Study On The On-line Detection And Control System Of Continuous Rock Grinder Based On Linear CCD

Continuous rock grinder is one of the widely used stone processing equipments.Currently,the continuous rock grinder has already reached a high level of automation and systems integration.Non-contact detection and grinding can be achieved automately,which makes the rock grinding process be efficiency and greatly improvs quality of grinding.The in-contact width detection system is still used in domestic rock processing equipment.There are many gaps between the non-contact and in-contact rock processing equipments.In order to enhance the automation and integration of domestic continuous rock grinder control systems,based on traditional grinder,the continuous rock grinder is developed by using machine vision detection,real-time communication between IPC and PLC and grinding automation control technology.The main research can be summarized as follows.(1)In order to complete the design of the continuous rock grinder control system,the mechanical structure of the traditional continuous rock grinder are described and analyzed.Through the selection of the main components control system of the continuous rock grinder and the elaboration of the work process,the online detection system and polishing control system of the continuous rock grinder is designed.(2)In order to achieve automatic detection of the width of rock slab,a visual detection technology is proposed for rock slab.Using linear CCD camera to acquire image information,the noise is removed by the one-dimensional filtering technology.By using one-dimensional image adaptive thresholding techniques based on Otsu method,large stone slab width data is obtained.In order to obtain the width data of real rock slab,the camera calibration technology is used to obtain internal and external camera parameters of linear CCD camera.The transform of image coordinates and world coordinates is achieved through coordinate transformation technology.The measurement accuracy and measurement efficiency of continuous rock grinder can be improved by this technique,and the labor intensity is reduced effectively.(3)In order to achieve real-time communication between IPC and PLC,the RS-485 communication of PPI protocol communication method is proposed.The communication program for IPC are studied and prepared by C++/MFC MSComm.By using S7-200 PLC in STEP 7-Micro WIN programming software,the free port communication data reception procedures were studied and prepared.Data communications between IPC and PLC is achieved by the communication system,which the guarantee polishing processing of PLC control system of continuous rock grinder.(4)In order to achieve automatic grinding control of continuous rock grinder,three key technologies of PLC control system are analyzed and studied.The details are described as follows:Considering the disadvantages of traditional continuous rock grinder speed control system,the speed control method based on S curve is propoesd to avoid mechanical system movement jiggly and nonuniform situation.Because continuous rock grinder needs a large number of I/O interface,only using I/O module expansion can not meet the requirement.Through using matrix scanning principle in continuous rock grinder control system,the I/O virtual interface is increased to meet the demanding of the input and output.Considering the beam and belt mathematical models of the dropping condition of the grinding head,the mathematical model of final dropping condition is obtained.(5)In order to achieve the automatic processing of the grinding and polishing system of the continuous rock grinder,the main control system of the three movement direction are expounded and analyzed.A PLC-based control process is proposed based on the control mode of the motion,and the controlled objective and the input and output interfaces are determined for the control system.The program for control system of continuous rock grinder is designed and compiled by STEP7-MicroWIN software.Based on the above research,the intelligent automation of grinding and polishing process is achieved by reforming the traditional continuous rock grinder and introducing the visual width measurement technology of the rock slabs,and the problems that the continuous rock grinder automation degree is not high and the precision is not enough are solved.The intelligent degree,production efficiency and economic benefit are improved,which have significant effects on the stone production and processing industry.