Design And Development Of Control System For EMU Wheels Automatic Assembly Line

With the development of China’s EMUs from "import" to "go out",our life is more and more inseparable from EMUs,and EMU technology has also been introduced from "import"to localization.Wheelset technology of EMU is one of them.However,due to the particularity of wheel and brake disc in structure and quality,the automatic assembly of EMU has not been realized in our country,and it still depends on the manual work of workers.This topic originates from the actual enterprise’s demand for intellectualization,informatization,safety and efficiency.Aiming at the problems of low efficiency,poor safety,high labor intensity and low level of informatization management in manual assembly of wheels,an automatic assembly line for motor vehicle wheels with high degree of automation and informatization is designed to meet the requirements of process and production.It realizes a series of automation processes,such as automatic feeding of wheels,bolting,pre-screwing nuts,final screwing nuts,drawing anti-loosening lines,report generation and uploading.Firstly,the overall implementation scheme of the control system is designed.On the basis of defining the task requirements of the control system,the functional requirements are analyzed,and the key technical difficulties in realizing the control system are refined.According to the task requirements,the overall implementation scheme is designed.By dividing the system into six modules,the complexity of the system is reduced and the design cycle is shortened.In addition,from the point of view of improving the stability and reliability of the system,the control scheme with iFIX as information management,PLC and other controllers as slave computers is worked out.Secondly,the key technologies of the system are studied.Aiming at the key technical difficulties of the control system,the algorithm is designed and related technologies are adopted to solve them.Including improving the reliability of the system by means of two-machine hot standby,designing relevant algorithms to realize wheel unbalance positioning,using RGB color model of the brake disc recognition algorithm to locate the brake disc,comparing the new hexagonal tightening method with the traditional diagonal tightening method,and studying the data access mode of the control system.Thirdly,the hardware and software of the control system are designed.Including the design of the monitoring system based on iFIX to realize the alarm management,monitoring,control and data management of the whole system;the design of Halcon-based visual aided system to avoid collision caused by human errors;the design of PLC-based control system to achieve signal acquisition and control of motion components.Finally,the designed control system is debugged and optimized,and the performance of the control system is tested and verified.The timing logic,stability and fault handling of the established control system are optimized to make the control system run more stably and efficiently.In addition,the operation performance of the control system is tested and verified.The results show that the system meets all the functional requirements and technical specifications,and has been put into production,which has high use value.