The intelligent insulating glass storage system based on servo control: A must-read for glass deep processing practitioners.

1. The preface

Insulating glass is widely used in construction, furniture, and other industries because of its good thermal insulation effect and strong sound insulation effect. The glass storage system is a new type of intelligently controlled glass deep-processing equipment that integrates glass pairing, sorting, and storage. It is suitable for glass production buffer storage after the glass is tempered and before making insulating glass. Jinan LIJIANG Glass develops and produces an insulating glass intelligent storage system based on a servo motor and PLC system control, which realizes precise glass pairing, and rapid scheduling, and reduces glass scratches caused by multiple storages.

With the rapid development of the insulating glass deep processing industry, the fully automatic glass deep processing equipment developed and produced by manufacturers has gradually caught up with the world level, but the insulating glass storage system is still far behind that of well-known foreign brands.

The automated glass storage system is a system that can automatically store and take out materials without manual processing. As the research on insulating glass storage systems by those glass deep processing equipment manufacturers is mainly to simulate and analyze the reliability of equipment operation on the software platform, it is of great significance to independently design a set of the intelligent glass storage system. This article will introduce the latest research and development achievements of Jinan LIJIANG Glass-that is, based on automatic storage, an intelligent insulating glass storage system is proposed, and access, storage mechanism, and conveying equipment that completely includes the intelligent storage of insulating glass is designed. and controls and many other functions.

2. The overall design of glass storage system

As the core of the glass deep processing production line, the glass storage system exists in front of the hollow area after the flow area, plays the role of glass buffer, and is the most critical intermediate link in the hollow glass deep processing process. The flow chart of deep processing of insulating glass is shown in Figure 1.

^{Figure 1 The flow chart of deep processing of insulating glass}

The intelligent insulating glass storage system, includes ERP (Enterprise Resource Planning) system, IPC (Industrial Control Computer) module, in-out, and out-warehouse handling trolley system, grid rack system, etc. The basic framework of its system is shown in Figure 2.

^{Figure 2 The basic frame diagram of glass storage control system}

The grid frame is divided into several lanes, and each lane is a storage unit. The ERP system distributes the roadway information for the glass in and out of the warehouse, and the IPC system coordinates the movement between the trolleys (position command transmission, sensor information collection, etc.).

When the glass is put in or out of the warehouse, the in-out and out-of-warehouse handling trolley and the bottom handling trolley under the grid frame receive the position command sent from the ERP system through IPC, and at the same time move to the roadway position that needs to be put in or out of the warehouse. After reaching the designated position, the transmission belt of the out-and-in-warehouse trolley and the transmission wheel of the bottom trolley perform the synchronous movement in the same direction to complete the out-and-in-warehouse work of glass. Under normal circumstances, multiple pieces of glass can be put into the warehouse at one time; when leaving the warehouse, the warehouse will be released according to the glass pairing situation.

2.1 The inbound and outbound handling trolley

The high-precision outbound and inbound handling trolley equipment have three-dimensional motion capabilities. The X-direction adopts a chain-connected roller group to realize the translation of the glass in the outbound and warehoused; in the Y-direction, horizontal parallel guide rails are used to achieve rapid glass handling; in the Z-direction The connecting rod bearing drives the glass receiving plate to swing to prevent the glass from falling due to inertia during rapid handling. Its basic structure is shown in Figure 3

^{1-Reduction box:} 

^{2-Turn motor;} 

^{3-Guide rail;} 

^{4-Glass receiving plate;} 

^{5-Y-axis transmission motor;} 

^{6-Roller group;} 

^{7-X-axis transmission motor}

^{Figure 3 Schematic diagram of the equipment structure of the in-out and out-of-warehouse handling trolley}

The function of the out-and-in-warehouse handling trolley is to store the glass according to the classification. Before the hollow operation, the glass in the grid frame aisle is selectively released from the warehouse according to the matching situation, which reduces the time for glass pairing before the insulated glass is glued and improves efficiency. The production efficiency of glass made insulated glass.

The handling trolley is mainly composed of three servo motors on the X-axis, Y-axis, and Z-axis, a parallel guide rail module, a glass bearing plate module, and several sensors.

When the equipment is working, the servo system of the inbound and outbound trolley obtains the position information of the roadway given by the ERP through IPC and drives the Y-axis transmission.The feeding motor moves to the corresponding position on the parallel guide rail, and real-time monitoring of the motor feedback detects the real-time position information of the trolley; to prevent the glass from sliding down during the high-speed traveling of the trolley, the Z-axis flip motor drives the connecting rod bearing to drive the bearing plate to flip correspondingly. Angle; X-axis transmission electricity works when the trolley moves to the roadway position and performs the glass in and out of the warehouse.

2.2 The grid rack system

The grid frame system mainly includes a steel grid frame and a bottom handling trolley under the grid frame. The bottom handling trolley also has three-dimensional motion capability. The main structure consists of a high-precision Y-axis transmission motor, and two X-axis transmission motors, and the Z-axis consists of two cylinders and sensor devices that can lift the transmission wheel. The basic structure is shown in figure 4 shown.

^{1 a grid frame;} 

^{2 a Y-axis transmission motor;} 

^{3 a cylinder device;} 

^{4 a travel switch;}

^{5 one transmission wheel;} 

^{6 X axis transmission motor;} 

^{7 one roadway}

^{Figure 4 The schematic diagram of grid system structure}

The bottom handling trolley relies on the Y-axis transmission motor for motion addressing and reaching the designated tunnel; it relies on the X-axis transmission motor for glass in and out of the warehouse; it relies on the Z-axis cylinder device to lift and lower the bottom glass transmission rack. There are multiple bottom handling trolleys under the grid frame, and the bottom trolleys run slower than the inbound and outbound trolleys. According to the location information of the roadway to be reached, the principle of coordinated movement of multiple trolleys and the shortest distance in different areas is adopted to shorten the running distance and improve outbound and inbound efficiency.

3. The motion control process

The out-and-in-warehouse trolley equipment adopts 3 servo motors to realize the guide rail travel of the trolley, the overturning of the glass receiving plate, and the rolling operation of the glass roller group. The bottom trolley is driven and conveyed by two servo motors. The lanes of the grid frame correspond to different position information, and the motion control information such as acceleration, deceleration, and maximum speed at different positions are input into the server in advance, so that the running parameters can be quickly determined after the lane position is given during the movement. . The servo will adjust the motion control parameters in real-time according to the pulse data returned by the detection encoder to make the parking position more accurate. The flip angle of the receiving plate determines the reliability of glass transportation, and two limit switches are used to limit the flip angle.

During the working process, when the glass enters the measuring end, the ERP system will issue the location information of the roadway to the server after receiving the glass arrival instruction. After the servo receives the position information, it reads the motor running parameters of the position stored in the servo and outputs the speed command to the motor. At the same time, the absolute encoder that monitors the position will feedback on the pulse number to detect the position information in real-time, and the servo will adjust the speed according to the feedback information and control the precise stop of the motor. During the movement of the motor, the flipping motor will make the flip receiving plate flip at a certain angle to ensure the glass is stable and reliable during the handling process. After reaching the designated roadway position, it is linked with the bottom handling trolley to carry out the storage operation. During the operation of the glass, many sensors continuously monitor the real-time position of the glass to prevent the glass from moving too far and falling off when entering the storage.

Figure as shown in Figure 5

^{Figure 5 The control block diagram of glass storage system}

^{(A) Warehouse system control block diagram}

^{1 glass arrival information command;} 

^{2 a destination command;} 

^{3, 6 a target position Command;} 

^{4 - arrival command;} 

^{5, 8 Y-axis motion control of the car;} 

^{7 - flip command;}

^{9, 10 - reach the command position;} 

^{11 - the number of storage commands, and output speed commands to the motor.}

At the same time, the absolute encoder that monitors the position will feedback on the pulse number to detect the position information in real-time, and the servo will adjust the speed according to the feedback information and control the precise stop of the motor. During the movement of the motor, the flipping motor will make the flip receiving plate flip at a certain angle to ensure the glass is stable and reliable during the handling process. After reaching the designated roadway position, it is linked with the bottom handling trolley to carry out the storage operation. During the operation of the glass, many sensors continuously monitor the real-time position of the glass to prevent the glass from moving too far and falling off when entering the storage. The control and flow chart of the glass storage system is shown in Figure 5.

^{Figure 5 The flow chart of insulating glass warehouse system}

^{(B) The storage system control block diagram} 

^{1 glass arrival information command;} 

^{2 arrival destination command;} 

^{3,6 target position command;} 

^{4 – arrival command;} 

^{5, 8 – trolley, axis motion control;} 

^{7 – flip command;}

^{9, 10 reach the command position;} 

^{11 storage command}

4. The experiment and result analysis

The experiment is carried out on the experimental platform of Lenze's E94A series server, and the built servo control experimental platform is shown in Figure 6. In addition to the basic functions of the servo, the servo also has PLC functions. It can be programmed as needed, and the program parameters can be modified to meet different functions. The data information fed back by the servo can be monitored in real-time through the diagnostic configurator. In the experiment, to be close to the needs of the industrial site, 380V AC is used to power the servo and servo motor, and the digital switch is used to replace the industrial zero point.

^{Figure 6 Physical map of the server experimental platform}

In addition to driving, the servo motor in this system also has the function of precise positioning. The following is a simulation analysis of the motor in the Y-axis direction of the in-out and out-of-stock handling trolley. The external electrical connection diagram of the servo and servo motor in this experiment is shown in Figure 7.

^{T1, T2—temperature sensor;} 

^{Ya—motor holding brake;} 

^{X8—absolute encoder feedback;} 

^{Rb—braking resistance}

^{Figure 7 External wiring diagram of the server}

T1 and T2 are connected with the temperature sensor of the motor to avoid short circuits of the motor; Rb is to prevent the damage to the servo caused by a large amount of braking energy generated when the motor is braking, and Y is the emergency stop module of the motor, X8 is the absolute value encoder, The position information of the motor is detected in real-time. The reliable protection and feedback system ensures the stable and safe operation of the whole equipment.、

This study adopts the position positioning method of table positioning and simulates it in the Engineer software developed by Lenze Company. The motion parameters of table positioning are shown in Table 1.

Table 1 table positioning motion parameters

In this study, the parameters of the position shown in Table 1 are input into the function block of the server table positioning, and the data information inside is located by using the software call table.

In this study, the actual speed of the motor is monitored by the software, the actual position of the motor is returned by the photoelectric position sensor, and the simulated waveform is obtained in the Data logger interface. The simulation results are shown in Figure 8.

^{1-Actual speed curve (ActuaI speed [rpm] 1 /Div = 20);}

^{2.-Position curve of table positioning (Table: Position x [unit1 1 /Div = 1k);}

^{3-Actual position curve (ActuaI position [unit] 1 /Div = 1 k)}

^{Figure 8 The location simulation diagram}

The actual position to U reaches 2999. 992 7 units (unit = πD/1800, the diameter of the turntable D = 50 mm), the absolute error is -6. 37*10^-4 mm. The maximum speed of the motor is also about 800 rap, and The results of the settings are approximately equal. To prevent accidental errors, the method of taking the average of multiple experimental measurements at each location is carried out in this study. The experimental results are shown in Table 2.

Table 2 Motion parameters at different positions

After the calculation, the relative errors are 0.00013%, 0.0001%, and 0.0002%, respectively, and the experimental results are sufficient to meet the requirements of the actual equipment for accurate position.

5. Summary

This article proposes an overall scheme of an intelligent insulating glass storage system developed and produced by Jinan LIJIANG Glass, and builds a hardware platform for experimental verification. The results show that the system can realize the precise parking of the handling trolley. Jinan LIJIANG Glass used the physical platform design and application in the research and development and verified the proposed intelligent insulating glass storage system. The level is similar to that of well-known foreign brands, and the operation is reliable. In addition, Jinan LIJIANG Glass will also develop or open-source a set of ERP systems for the system, which is compatible with the world's mainstream glass deep-processing equipment manufacturers. It is necessary to improve the control method of the ERP system for the coordinated movement of the trolleys to improve the efficiency of the entire system.

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