Intelligent Control System Of Power Station Boiler Bender

Tube bending is an important technology in modern industrial production. It is widely used in auto industry, aerospace industry, shipbuilding, boiler industry and so on. Because the traditional tube bending technology is not good at controlling the forming quality and setting process parameters, it usually lengthens the production cycle and wastes costs. There is an inevitable trend of intelligent control for bender. However, there is much difficulty for intelligent control system. Especially there is no theoretical method to set process parameters that makes the intelligent control limited. This paper studies the forming characteristics of tube bending and establishes the prediction model of process parameters and designs the intelligent control system for boiler bender.Firstly, this paper introduces research status at home and abroad for influence factors and influence laws of tube bending forming quality. It can be summarized that researches mostly focus on spring-back and ignore other forming qualities. It is more common to use analytical calculation than finite element analysis. And there are seldom cases to use ANN technology for tube bending forming quality prediction model. This paper analyzes the forming qualities such as ovality, thinning rate and thickening rate after the tube bending and proposes the method to control the process parameters.Secondly, this paper introduces all kinds of failure mode of forming quality and uses finite element simulation to study the influence of forming qualities from bending process parameters so as to establish basis for prediction model. The material properties affect the forming qualities in large extend, so it is necessary to make performance test for material.Artificial neural network (ANN) has many advantages such as fast computing speed, high precision and less model restrict. It is so applied and effective to be lead into tube bending. Improved BP neural network is used to establish bender intelligent control system model which can predict and analyze the forming qualities after tube bending. The system determines the reasonableness of process parameters from the result of forming qualities and gives the revised parameters back to the intelligent control system. ANN technology is one of the innovations also difficulties.This paper uses previous intelligent control system to reform the WA27YPC-63 bender. It makes use of programmable controller to design lower computer and sends the process parameters form the system to the bender. Finally, the intelligent control system is tested. The result of test proves that this technology can be applied in practical production.