全自動(dòng)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密封鋁條的生產(chǎn)。近年來(lái)隨著(zhù)對建筑環(huán)保要求的提高，中空玻璃市場(chǎng)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，構建以和利時(shí)MC運動(dòng)控制器+RTEX總線(xiàn)系統+松下A6N交流伺服系統為核心的鋁條全自動(dòng)折彎機控制系統，實(shí)現上料、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：折彎機、MC運動(dòng)控制器、RTEX總線(xiàn)、中空玻璃

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

國內高端鋁條折彎機市場(chǎng)一直都被國外品牌所壟斷，國內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，使用的折彎機存在鋁條精度不足、折角不美觀(guān)等問(wèn)題。因此，鋁條自動(dòng)折彎機的國產(chǎn)化，尤其是控制系統國產(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(dòng)接料裝置、步進(jìn)給料機構、折彎機構、自動(dòng)斷料機構、電氣控制系統、動(dòng)力控制系統、控制箱及觸摸屏人機界面等結構組成。

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)折彎機設備組成圖

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，當鋁條尾部到達信號發(fā)出時(shí)，接料系統會(huì )自動(dòng)定位鋁條尾部，等待下一條鋁條的自動(dòng)續接。

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)給料機構：當控制系統發(fā)出步進(jìn)長(cháng)度信號時(shí)，由該系統執行給料。

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

折彎機構：折彎機構的折彎角度可以精確調節和控制。

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

自動(dòng)斷料機構：

Automatic cutting mechanism:

當初始上料或一個(gè)框折彎完成時(shí)，斷料機構會(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)斷料機構：

Automatic cutting mechanism:

當初始上料或一個(gè)框折彎完成時(shí)，斷料機構會(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：

Electrical control system:

電氣控制系統是整個(gè)設備的核心部分，設備的控制軟件安裝在MC運動(dòng)控制器中。所有的控制指令、運算工作、輸入輸出信號、系統狀態(tài)監視，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.

該系統采用松下支持RTEX總線(xiàn)的A6N伺服及電機。RTEX具有極高的性?xún)r(jià)比，采用RTEX總線(xiàn)控制系統后，客戶(hù)在不增加電機成本的情況下，大幅降低了配線(xiàn)安裝工作。100M的網(wǎng)絡(luò )帶寬和RTEX優(yōu)異的穩定特性，確保了MC1002R與系統各個(gè)A6N伺服驅動(dòng)器之間的控制周期能夠達到0.5ms，從而大幅提高了客戶(hù)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(dòng)力控制系統：

Power control system:

由數個(gè)氣動(dòng)電磁閥、相應氣路、眾多氣動(dòng)元件，以及控制信號回路組成氣動(dòng)動(dòng)力系統，負責完成設備復雜的程控動(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:

操作人員對設備的使用、所需要的大量的數據輸入，以及操作人員需要了解的設備運行的信息，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

設備上電后，通過(guò)觸摸屏輸入鋁框圖形參數，踩下腳踏開(kāi)關(guān)設備開(kāi)始運行，控制系統通過(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)判斷當前原料的余料接頭位置是否出現在禁折區。步進(jìn)給料系統將由控制系統計算后的料長(cháng)精確的給進(jìn)至折彎刀頭，由折彎系統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 )出現當前加工的鋁條即將用完的情況，通過(guò)系統自動(dòng)判斷可使后續鋁條自動(dòng)續接至當前鋁條尾部，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(shí)MC1002R，是專(zhuān)用于運動(dòng)控制的可編程控制器，一般用作單臺復雜運動(dòng)機械設備的控制核心。MC1002R支持RTEX總線(xiàn)控制系統，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(dòng)解算，雙核ARM Cortex-A9 CPU，667M主頻控制器采用ARM Cortex-A9 CPU、667M主頻；運算采用64位雙精度浮點(diǎn)數進(jìn)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.