Steel cage roll welding machine is a kind of mechanized production equipment for making steel cages. Traditionally, in the construction works with pile foundations, the steel cages used for pile foundations have been manually tied or bent and then welded. The application of programmable control and modern drive technology has made the automation degree of the domestic steel cage roll welding machine more and more high, greatly reducing the labor intensity of the workers and improving the production efficiency.
I. Overview
Steel cage roll welding machine is a kind of mechanized production and production of steel cage machinery equipment, traditionally, in the construction of pile foundation construction, the reinforcement cage used for pile foundation has been manually wound or bent after welding, in foreign construction Developed countries have long had a history of applying mechanical manufacturing. In China, the first case of mechanized steel cage production was documented in the Wuhan-Guangzhou Passenger Dedicated Line constructed by China Railway 18th Bureau in 2006, and its application was developed by Xiamen Lianhuan. The rebar welding machine is also the first such equipment in China. After several years of development, other domestic machinery manufacturers have also been involved in R&D since 2008. We believe that the future development will lead to the roll-welding of steel cages made in China. Welding opportunities are more humane and easier to use. However, Alpha AS600 servo products are in line with the market and technological development requirements, replacing the traditional transmission mechanism as the main power source in the rebar welding machine, completely eliminating the various drawbacks of the previous machine. The entire electronic control and automation upgrade of the whole machine is realized, and the production efficiency, control accuracy, mechanical manufacturing cost and maintenance cost are greatly improved. This system also uses Alpha's programmable controller AT100 series and human-machine interface AP series products.
Second, product introduction
AS600 servo drive is a high-performance servo driver independently developed by our company with complete independent intellectual property rights.
Full closed-loop vector control, precise timing and positioning, low-frequency torque, strong load response, and improved weak magnetic algorithm
The high-speed zone is still capable of rapid acceleration and deceleration under large inertia loads, providing high-performance speeds for your equipment and
Position servo function.
The AT100 series are Alpha's small programmable controllers, which are suitable for machine and system control with a total of 256 points and can expand analog modules.
The AP series touch screen is Alpha's economical human-machine interface product, especially suitable for small-sized machine equipment.
Third, the system equipment structure and process introduction
1. Working principle and equipment structure
(1) Working principle
According to the construction requirements, the main ribs are passed through the holes of the corresponding template in the fixed turntable to the corresponding holes of the moving turntable for fixing. The end of the ribs is first welded to a main rib. Then, by rotating the fixed turntable and the moving turntable, the coils are wound around the main ribs (the moving disk is rotated while being moved backwards), and welding is performed at the same time until welding to the specified position at the end of the main ribs, thereby forming a product reinforcing cage.
(2) Equipment Structure
The mechanical system of the reinforcement cage roller welding machine is composed of a frame, a walking trolley, a fixed plate mechanism, a moving plate mechanism, and a fixed support plate group; wherein the walking trolley, the fixed plate mechanism and the moving plate mechanism are respectively driven by the AS600-004T3E servo system, totaling three Taiwan, as shown below.
2. Process flow
3. Equipment operation process
4. Electrical system description
The following figure shows the structure of the control system of the Alfa AS600 servo system in the rebar welder. The host computer PLC (using the Alpha AT100 series PLC and AP series touch screen) sends start/stop signal commands and operation commands to the servo. At the same time, the host computer obtains the real-time servo position signal through communication with the servo. The host computer simultaneously monitors the servo alarm signal. The servo driver can feed back signals such as alarm and running status, thus the host computer and the servo system form a closed-loop control mode.
Fourth, system technical characteristics
The AS600 servo system developed by Shenzhen Alfa Electric Technology Co., Ltd. has three roles on this kind of and similar machinery. The first is the torque output, which is used as the power source for front-end walking and fixed winding discs, where high-power output capability must be ensured to prevent the equipment from shutting down due to heavy rebar cages or chucks. The second high-precision positioning, servo drive faster and accurate positioning of the brake through the position command, to servo drive higher dynamic response speed. The third is anti-jamming capability. This requires both the servo driver itself to reduce interference and the driver itself to overcome the interference of the welding machine and external equipment to the servo driver. It also requires the servo driver to have a certain degree of stability to ensure the equipment and surrounding electrical control equipment. Can use normal operation.
The Alpha AS600 servo system maintains high rigidity, rapid start and stop, and reciprocating motion under adverse conditions such as voltage fluctuations and mechanical disturbances. Successfully achieved perfect performance on similar machines of many customers and won the praise of customers.
â— Under the same power conditions, Alpha servos have a higher overload capacity, so the system has a wider range of applications and saves customers cost. At the same time, the rated current of Alpha's motors is relatively small, which is more energy-efficient than other systems.
â— Alpha servo system has divided frequency output and two-channel encoder pulse input function for the encoder signal, which can specify the frequency multiplication of the signal, so it can meet the requirements of the vast majority of superior monitoring systems, especially with the PLC ;
â— The servo has strong anti-interference ability, which effectively solves the problem of position deviation caused by other system disturbances in the servo system of the machine;
â— The electrical part of the servo system has been pre-processed for the characteristics of the industry, which can effectively reduce the technical difficulties in the industry;
Customer equipment actual data:
The measured data of the Alfa AS600 servo system applied to the customer's steel cage roll welding machine are as follows:
Reinforcing cage length 22 meters; Main rib diameter Φ35mm; Disc rib diameter Φ10mm; Stirrup spacing 250mm;
The main rib spacing is 50mm.
With the successful application of Alpha AS600 servo system in the reinforcement cage roll welding machine, it solved the problems caused by the inherent problems of the traditional transmission system such as noise, vibration, low efficiency, inconvenient control, unstable and reliable product quality, and effectively The system's responsiveness, position control accuracy, processing quality, stability, reliability, and processing efficiency have been improved, which has been well received by customers.
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