圆柱模具式软胶囊机设计【含5张CAD图纸、说明书】
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含5张CAD图纸、说明书
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模具设计【含5张CAD图纸
圆柱模具式软胶囊
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设计含CAD图纸
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附录A译文新型六头软胶囊滴丸机控制系统的改进1. 引言滴丸机是鱼肝油生产行业非常典型和极为重要的设备，六头软胶囊滴丸机是近年自行研制开发的专用设备，具有较高的技术含量，己成功研制出第一代和第二代设备，取得了非常好的经济效益和社会效益为了企业更好地发展以适应新的形势，经集体研究决定再研制2台六头软胶囊滴丸机第三代设备通过对前面己投入使用的两台六头软胶囊滴丸机的实际工作情况及其工作状态进行研究分析，对不足之处进行改进，研制出更理想的第三代新设备，以满足生产需要新机台电气部分主体方案依然采用PLC与HITECH工业级人机界面进行控制和设计，并针对前两台设备在使用过程中存在的不足之处如：液位控制系统低位槽溢油现象和胶温控制系统超调现象进行改进，同时设计和完善相应的人机界面的功能以及报警、帮助和历史趋势图等信息保存功能2. 六头滴丸机系统的构成根据新设备控制系统的要求及安装的需要，既要继承前两代设备的优点，又要对其不足之处进行改进和完善，采用DELTA DVP14SS11T2型PLC，可带模拟量I/O模块，方便地实现温度、电流等模拟量的显示与控制本机电气控制系统主要包括六个滴头的控制，以两个滴头为一组，共三组；每组含电机两台以及胶温控制系统和电流采集控制系统。此外，石蜡油循环泵和液位控制系统构成石蜡油循环系统，并有石蜡油制冷控制系统以及胶丸输送系统为三组共用控制系统结构示意图见图11要求能够在人机界面上实现对系统的控制和状态显示，参数设定、修改和当前值的显示，报警功能；在此基础上，对胶温控制系统和液位控制系统进行改进设计，并进一步完善人机界面的功能.3. 控制系统的改进与技术处理3.1 温度控制系统的改进温度控制系统主要由胶加热系统和石蜡油制冷系统两部分组成，温度主要是由传感器PT100采集温度参数，传给PLC的PT模组，然后通过PLC对模组所采集的信息进行处理处理方式是采用明胶加热和石蜡油制冷两种模式，在胶加热系统中，由于采用PT模组作为温度的采集，需要编制PLC程序实现PID控制，通过PLC晶体管控制固态继电器的输出，以达到对明胶加热的控制制冷部分主要对PT模组的信息进行处理，根据工艺要求控制好冷冻机组的温度在胶加热系统中，由于明胶温度的控制采用PLC的PT模组控制电加热器通过石蜡油域隔层对明胶进行间接加热石蜡油的热导率介于不锈钢和明胶之间，因为是间接加热，控制效果要经过一定的延迟才能作用到胶液，呈现纯滞后环节特征，胶箱采用不锈钢材质，热导率较高，具有小惯性环节特征；明胶自身的热导率则较低，具有大惯性环节特征，采用传统PID控制存在启动过程超调大，过渡时间长的问题3.1.1控制器的设计与实现基于以上分析，本文将传统PID控制和模糊控制结合起来，设计出一种新的混合型模糊PID控制器，对温度控制系统进行改进，并给出系统的MATLAB仿真和基于PLC的软硬件设计和实现混合型模糊PID温度控制器的系统控制框图如图2所示.图中u*(t)为PID控制的输出，u(t)为模糊控制的输出，u(t)为总的控制输出模糊控制器设计的基本思路是以误差e和和误差变化e为输入，进行模糊推理，适当增大或减小比例部分的控制作用，如当温度接近设定值时，适当减小比例部分的作用，以减小超调量；在温度上升的初始阶段则适当增大比例部分的作用，以加快响应速度；从而同时获得较小的超调量和较快的响应速度。3.1.2 仿真分析温度控制系统控制对象的近似数学模型为，取K0 =2, *=3, T=10. 图3分别是采用不同的控制方式时，系统阶跃响应过渡过程曲线二者对比，可以发现传统PID控制的超调量高达50%，而模糊PID控制的超调量明显减小，可见模糊PID控制效果明显优于传统PID控制3.1.3 基于PLC的控制器的实现在仿真的基础上，设计基于PLC的控制器，新型全自动软胶囊机采用DELTA DVP-14SS11T2 PLC和HITECH PWS3260DTN可编程触摸终端作为实现平台胶温控制系统是由DVP04PT-S PT模组采集温度参数，再经PLC进行逻辑运算，实现温度控制DELTA DVP-14SS11T2本身没有模糊控制器功能为了达到模糊PID控制功能，需编写模糊运算功能的PLC程序和PID的逻辑运算程序模糊运算主要包括精确量模糊化，模糊推理,去模糊化等步骤，最后用查表的方法计算出模糊控制的输出u(t)；将按常规方法整定出的PID参数输入相应的单元，并用PID指令直接计算出PID控制器的输出u*(t)，最后把两部分合在一起作为控制器的输出输出PWM信号控制加热管接通时间的占空比，从而对温度进行控制在计算u(t)时，因为已经对模糊规则进行了合理的简化，所以，减小了在线计算的工作量程序流程图如图4所示：因为新的滴丸机正在设计和组装中，因此采取模拟实验的方式，图5(a)显示的是采用常规PID控制的温度历史曲线，图5(b)是采用本文提出的混合型模糊PID控制的温度曲线通过两者对比不难发现，混合型模糊PID 控制较好地解决了常规PID控制目标值跟随能力欠佳的问题，超调量明显减小，而且响应速度变快3.2 液位控制系统的改进3.2.1 液位控制硬件的改进与实现液位控制系统主要由低位槽、高位贮油罐、管道、循环泵及制冷机组等组成主要控制流程是：启动循环泵开关，石腊油进入自动控制状态，当低位油箱的石腊油到达预定油位时，循环泵开始工作，同时启动制冷控制系统，制冷机组开始工作正常的工作状态是石腊油经管道均匀地分配到六个滴头的贮油杯和滴头上，带动己滴出来的软胶囊流向定型桶后，经输送带将软胶囊输送至下一道工序石腊油则流到低位槽，当低位槽石蜡油达到一定的液位时，启动循环泵将石腊油送到高位贮油罐里，如此循环工作由于石腊油不导电、比重较轻，且较粘，还要满足GMP（Good Manufacture Procedure）的要求，所以原机低位槽的液位传感器选用不锈钢浮球，小巧玲珑，但是在使用一段时间后浮球的运动部位出现结洉现象，严重地影响浮球的灵敏度，经常出现低位槽石蜡油溢出现象，严重污染了工作现场,同时也经常出现由操作工误关循环泵而引起的报警或溢油现象针对此问题，改进方案是采用SMC的压力传感器，在低位槽里增加一根不锈钢管，然后用一根气管与传感器连接，当液位槽的液位发生变化，传感器的电流毫安信号也发生变化，通过PLC模拟量的AD模组采集数据，并经逻辑运算后输出至执行机构，从而对液位进行控制3.2.2 液位控制在人机界面和PLC上的实现在人机界面上主要设计了水位参数设置画面，通过三个参数数值输入键，分别设计为低水位、高水位和报警水位，并在监控画面增加一个液位显示通过观察低位槽液位在理想的低位或高位所显示的实际数值，在水位模拟量设置画面中，作为人机界面的参数设定值为防止操作人员随意修改参数，该画面置于特殊参数画面后，需输入密码方可进入，并专门增加了一个进入修改密码画面特殊参数画面主要包括PID参数的设置、特殊模块出错显示、历史趋势图、水位模拟量参数设置等图6(a)为水位模拟量参数设置画面，通过此画面直接设置或修改理想液位的参数值；图6(b)为监控画面，可以监控各胶温和石腊油温度值、各加热器电流，及新增的水位模拟量值为了防止在人机画面里，由于误操作关闭己开启的循环泵而引起的石腊油溢出的现象，修改人机界面和PLC的程序控制方案，将循环泵的开关按钮由交替型改为保持型，并增加关闭循环泵的换画面按钮图6(c)为六头滴丸机主画面，在循环泵按钮下面增加一个“关循环泵”的切换画面按钮，并链接至专门用于关闭循环泵的画面如图6(d)，降低了操作人员误操作的可能性3.3 报警、帮助及历史趋势图的设计人机界面报警主要由状态指示灯、走马灯及保持型按钮等组成，当系统出现故障时，工作画面里跳出警报状态灯，并触发PLC报警输出蜂鸣器，工作画面的相应位置上跳出相关信息如“加热棒断一根，请确认！”或“加热棒断或空开跳闸，请确认！”“马达故障”等跑马灯信息，让操作人员能够清楚故障原因，触摸警报按钮即可关闭警报声音，故障排除后故障显示信息即自动关闭操作人员也可进入报警画面观看详细信息，或进入帮助画面了解故障处理方法报警信息主要由16#滴头故障、循环泵和输送带故障、13#加热棒断一根或二根全断的故障、13#温度偏高故障及石腊油冷却系统故障及石腊油液位过高等故障信息组成故障原因的采集与判断，如加热棒主要是由交流电流输入隔离器DZ-10/321采集加热棒的电流信息，并转换成模拟量信号输到PLC，通过比较判断加热棒是否断开，一根还是两根，并触发显示相应的走马灯报警信息为了保存重要的历史数据，本次编程增加了历史曲线图，历史数值资料表、历史讯息表、历史警报表、当前警报表、警报频次表等信息主要针对如胶温或石腊油温度的工作状况的历史曲线进行采集附录B 原文New six soft capsules Pill Machine Control System1. Introduction Pill machine is cod liver oil production industry is very typical and very important equipment, six soft capsules pill machine in recent years developed their own special equipment with high technology content, have successfully developed first-and second-generation equipment, achieved very good economic and social benefits. In order to better develop the business to adapt to new situations, by collectively decided to develop 2 sets of six soft capsules pill machine third-generation equipment. Already in use by the two previous six soft capsules pill machine work and the work of the actual state of research and analysis to improve on the shortcomings, developed a better third-generation new equipment to meet production needs. The new machine is still using the electric part of the main program and the HITECH industrial PLC control and man-machine interface design, and for the two devices in use before the existing shortcomings, such as: low level control system and the plastic tank of oil-spills temperature control system overshoot is improved, while the design and improve the function of the corresponding human-machine interface, and alarm, and historical trends to help save information such as function. 2. 6 Pill Machine structure of the system Under the new device control system requirements and installation needs, not only to inherit the advantages of previous generations of equipment, but also to improve their shortcomings and improve, using DELTA DVP14SS11T2 type PLC, which can carry analog I / O modules to facilitate to achieve temperature, current and other analog display and control. The electrical control system includes six emitter control to the two emitters as a group, a total of three groups; each with two motors and rubber temperature control system and current collection and control system. In addition, the paraffin oil circulation pump and liquid level control system constitutes a paraffin oil circulation system, and a paraffin oil cooling control system, and capsule delivery system for the three groups shared. Control system structure diagram of Figure. Required to realize the human-machine interface, system control and status display, parameter setting, modify, and the current value of the display, alarm function; On this basis, the plastic temperature control system and liquid level control system to improve design and further improve the human-machine interface functions. 3 control system to improve processing and technology 3.1 Temperature Control System Temperature control system is composed of rubber and mineral oil heating system, cooling system composed of two parts, the temperature is mainly collected by the sensor PT100 temperature parameter, pass the PT PLC module, and then collected through the PLC to the module information for processing. Approach is the use of gelatin heating and cooling modes paraffin oil in plastic heating system, thanks to PT module as the temperature of the collection, compiled PLC program needed to achieve PID control, control by PLC transistor output solid state relays to achieve heating of the gelatin control. Cooling part of the main modules of information on the PT processing, control technology requirements under good refrigeration units temperature. The plastic heating system, temperature control gelatin used as the PT PLC control module heater paraffin oil field compartment through indirect heating of the gelatin. Paraffin oil between the thermal conductivity between stainless steel and gelatin, as an indirect heating, control effects can be delayed after a certain role to the glue, showing lag element characteristics of plastic and stainless steel, high thermal conductivity, with small inertia characteristics; gelatin own thermal conductivity is low, with large inertia characteristics of the traditional PID controlling the boot process exist large overshoot, long transition issues. 3.1.1 Controller Design and Implementation Based on the above analysis, the conventional PID control and fuzzy control 3 4 5 together, to design a new hybrid fuzzy PID controller to improve the temperature control system, and gives the system MATLAB simulation and PLC-based hardware and software design and implementation. Hybrid Fuzzy PID temperature controller system control block diagram shown in Figure 2. Map u * (t) for the PID control output, u (t) for the fuzzy control output, u (t) for the overall control output . The basic idea of fuzzy controller design is based on the error and error change e and e as input, the fuzzy reasoning, the appropriate increase or decrease the proportion of part of the control functions, such as when the temperature is close to the set value, the appropriate part of reducing the proportion of role to reduce the overshoot; rise in temperature increases the initial stage, the appropriate role of the proportion of parts to speed up the response speed; to simultaneously access a smaller overshoot and fast response. 3.1.2 Simulation Temperature control system controls the approximate mathematical model of the object ，, Take K 0 = 2, * = 3, T = 10. Figure 3 are different control methods, the system step response curve of the transition process. Difference of the two, you can find the traditional PID control overshoot up to 50%, while the fuzzy PID control overshoot significantly reduced, showing that fuzzy PID control is better than traditional PID control. 3.1.3 Implementation of the controller-based PLC In the simulation, based on PLC-based controller design, the new fully automatic soft capsule machine DELTA DVP-14SS11T2 PLC and HITECH PWS3260DTN programmable touch terminals as implementation platform. Plastic temperature control system is DVP04PT-S PT temperature parameter acquisition module, and then carried out by the PLC logic operations, to achieve temperature control. DELTA DVP-14SS11T2 DELTA DVP-14SS11T2 fuzzy controller itself does not function. In order to achieve fuzzy PID control, fuzzy computing capabilities need to prepare the PLC program and the PID of the logical process. Exact amount of computing includes fuzzy fuzzy, fuzzy inference, defuzzification and, finally, the method used to calculate look-up table of fuzzy control output u (t); will be a whole set of conventional methods corresponding PID parameter input unit Direct instruction with PID PID controller calculates the output u * (t), finally put the two together as part of the controller output. utput PWM signal control heating pipe connected to the time of the duty cycle, and thus temperature control. In the calculation of u (t), because the fuzzy rules have been a reasonable simplification, therefore, reduce the workload of online computing. Program flow chart shown in Figure 4: Because the new pill machine is being designed and assembled, so the way to simulation, Figure 5 (a) shows the conventional PID control of temperature history curve, Figure 5 (b) is with the proposed hybrid fuzzy PID control temperature curve. By comparing the two is not difficult to show that the hybrid fuzzy PID control can solve the conventional PID control problem of poor ability to follow the target value, the overshoot significantly reduced, and the response speed becomes faster. 3.2 Level Control System 3.2.1 Level control improvement and implementation of hardware Level control system mainly consists of low slots, high storage tanks, pipes, circulation pumps and refrigeration units and other components. Main control flow is: start circulating pump switch, paraffin oil into the control state, when the low tank of paraffin oil arrived at the oil level, the circulation pump to work at the same time start the refrigeration control systems, refrigeration units to work. Normal working state is paraffin oil by pipeline evenly assigned to six emitters of oil storage cup and drops his head, lead has been dropping out of the barrel shaped the flow of soft capsule, soft capsule transport by conveyer belt to the next process . Paraffin oil tank is low flow, when the low slot paraffin oil reached a certain level, the startup circulation pump will be sent to the high paraffin oil storage tank in, so the cycle work. As the paraffin oil is not conductive, the proportion of lighter and less sticky, but also to meet the GMP (Good Manufacture Procedure) requirements, so the original low slot machine use stainless steel float liquid level sensor, small size, but after some time floating in the use ball sports site appears Results Hou has seriously affected the sensitivity of float, often low slot paraffin oil spill has seriously polluted the work site, but also often related by a circulating pump operator error caused alarm or oil spill phenomenon. For this problem, the program is used to improve SMCs pressure sensor, in the low slot to increase a stainless steel tube, then a pipe with sensor connection, when the liquid tank level changes, the sensor signal also occurred in the current mA changes in the AD through the PLC analog data acquisition module and the output by the logic operation to the implementing agencies to control the liquid level. 3.2.2 Level Control in man-machine interface and PLC on the implementation Human-machine interface in a water main design parameter settings screen, enter the key by the three parameter values, were designed for low water level, high water level and alarm level, and add a level in the monitor screen display. By observing the low level trough of low or high in ideals and the actual value shown in the water level analog setting screen, as the man-machine interface parameter settings. To prevent the operator free to modify the parameter, the screen frame placed in a special parameter, the need to enter a password to enter, and specifically the addition of a modified password into the screen. Screen includes a special parameter setting PID parameters, a special module error display, historical trends, the water level analog parameter settings. Figure 6 (a) parameter settings for the water level analog images, directly through this screen to set or modify the ideal level of parameter values; Figure 6 (b) for the monitor screen, you can monitor the glue mild paraffin oil temperature, the heater current, and the new water level simulation for money. In order to prevent human-computer screen, because of the misuse closed circulation pump has been turned on paraffin oil spill caused by the phenomenon of human-machine interface and modify the program PLC program control, will switch the button from the circulation pump to maintain the Alternating type, and to increase the closed loop pump for screen button. Figure 6 (c) for the six Pill Machine main screen, the circulation pump button below to add a close loop pump toggle screen button, and link to the circulating pump designed to turn off the screen shown in Figure 6 (d), lower the operator the possibility of misuse. 3.3 Alarm, and historical trends to help design Mainly by man-machine interface alarm status indicators, and maintain a revolvi
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