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CN-122007304-A - Cold heading forming machine and automatic control method thereof

CN122007304ACN 122007304 ACN122007304 ACN 122007304ACN-122007304-A

Abstract

The invention relates to the technical field of cold heading machines, and provides a cold heading forming machine and an automatic control method thereof, wherein the method comprises the steps of synchronously collecting material characteristic parameters, equipment operation parameters and forming quality parameters in the cold heading forming process, and preprocessing collected original parameter data; the method comprises the steps of carrying out real-time analysis on the preprocessed parameter data, identifying the current material adaptability working condition, the equipment operation health working condition and the forming quality standard working condition, outputting a parameter adjustment instruction based on the current material adaptability working condition or outputting a fault early warning instruction based on the equipment operation health working condition, and regulating the feeding speed of a feeding driving mechanism, the cold heading pressure, the stroke frequency and the die closing gap of a cold heading forming driving mechanism in real time based on the parameter adjustment instruction to realize closed-loop self-adaptive control of the forming process. The invention can realize accurate collaborative identification and judgment of multidimensional working conditions, and is beneficial to improving the quality stability and qualification rate of products.

Inventors

  • FANG GUOJIAN

Assignees

  • 佛山市桥亿汽车零部件有限公司

Dates

Publication Date
20260512
Application Date
20260206

Claims (10)

  1. 1. The utility model provides a cold-heading forming machine, includes feeding actuating mechanism and cold-heading forming actuating mechanism, its characterized in that, cold-heading forming machine still includes: The multi-dimensional parameter acquisition module is used for synchronously acquiring material characteristic parameters, equipment operation parameters and forming quality parameters in the cold heading forming process, preprocessing the acquired original parameter data and transmitting the preprocessed data to the edge calculation module; The edge calculation module is used for analyzing the preprocessed parameter data in real time, identifying the current material suitability working condition, the equipment operation health working condition and the forming quality standard working condition, and outputting a parameter adjustment instruction based on the current material suitability working condition or outputting a fault early warning instruction based on the equipment operation health working condition; The main controller is used for adjusting the feeding speed of the feeding driving mechanism, the cold heading pressure, the stroke frequency and the die closing gap of the cold heading forming driving mechanism in real time based on the parameter adjustment instruction, so as to realize closed-loop self-adaptive control of the forming process; The feeding driving mechanism and the cold heading forming driving mechanism are respectively and electrically connected with the main controller, the multidimensional parameter acquisition module is electrically connected with the edge calculation module, and the edge calculation module is electrically connected with the main controller in a bidirectional manner.
  2. 2. A cold header as defined in claim 1, the cold heading forming machine is characterized by further comprising: The remote operation and maintenance platform is used for receiving, storing and processing the working condition information, the parameter adjustment information and the fault early warning information processed by the edge calculation module, and realizing remote monitoring and predictive maintenance of equipment.
  3. 3. A cold header as defined in claim 2, the cold heading forming machine is characterized by further comprising: And the communication module of the Internet of things adopts a 5G industrial module or WiFi-6 communication protocol and is used for realizing data bidirectional interaction between the edge computing module and the remote operation and maintenance platform.
  4. 4. The cold header of claim 3, wherein said edge calculation module comprises: the strain hardening term acquisition unit is used for acquiring real-time strain rate, plastic strain and strain rate reference values of the material, and acquiring a strain hardening term used for representing the hardening effect of the material according to the real-time strain rate, the plastic strain and the strain rate reference values; the heat softening item acquisition unit is used for acquiring the real-time temperature of the die and the real-time temperature of the material, acquiring a die temperature difference value according to the die real-time temperature and the real-time temperature of the material, and acquiring a heat softening item for representing a heat softening effect according to the die temperature difference value; the micro damage item acquisition unit is used for acquiring an acoustic emission root mean square signal and acquiring a micro damage item for quantifying the damage degree of the material according to the acoustic emission root mean square signal; And the adaptive working condition acquisition unit is used for acquiring real-time deformation resistance according to the strain hardening item, the heat softening item and the microscopic damage item and identifying the current material adaptive working condition according to the real-time deformation resistance.
  5. 5. The cold header as set forth in claim 4, wherein said microscopic damage item obtaining unit includes: The threshold value judging subunit is used for acquiring an acoustic emission saturation threshold value and an acoustic emission damage threshold value and judging whether the acoustic emission root mean square signal is larger than the acoustic emission damage threshold value and smaller than the acoustic emission saturation threshold value; The softening factor obtaining subunit is used for obtaining a microscopic damage softening factor for characterizing the resistance softening proportion caused by microscopic damage according to the acoustic emission damage difference value between the acoustic emission root mean square signal and the acoustic emission damage threshold value; and the micro damage acquisition subunit is used for acquiring micro damage items according to the micro damage softening factors.
  6. 6. An automatic control method of a cold header forming machine, applied to the cold header forming machine according to any one of claims 1 to 5, characterized in that the automatic control method of the cold header forming machine comprises the following steps: Synchronously collecting material characteristic parameters, equipment operation parameters and forming quality parameters in the cold heading forming process, and preprocessing collected original parameter data; The preprocessed parameter data are analyzed in real time, the current material adaptability working condition, the equipment operation health working condition and the forming quality standard working condition are identified, and a parameter adjustment instruction is output based on the current material adaptability working condition or a fault early warning instruction is output based on the equipment operation health working condition; Based on the parameter adjustment instruction, the feeding speed of the feeding driving mechanism, the cold heading pressure, the stroke frequency and the die closing gap of the cold heading forming driving mechanism are adjusted in real time, and closed-loop self-adaptive control of the forming process is realized.
  7. 7. The automatic control method of a cold header forming machine according to claim 6, wherein the automatic control method of the cold header forming machine comprises the steps of: The working condition information, the parameter adjustment information and the fault early warning information processed by the edge calculation module are uploaded to the remote operation and maintenance platform in real time through the communication module of the Internet of things, and meanwhile, a parameter configuration instruction or a model updating instruction issued by the remote operation and maintenance platform is received; The remote operation and maintenance platform receives, stores and transmits the working condition information, the parameter adjustment information and the fault early warning information processed by the edge calculation module, and issues a parameter configuration instruction and a model updating instruction to realize remote monitoring and predictive maintenance of equipment.
  8. 8. The automatic control method of cold header forming machine according to claim 7, wherein the specific method for analyzing the preprocessed parameter data in real time comprises the steps of: Acquiring a real-time strain rate, plastic strain and a strain rate reference value of the material, and acquiring a strain hardening term for representing a hardening effect of the material according to the real-time strain rate, the plastic strain and the strain rate reference value; Acquiring a real-time temperature of a mold and a real-time temperature of a material, acquiring a mold temperature difference value according to the real-time temperature of the mold and the real-time temperature of the material, and acquiring a heat softening item for representing a heat softening effect according to the mold temperature difference value; Acquiring an acoustic emission root mean square signal, and acquiring a microscopic damage item for quantifying the damage degree of the material according to the acoustic emission root mean square signal; and acquiring real-time deformation resistance according to the strain hardening item, the heat softening item and the microscopic damage item, and identifying the current material suitability working condition according to the real-time deformation resistance.
  9. 9. The automatic control method of a cold header forming machine according to claim 8, wherein the specific method for taking the microscopic damage item comprises the following steps: Acquiring an acoustic emission saturation threshold value and an acoustic emission damage threshold value, and judging whether an acoustic emission root mean square signal is larger than the acoustic emission damage threshold value and smaller than the acoustic emission saturation threshold value; If yes, acquiring a microscopic damage softening factor for characterizing the resistance softening proportion caused by the microscopic damage according to the acoustic emission damage difference value between the acoustic emission root mean square signal and the acoustic emission damage threshold; And obtaining a microscopic damage item according to the microscopic damage softening factor.
  10. 10. The automatic control method of a cold header forming machine according to claim 9, wherein the specific method of outputting the parameter adjustment command comprises the steps of: Acquiring the total driving power of the system and the yield of qualified products in unit time, and acquiring an energy consumption economic item for quantifying the comprehensive energy consumption of a single product according to the total driving power of the system and the yield of qualified products in unit time; acquiring 3D point cloud of an ideal product and 3D scanning data of an actual product, calculating a structural similarity index according to the 3D point cloud of the ideal product and the 3D scanning data of the actual product, and acquiring a quality loss item for evaluating the quality of the product according to the structural similarity index; Acquiring single theoretical processing time and a product size deviation value, and acquiring an efficiency penalty term for evaluating production efficiency according to the single theoretical processing time and the product size deviation value; And constructing a multi-objective optimization function according to the energy consumption economic term, the quality loss term and the efficiency penalty term, and acquiring a parameter adjustment instruction according to the multi-objective optimization function.

Description

Cold heading forming machine and automatic control method thereof Technical Field The invention relates to the technical field of cold heading machines, in particular to a cold heading forming machine and an automatic control method thereof. Background The cold header is a special device mainly used for heading and specially used for mass production of fasteners such as nuts, bolts and the like, is an important stamping processing device in the field of machine manufacturing, and mainly aims to shape raw materials (such as metal wires) into a specific shape, and the working principle of the cold header in a step shape is that the cold header is molded by mechanical force under the condition of not changing the properties (such as softening and hardening treatment) of the raw materials. At present, the automatic control technology of the existing cold heading forming machine has preliminarily realized mechanized linkage of processes such as feeding, cold heading, discharging and the like, mainly relies on a Programmable Logic Controller (PLC) as a core control unit, and is matched with a simple sensor (such as a pressure sensor and a displacement sensor) to realize acquisition and closed-loop control of basic parameters. For example, chinese patent No. CN208787459U discloses a multi-station cold header feeding device, detection signals of a feeding detection sensor are input to a PLC control system, the PLC control system outputs motor starting signals to automatically control the feeding length, chinese patent No. CN117282900A discloses a high-precision cold header, a plurality of electric telescopic cylinders are designed to produce high-strength hardness products, and the high-precision cold header is matched with a pressure sensor and an alarm, so that automatic alarming can be carried out when a machine fails, an automatic feeding port is carried out through an adjusting device, and a feeding size device is adjusted, so that the precision and hardness of the products can reach the expected standards at the same time. The prior art only monitors and controls single parameters (such as pressure, displacement and the like), and can not synchronously identify three core working conditions of material suitability, equipment operation health state and molding quality standard condition, and the problem of lacking multidimensional collaborative judgment capability exists. Disclosure of Invention Based on the above, in order to improve the multi-dimensional collaborative judgment capability of the cold header, the invention provides a cold header forming machine and an automatic control method thereof, and the specific technical scheme is as follows: the cold heading forming machine comprises a feeding driving mechanism and a cold heading forming driving mechanism, and further comprises: The multi-dimensional parameter acquisition module is used for synchronously acquiring material characteristic parameters, equipment operation parameters and forming quality parameters in the cold heading forming process, preprocessing the acquired original parameter data and transmitting the preprocessed data to the edge calculation module; The edge calculation module is used for analyzing the preprocessed parameter data in real time, identifying the current material suitability working condition, the equipment operation health working condition and the forming quality standard working condition, and outputting a parameter adjustment instruction based on the current material suitability working condition or outputting a fault early warning instruction based on the equipment operation health working condition; The main controller is used for adjusting the feeding speed of the feeding driving mechanism, the cold heading pressure, the stroke frequency and the die closing gap of the cold heading forming driving mechanism in real time based on the parameter adjustment instruction, so as to realize closed-loop self-adaptive control of the forming process; The feeding driving mechanism and the cold heading forming driving mechanism are respectively and electrically connected with the main controller, the multidimensional parameter acquisition module is electrically connected with the edge calculation module, and the edge calculation module is electrically connected with the main controller in a bidirectional manner. The cold heading forming machine synchronously collects three core parameters of material characteristics, equipment operation and forming quality through the multidimensional parameter collecting module, and breaks through the defect that only single parameter monitoring and working condition identification are on one side in the prior art. Specifically, the suitability of materials and technological parameters can be accurately judged through the acquisition and analysis of the characteristic parameters (such as hardness, diameter deviation and the like) of the materials, forming defects caused by batch fluctuation of t