| With the sustained and rapid growth of China’s economy,the improvement of residents’ consumption level,and industrial policy support,the overall automotive industry in China has shown a rapid growth trend.Commercial vehicles represented by heavy trucks are means of production and labor tools,and their production,sales and ownership largely reflect the state of economic development.The key load-bearing component in the heavy-duty truck frame is the longitudinal beam,and the quality of the frame is affected by the quality of the longitudinal beam in all aspects.The U-shaped longitudinal beam has good strength,is convenient for component assembly,and the forming and subsequent processing process of the longitudinal beam is simple.Therefore,the U-shaped longitudinal beam is widely used in the frame.In order to improve the automation,production efficiency,and product quality of the heavy truck Ushaped longitudinal beam roller production line,and save labor costs,it is of great significance to study the control system of the heavy truck U-shaped longitudinal beam roller production line.This article first studies and analyzes the mechanical structure and control principle of the U-shaped longitudinal beam roller production line.Then,the control system of the roller production line is designed and optimized using Siemens PLC and SIMOTION D controller.Finally,the control system of the roller production line is debugged and tested in production.The main work completed in this article is as follows:(1)Analyzed the current domestic and international development status of roller forming technology,elaborated on the development status of PLC control technology and U-shaped longitudinal beam roller production line,and clarified the research content of roller production line control system.(2)The mechanical structure layout and production process of the entire roll production line were analyzed.The mechanical structure was divided into coil feeding section,leveling section,roller forming section,flying shear cutting section,discharge conveying section,and electromagnetic cutting section.The mechanical structure of each part of the roll production line was discussed.The mechanical structures of the roller forming and flying shear cutting parts of the U-shaped longitudinal beam roller production line were explained in detail,and the working principles of roller forming and flying shear cutting for the coil were explained.A control plan for the roller forming and flying shear cutting actions was designed.(3)The Siemens PLC and SIMOTION D controllers used in this article were explained,and combined with the production process of the U-shaped longitudinal beam roller production line,the entire roller production line control system was developed.The hardware construction of the roller production line control system was completed,and the hardware configuration of the entire control system was carried out using debugging software TIA Portal V15 and SCOUT.(4)Based on the mechanical layout and production process of the roller production line,an overall plan for the control system of the roller production line has been designed,which mainly includes coil feeding control,leveling machine leveling control,forming host control of coil rolling forming,flying shear fixed length follow-up cutting control,multi beam discharge conveying control,electromagnetic automatic cutting,and calibration and calculation of cutting coordinates.It can achieve high-speed continuous production of U-shaped longitudinal beams,Improved the production efficiency and product quality of the roll production line.(5)Production debugging and testing were conducted on the control system of the roll production line.Using INVT frequency converter to control the movement of the uncoiler and leveling machine,the uncoiling and leveling of the coil material were completed;Completed the optimization of roller forming and flying shear cutting control,achieving high-speed continuous production of U-shaped longitudinal beams of different specifications;Completed the precision test of flying shear cutting to length and conducted compensation optimization,controlling the precision of flying shear cutting to within 1mm;Realized the control of simultaneous discharge and transportation of multiple beams,improving the speed of longitudinal beam discharge and transportation;The G120 frequency converter was used to control the movement of the feeding motor,improving the feeding speed;The HMI touch screen screen screen has been optimized.The roller production line control system studied and designed in this article can meet normal production needs and can flexibly produce U-shaped longitudinal beams of different specifications and sizes.The entire production line equipment is easy to operate,and the production efficiency of each longitudinal beam is improved by about 25%.At the same time,it ensures the quality of the U-shaped longitudinal beam produced and can meet the accuracy requirements of subsequent longitudinal beam processing. |
