machine real electric simulation as the control system of the real machine, glazed tile experiments were processed on the cold roll machine. The rolls’ forming scheme were proved reasonable by analyzing shape precision of the processed glazed tile, the control system’s dimensional accuracy were met the standard, the debugging time were greatly reduced, which demonstrated that the virtual reality technology had improve the design efficiency.