Background introduction

Tangshan Zhengfeng Iron and Steel Co., Ltd. is a leading enterprise in the production of structural steel in Tangshan city. The traditional steel stacking area is manually stacked by hand. With the continuous increase in labor costs, enterprises have decided to upgrade and transform this work area using robot palletizing machines to reduce the number of workers and save labor costs.

Project Objective:

1

Steel sections are automatically counted and grouped according to preset stacking types, without the need for manual intervention.
2

Automatic stacking of steel sections, the robot automatically stacks the grouped steel sections according to the preset stacking type.
3

The finished products after stacking are automatically conveyed according to the steel demand signal of the downstream baler.

Solution

To achieve the above goals, the company has chosen a comprehensive solution that combines Siemens S7-1500 automation system with Sinamics DCM DC speed control system.

To achieve the above goals, our company independently designed and manufactured an 800KG steel palletizing robot, and used the CX2030 controller from Beifu Company and the TWINCAT2.0 motion control platform to create a robot motion control system that is compatible with the robot.

System configuration

1. CX2030, as the main PLC, is responsible for controlling 16 servo motors. Based on the preset picking and placing coordinates, it performs trajectory planning calculations and uses the inverse solution algorithm to generate the set position of a single servo motor. The set position is then sent to the servo driver at a high speed with a 1ms cycle using the ETHERCAT communication protocol.

2. The Huichuan SV660N servo control system adopts a high-precision 23 bit absolute value encoder, with a minimum operation cycle of 125 μ s for the position loop and velocity loop, and a maximum overload capacity of 300% for the motor, ensuring high-speed response of the servo motor to position commands.

3. The equipment adopts a dual human-machine interface of touch screen and upper computer. There is a touch screen and operation box next to the equipment to operate the equipment. At the same time, one upper computer is equipped in the background, using Siemens WINCC software, which can perform more complex control and diagnosis of the entire system.

Solution

Implementation steps

On site investigation comprehensively understand the process flow, equipment status, and control requirements of the existing production line.
Mechanical scheme design
Based on the specifications of the user's production variety, the robot design load target is set at 800KG, and combined with the size of the working area, the robot's 1 axis and 2 axis arm extensions are determined to be 1250mm and 1394mm.
Motor scheme design
According to the robot design specifications, it is determined to use the high-end SV660N series servo motor from Huichuan brand.
Automation solution design Through continuous comparison of supplier solutions, it was finally determined to use the CX2030 high-end controller and TWINCAT2.0 motion control software platform from Germany's Beifu company.
Program development
Develop PLC control programs and HMI operation interfaces according to production process requirements.
System debugging
After the equipment installation is completed, perform system debugging to ensure the correctness of control logic and the stability of the system.
Training and delivery
Train operators on system operation and maintenance, and deliver the renovated production line for use.

Projectachievements

Summary:

The equipment upgrade and renovation in the section steel palletizing area of Tangshan Zhengfeng Iron and Steel Company has been successful, not only improving production efficiency

By reducing the number of workers and lowering their labor intensity, the packaging quality has also improved compared to the past, making the products more competitive and laying a solid foundation for the sustainable development of the enterprise.

01.

The production line has achieved full automation control, significantly reducing the number of workers and greatly lowering their labor intensity.
02.

Through continuous improvement, the quality of the packaging is more uniform than before.
03.

Able to adapt to different types of steel, including equilateral angle steel (No. 3-12.5), unequal angle steel (40 * 25-140 * 90), channel steel (No. 5-20), and I-beam (No. 10-20).