High-speed tufting machine / tufting machine toothbrush tufting machine system solution

I. Project process introduction

The transmission structure of the high-speed toothbrush tufting machine consists of a main drive shaft and four servo drive shaft systems. The four servo axes are horizontal X axis, vertical Y axis, moulting Z axis and rotating A axis. The XY two-axis coordinates determine the position of the toothbrush hole, the A-axis plays the role of changing to the next toothbrush, and the Z-axis plays the role of changing the toothbrush bristles. When the spindle motor (controlled by the frequency converter) is running, the four electronically controlled servo axes will run along with it, and when the spindle stops, the remaining four axes will follow-up and stop. The rotation speed of the main shaft determines the speed of planting hair, and the four servo axes respond to the coordinated drive, otherwise there will be hair loss or uneven hair.

Process of action: the clip clamps the toothbrush handle from the Y axis direction → the clip is positioned at 90 degrees to the Z axis direction → the platform drives the clip to do X, Y axis movement so that the bristles can be hit to the toothbrush head In the pores→hair transplanting is completed, the clip is rotated 90 degrees downwards→the clip is loosened, and the processing of a toothbrush is completed. The application of XDM series plc and DS5 servo system of our company (Xinje) can achieve 900 times per minute of tufting speed. Moreover, while starting and stopping at high speed, the smoothness and softness of the overall action is more prominent. Through the application of the self-made pulse S-curve in the PLC, it is possible to skip holes and plant hair, and when skipping holes, while ensuring the accuracy of skipping holes, the machine is basically as stable as usual without obvious jitter.

2. Products used in the project

Product name

Model

Quantity

PLC

XDM-60T4-E

1

Extension Module

XD-E2DA

1

Touch screen

TG865-MT(U)

1

Servo

DS3-20P7-PQA

3

Servo

DS3-20P4-PQA

1

3. System hardware composition

4. Field equipment

5. Sequence of actions

6. Control scheme

Currently, the structure of the electric control system for hair planting is mainly divided into a single-chip control system or a CNC numerical control system. Among them, the single-chip control system is based on the integrated supporting services of the automation system manufacturer, and the independent research and development of the toothbrush equipment manufacturer is supplemented.

Mainly control axis pulse command signal to realize servo drive, usually four-axis control output realization, Xinje XDM-60T4-E, motion control PLC. With a response speed of 0.1ms and 4 high-speed pulses, the toothbrush tufting machine requires the system to realize two-axis interpolation operation. The four sets of servo drive models are DS3 series AC servo systems with a power of 400W-750W. The drive has a variety of functional controls, with strong overload capacity, strong anti-load disturbance ability, large starting torque, high dynamic response speed, and short positioning time. The spindle motor inverter model is Xinje's VB5N series, with a power of 400W.

Seven. Debugging points

The difficulty in the development of the servo solution is the joint debugging of the electromechanical system, which is mainly the adjustment of the servo gain and the cooperation of the plc's trigonometric function curve. Among the four servo axes, the X axis and Y axis are relatively stable due to the mechanical inertia of the screw drive structure, and debugging is relatively easy, just modify the speed gain. The Z-axis of the flap is a rotating axis. High-speed rotation has centrifugal force. If the gain is simply set to a high value, the motor will vibrate when it starts and stops. At this time, the position filter time parameter can be modified to eliminate the vibration. Relatively speaking, the mechanical structure of the cam mechanism of the U-axis for hair removal makes debugging difficult. In addition, the mechanical rigidity of the U-axis is not good. When the motor is running, the inertia ratio changes greatly, and the motor output current changes greatly, so the parameters cannot be adjusted. Well, when the motor is running left and right, this axis either vibrates or screams, or is unresponsive. When adjusting the parameters, the speed loop gain, filter time parameter and position loop gain need to be adjusted accordingly.

8. Performance advantages

1. Use the trigonometric function pulse curve made by the department in PLC and cooperate with the DS3 servo system to achieve precise positioning and improve the accuracy of hair transplanting. According to the jump holes at different distances, the parameters of the curve are changed in real time, making the overall machine more stable and soft, while the speed is not reduced, and the accuracy is higher.

2. In addition to ordinary buttons, indicator lights, mode switching, and parameter settings, the touch screen has added 100 recipes. The data of 100 kinds of toothbrushes can be stored at the same time. Different toothbrushes only need to import different formulas, which is convenient and fast. The touch screen can also draw the color model of the toothbrush under the current formula on the touch screen in real time according to the formula change, and the simulation model can dynamically draw pictures according to the actual working conditions, making the user more convenient and quick to understand the current working status. Each formula can also be exported to or imported from a U disk according to customer requirements.

Nine. Summary

Xinje’s complete product system almost covers the industrial control products needed by the tufting machine, and each product has its own independent advantages and a high degree of compatibility between our products. This not only saves workload and development costs, but also greatly improves the overall performance of the machine.

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