Study On Key Techniques Of Automatic Control System For Copper Valve Hot Forging

Valve is a typical fluid control equipment, it plays an integral role in the petrochemical,power systems, industrial, aerospace and various fields. With the development of the industry,the existing copper valve manufacturing technology and equipment unable to meet the requirements of enterprises’ development, labor-intensive copper valve manufacturing enterprises are seeking industry transformation. The Key production process of copper valve manufacturing-hot forging is the breakthrough point for the transformation of enterprises. Hot forging automation of copper valve has become a research focus in the industry. Although there are some successful cases of hot forging automation in other industries, but them do not apply to copper valve industry, according to the characteristics of copper valve production,this paper developed an automatic production system for hot forging copper valve.Firstly, analyzing the common characteristics of hot forging automation system.Combining the requirement of production process of copper valve with the key technologies of automation system for hot forging, the overall scheme of automatic control system is designed. Putting forward four solutions of key problems of hot forging system to realize the feeding automation, induction heating temperature controlling, manipulator operation and the linkage of punch in automatic hot forging process of copper valve,we carried out a detailed analysis and designing for solutions on the base of that.Using dedicated rhythm type feeder instead of artificial feeding to realize automation feeding. Using induction heating,in order to improve the quality of forging blank,the temperature of induction heating was controlled. In this paper, we carried out a detailed electromagnetic and thermodynamic analysis of copper bar induction heating process and successfully established the mathematical model of the controlled object. Using specially designed Five degrees of freedom manipulator to instead of manual. At the same time, the punch is included in control system.Putting forward the control system with PLC as the controller and carrying out electrical designing, including components selection and circuit design. Showing the control logic of automatic control system of the hot forging process, including the program flow chart of the feeding machine, auxiliary mechanism, electric furnace, manipulator and punch. Designing the human-machine interface and programming corresponding PLC function.Finally, the prototype production and commissioning have been carried on, the system’s run result have been given. The deficiencies that exist in the system were analyzed and the next goal was made.