全自動(dòng)鋁條折彎?rùn)C(jī)歸屬于玻璃加工行業(yè)，主要用于真空玻璃外側(cè)密封鋁條的生產(chǎn)。近年來(lái)隨著對(duì)建筑環(huán)保要求的提高，中空玻璃市場(chǎng)需求不斷擴(kuò)大。

The fully automatic aluminum strip bending machine belongs to the glass processing industry and is mainly used for the production of vacuum sealed aluminum strips on the outside of glass. In recent years, with the increasing demand for building environmental protection, the demand for insulated glass in the market has continued to expand.

本文分析了鋁條折彎?rùn)C(jī)設(shè)備組成和工藝流程，構(gòu)建以和利時(shí)MC運(yùn)動(dòng)控制器+RTEX總線系統(tǒng)+松下A6N交流伺服系統(tǒng)為核心的鋁條全自動(dòng)折彎?rùn)C(jī)控制系統(tǒng)，實(shí)現(xiàn)上料、接料、進(jìn)給、折彎等全過(guò)程的自動(dòng)化生產(chǎn)，提高了生產(chǎn)效率和折彎質(zhì)量。

This article analyzes the composition and process flow of aluminum strip bending machine equipment, and constructs a fully automatic aluminum strip bending machine control system with the core of Hollysys MC motion controller+RTEX bus system+Panasonic A6N AC servo system, realizing the automation of the entire process of feeding, receiving, feeding, bending, etc., improving production efficiency and bending quality.

關(guān)鍵詞：折彎?rùn)C(jī)、MC運(yùn)動(dòng)控制器、RTEX總線、中空玻璃

Keywords: bending machine, MC motion controller, RTEX bus, insulated glass

國(guó)內(nèi)出眾鋁條折彎?rùn)C(jī)市場(chǎng)一直都被國(guó)外品牌所壟斷，國(guó)內(nèi)鋁條的加工主要以手動(dòng)折彎和鋁條拼接方式為主。手動(dòng)折彎存在鋁條剛度差、四角漏氣、生產(chǎn)效率低下等問(wèn)題，使用的折彎?rùn)C(jī)存在鋁條精度不足、折角不美觀等問(wèn)題。因此，鋁條自動(dòng)折彎?rùn)C(jī)的國(guó)產(chǎn)化，尤其是控制系統(tǒng)國(guó)產(chǎn)化已迫在眉睫。

The domestic high-end aluminum strip bending machine market has always been monopolized by foreign brands, and the processing of aluminum strips in China mainly relies on manual bending and aluminum strip splicing methods. Manual bending has problems such as poor rigidity of aluminum bars, air leakage at the four corners, and low production efficiency. The bending machine used has problems such as insufficient accuracy of aluminum bars and unsightly bending angles. Therefore, the localization of aluminum strip automatic bending machines, especially the localization of control systems, is urgently needed.

設(shè)備組成與工藝流程

Equipment composition and process flow

鋁條折彎?rùn)C(jī)的設(shè)備組成：

Equipment composition of aluminum strip bending machine:

該設(shè)備本體由機(jī)身機(jī)架、鋁框背板、自動(dòng)接料裝置、步進(jìn)給料機(jī)構(gòu)、折彎?rùn)C(jī)構(gòu)、自動(dòng)斷料機(jī)構(gòu)、電氣控制系統(tǒng)、動(dòng)力控制系統(tǒng)、控制箱及觸摸屏人機(jī)界面等結(jié)構(gòu)組成。

The device body consists of a body frame, an aluminum frame backplate, an automatic feeding device, a stepper feeding mechanism, a bending mechanism, an automatic cutting mechanism, an electrical control system, a power control system, a control box, and a touch screen human-machine interface.

鋁條全自動(dòng)折彎?rùn)C(jī)設(shè)備組成圖

Composition diagram of aluminum bar fully automatic bending machine equipment

自動(dòng)接料裝置：

Automatic feeding device:

由接頭定位部件和鋁條定位部件組成，當(dāng)鋁條尾部到達(dá)信號(hào)發(fā)出時(shí)，接料系統(tǒng)會(huì)自動(dòng)定位鋁條尾部，等待下一條鋁條的自動(dòng)續(xù)接。

Composed of joint positioning components and aluminum strip positioning components, when the signal is sent out at the tail of the aluminum strip, the feeding system will automatically locate the tail of the aluminum strip and wait for the automatic continuation of the next aluminum strip.

步進(jìn)給料機(jī)構(gòu)：當(dāng)控制系統(tǒng)發(fā)出步進(jìn)長(zhǎng)度信號(hào)時(shí)，由該系統(tǒng)執(zhí)行給料。

Step feeding mechanism: When the control system sends a step length signal, the feeding is executed by the system.

折彎?rùn)C(jī)構(gòu)：折彎?rùn)C(jī)構(gòu)的折彎角度可以準(zhǔn)確調(diào)節(jié)和控制。

Bending mechanism: The bending angle of the bending mechanism can be precisely adjusted and controlled.

自動(dòng)斷料機(jī)構(gòu)：

Automatic cutting mechanism:

當(dāng)初始上料或一個(gè)框折彎完成時(shí)，斷料機(jī)構(gòu)會(huì)自動(dòng)切斷鋁條。

When the initial loading or bending of a frame is completed, the cutting mechanism will automatically cut off the aluminum strip.

自動(dòng)斷料機(jī)構(gòu)：

Automatic cutting mechanism:

當(dāng)初始上料或一個(gè)框折彎完成時(shí)，斷料機(jī)構(gòu)會(huì)自動(dòng)切斷鋁條。

When the initial loading or bending of a frame is completed, the cutting mechanism will automatically cut off the aluminum strip.

電氣控制系統(tǒng)：

Electrical control system:

電氣控制系統(tǒng)是整個(gè)設(shè)備的核心部分，設(shè)備的控制軟件安裝在MC運(yùn)動(dòng)控制器中。所有的控制指令、運(yùn)算工作、輸入輸出信號(hào)、系統(tǒng)狀態(tài)監(jiān)視，以及與操作人員的信息交流均由該部分完成。

The electrical control system is the core part of the entire equipment, and the control software of the equipment is installed in the MC motion controller. All control instructions, computational work, input/output signals, system status monitoring, and information exchange with operators are completed by this section.

該系統(tǒng)采用松下支持RTEX總線的A6N伺服及電機(jī)。RTEX具有出眾的性?xún)r(jià)比，采用RTEX總線控制系統(tǒng)后，客戶(hù)在不增加電機(jī)成本的情況下，大幅降低了配線安裝工作。100M的網(wǎng)絡(luò)帶寬和RTEX優(yōu)異的穩(wěn)定特性，確保了MC1002R與系統(tǒng)各個(gè)A6N伺服驅(qū)動(dòng)器之間的控制周期能夠達(dá)到0.5ms，從而大幅提高了客戶(hù)機(jī)器的控制精度。

The system adopts Panasonic's A6N servo and motor that supports RTEX bus. RTEX has a high cost performance ratio. By adopting the RTEX bus control system, customers can significantly reduce wiring and installation work without increasing motor costs. The 100M network bandwidth and excellent stability of RTEX ensure that the control cycle between MC1002R and various A6N servo drives in the system can reach 0.5ms, greatly improving the control accuracy of customer machines.

動(dòng)力控制系統(tǒng)：

Power control system:

由數(shù)個(gè)氣動(dòng)電磁閥、相應(yīng)氣路、眾多氣動(dòng)元件，以及控制信號(hào)回路組成氣動(dòng)動(dòng)力系統(tǒng)，負(fù)責(zé)完成設(shè)備復(fù)雜的程控動(dòng)作。

The pneumatic power system consists of several pneumatic solenoid valves, corresponding pneumatic circuits, numerous pneumatic components, and control signal circuits, responsible for completing complex programmable actions of the equipment.

觸摸屏軟件界面：

Touch screen software interface:

操作人員對(duì)設(shè)備的使用、所需要的大量的數(shù)據(jù)輸入，以及操作人員需要了解的設(shè)備運(yùn)行的信息，均通過(guò)觸摸屏來(lái)完成。

The use of equipment by operators, the large amount of data input required, and the information about equipment operation that operators need to know are all completed through touch screens.

鋁條折彎的工藝流程

Process flow of aluminum strip bending

設(shè)備上電后，通過(guò)觸摸屏輸入鋁框圖形參數(shù)，踩下腳踏開(kāi)關(guān)設(shè)備開(kāi)始運(yùn)行，控制系統(tǒng)通過(guò)判斷原料位置選擇自動(dòng)上料流程還是直接進(jìn)入自動(dòng)折彎流程，并自動(dòng)判斷當(dāng)前原料的余料接頭位置是否出現(xiàn)在禁折區(qū)。步進(jìn)給料系統(tǒng)將由控制系統(tǒng)計(jì)算后的料長(zhǎng)準(zhǔn)確的給進(jìn)至折彎刀頭，由折彎系統(tǒng)完成需要的折彎形狀。

After the device is powered on, the aluminum frame graphic parameters are input through the touch screen, and the foot switch is pressed to start running. The control system determines whether the raw material position selects the automatic feeding process or directly enters the automatic bending process, and automatically judges whether the current position of the remaining material joint is outside the prohibited bending zone. The step feed material system will accurately feed the material length calculated by the control system to the bending tool head, and the bending system will complete the required bending shape.

重復(fù)以上兩步，直至完成整個(gè)鋁框成形流程。

Repeat the above two steps until the entire aluminum frame forming process is completed.

在鋁框折彎過(guò)程中，隨時(shí)會(huì)出現(xiàn)當(dāng)前加工的鋁條即將用完的情況，通過(guò)系統(tǒng)自動(dòng)判斷可使后續(xù)鋁條自動(dòng)續(xù)接至當(dāng)前鋁條尾部，不中斷當(dāng)前鋁條的成形工作。

During the bending process of the aluminum frame, there may be a situation where the currently processed aluminum strip is about to run out at any time. Through the system's automatic judgment, subsequent aluminum strips can be automatically connected to the tail of the current aluminum strip without interrupting the forming work of the current aluminum strip.

控制方案

Control scheme

控制器選用和利時(shí)MC1002R，是專(zhuān)用于運(yùn)動(dòng)控制的可編程控制器，一般用作單臺(tái)復(fù)雜運(yùn)動(dòng)機(jī)械設(shè)備的控制核心。MC1002R支持RTEX總線控制系統(tǒng)，可以連接多達(dá)32軸的松下A6N伺服。

The controller selected is the Hollysys MC1002R, which is a programmable controller specifically designed for motion control and is generally used as the control core for a single complex motion mechanical equipment. MC1002R supports RTEX bus control system and can connect up to 32 axes of Panasonic A6N servo.

MC具有高精度64位運(yùn)動(dòng)解算，雙核ARM Cortex-A9 CPU，667M主頻控制器采用ARM Cortex-A9 CPU、667M主頻；運(yùn)算采用64位雙精度浮點(diǎn)數(shù)進(jìn)行運(yùn)算，確保運(yùn)算精度。

MC has high-precision 64 bit motion calculation, dual core ARM Cortex-A9 CPU, and a 667M main frequency controller using ARM Cortex-A9 CPU and 667M main frequency; The operation is performed using 64 bit double precision floating-point numbers to ensure accuracy.