全自動鋁條折彎機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)。近年來隨著對建筑要求的提高，中空玻璃市場需求不斷擴大。

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機設備組成和工藝流程，構(gòu)建以和利時MC運動控制器+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折彎機控制系統(tǒng)，實現(xiàn)上料、接料、進給、折彎等全過程的自動化生產(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：折彎機、MC運動控制器、RTEX總線、中空玻璃

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

國內(nèi)高端鋁條折彎機市場一直都被國外所壟斷，國內(nèi)鋁條的加工主要以手動折彎和鋁條拼接方式為主。手動折彎存在鋁條剛度差、四角漏氣、生產(chǎn)效率低下等問題，使用的折彎機存在鋁條精度不足、折角不美觀等問題。因此，鋁條自動折彎機的國產(chǎn)化，尤其是控制系統(tǒng)國產(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.

設備組成與工藝流程

Equipment composition and process flow

鋁條折彎機的設備組成：

Equipment composition of aluminum strip bending machine:

該設備本體由機身機架、鋁框背板、自動接料裝置、步進給料機構(gòu)、折彎機構(gòu)、自動斷料機構(gòu)、電氣控制系統(tǒng)、動力控制系統(tǒng)、控制箱及觸摸屏人機界面等結(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.

鋁條全自動折彎機設備組成圖

Composition diagram of aluminum bar fully automatic bending machine equipment

自動接料裝置：

Automatic feeding device:

由接頭定位部件和鋁條定位部件組成，當鋁條尾部到達信號發(fā)出時，接料系統(tǒng)會自動定位鋁條尾部，等待下一條鋁條的自動續(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.

步進給料機構(gòu)：當控制系統(tǒng)發(fā)出步進長度信號時，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.

折彎機構(gòu)：折彎機構(gòu)的折彎角度可以精確調(diào)節(jié)和控制。

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

自動斷料機構(gòu)：

Automatic cutting mechanism:

當初始上料或一個框折彎完成時，斷料機構(gòu)會自動切斷鋁條。

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

自動斷料機構(gòu)：

Automatic cutting mechanism:

當初始上料或一個框折彎完成時，斷料機構(gòu)會自動切斷鋁條。

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)是整個設備的核心部分，設備的控制軟件安裝在MC運動控制器中。所有的控制指令、運算工作、輸入輸出信號、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。RTEX具有極高的性價比，采用RTEX總線控制系統(tǒng)后，客戶在不增加電機成本的情況下，大幅降低了配線安裝工作。100M的網(wǎng)絡帶寬和RTEX優(yōu)異的穩(wěn)定特性，確保了MC1002R與系統(tǒng)各個A6N伺服驅(qū)動器之間的控制周期能夠達到0.5ms，從而大幅提高了客戶機器的控制精度。

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.

動力控制系統(tǒng)：

Power control system:

由數(shù)個氣動電磁閥、相應氣路、眾多氣動元件，以及控制信號回路組成氣動動力系統(tǒng)，負責完成設備復雜的程控動作。

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:

操作人員對設備的使用、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備運行的信息，均通過觸摸屏來完成。

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

設備上電后，通過觸摸屏輸入鋁框圖形參數(shù)，踩下腳踏開關(guān)設備開始運行，控制系統(tǒng)通過判斷原料位置選擇自動上料流程還是直接進入自動折彎流程，并自動判斷當前原料的余料接頭位置是否出現(xiàn)在禁折區(qū)。步進給料系統(tǒng)將由控制系統(tǒng)計算后的料長精確的給進折彎刀頭，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.

重復以上兩步，直完成整個鋁框成形流程。

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

在鋁框折彎過程中，隨時會出現(xiàn)當前加工的鋁條即將用完的情況，通過系統(tǒng)自動判斷可使后續(xù)鋁條自動續(xù)接當前鋁條尾部，不中斷當前鋁條的成形工作。

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MC1002R，是專用于運動控制的可編程控制器，一般用作單臺復雜運動機械設備的控制核心。MC1002R支持RTEX總線控制系統(tǒng)，可以連接多達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位運動解算，雙核ARM Cortex-A9 CPU，667M主頻控制器采用ARM Cortex-A9 CPU、667M主頻；運算采用64位雙精度浮點數(shù)進行運算，確保運算精度。

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.