The equipment body is composed of a body frame, an aluminum frame back plate, an automatic material receiving device, a stepper feeding mechanism, a bending mechanism, an automatic material cutting mechanism, an electrical control system, a power control system, a control box, and a touch screen human-machine interface.

铝条全自动折弯机设备组成图

Equipment composition diagram of aluminum bar fully automatic bending machine

自动接料装置：由接头定位部件和铝条定位部件组成，当铝条尾部到达信号发出时，接料系统会自动定位铝条尾部，等待下一条铝条的自动续接。

Automatic material receiving device: composed of joint positioning components and aluminum strip positioning components. When the aluminum strip tail reaches the signal, the material receiving system will automatically locate the aluminum strip tail and wait for the automatic continuation of the next aluminum strip.

步进给料机构：当控制系统发出步进长度信号时，由该系统执行给料。

Step feeding mechanism: When the control system sends a step length signal, the system executes feeding.

折弯机构：折弯机构的折弯角度可以精确调节和控制。

Bending mechanism: The bending angle of the bending mechanism can be accurately adjusted and controlled.

自动断料机构：当初始上料或一个框折弯完成时，断料机构会自动切断铝条。

Automatic cutting mechanism: When the initial feeding or bending of a frame is completed, the cutting mechanism will automatically cut the aluminum strip.

电气控制系统：电气控制系统是整个设备的核心部分，设备的控制软件安装在MC运动控制器中。所有的控制指令、运算工作、输入输出信号、系统状态监视，以及与操作人员的信息交流均由该部分完成。

Electrical control system: the electrical control system is the core part of the whole equipment, and the control software of the equipment is installed in the MC motion controller. All control instructions, calculation work, input and output signals, system status monitoring, and information exchange with operators are completed by this section.

该系统采用松下支持RTEX总线的A6N伺服及电机。RTEX具有极高的性价比，采用RTEX总线控制系统后，客户在不增加电机成本的情况下，大幅降低了配线安装工作。100M的网络带宽和RTEX优异的稳定特性，确保了MC1002R与系统各个A6N伺服驱动器之间的控制周期能够达到0.5ms，从而大幅提高了客户机器的控制精度。

The system adopts Panasonic's A6N servo and motor that supports RTEX bus. RTEX has a very high cost-effectiveness. By adopting the RTEX bus control system, customers can significantly reduce wiring installation work without increasing motor costs. The 100M network bandwidth and excellent stability characteristics of RTEX ensure that the control cycle between MC1002R and various A6N servo drivers in the system can reach 0.5ms, greatly improving the control accuracy of the customer's machine.

动力控制系统：由数个气动电磁阀、相应气路、众多气动元件，以及控制信号回路组成气动动力系统，负责完成设备复杂的程控动作。

Power control system: composed of several pneumatic solenoid valves, corresponding air circuits, numerous pneumatic components, and control signal circuits, the pneumatic power system is responsible for completing complex program control actions of the equipment.

触摸屏软件界面：操作人员对设备的使用、所需要的大量的数据输入，以及操作人员需要了解的设备运行的信息，均通过触摸屏来完成。

Touch screen software interface: The operator's use of the device, the large amount of data input required, and the information that the operator needs to know about the device's operation are all completed through the touch screen.

铝条折弯的工艺流程

The process flow of aluminum bar bending

设备上电后，通过触摸屏输入铝框图形参数，踩下脚踏开关设备开始运行，控制系统通过判断原料位置选择自动上料流程还是直接进入自动折弯流程，并自动判断当前原料的余料接头位置是否出现在禁折区。步进给料系统将由控制系统计算后的料长精确的给进折弯刀头，由折弯系统完成需要的折弯形状。

After the device is powered on, input the aluminum frame graphic parameters through the touch screen, press the foot switch, and the device starts running. The control system selects the automatic feeding process or directly enters the automatic bending process by judging the position of the raw materials, and automatically determines whether the remaining material joint position of the current raw materials is out of the current folding zone. The stepper feed system will accurately feed the material length calculated by the control system to the bending tool head, and the bending system will complete the required bending shape.

重复以上两步，直完成整个铝框成形流程。

Repeat the above two steps until the entire aluminum frame forming process is completed.

在铝框折弯过程中，随时会出现当前加工的铝条即将用完的情况，通过系统自动判断可使后续铝条自动续接当前铝条尾部，不中断当前铝条的成形工作。

During the bending process of the aluminum frame, there may be situations where the currently processed aluminum bars are about to be used up. Through automatic judgment by the system, subsequent aluminum bars can be automatically connected to the tail of the current aluminum bar without interrupting the forming work of the current aluminum bar.

控制方案

Control plan

控制器选用和利时MC1002R，是专用于运动控制的可编程控制器，一般用作单台复杂运动机械设备的控制核心。MC1002R支持RTEX总线控制系统，可以连接多达32轴的松下A6N伺服。

The controller uses Hollysys MC1002R, which is a programmable controller specifically designed for motion control and is generally used as the control core of a single complex motion mechanical device. MC1002R supports RTEX bus control system and can connect up to 32 axis Panasonic A6N servo.

具有高精度64位运动解算，双核ARM Cortex-A9 CPU，667M主频控制器采用ARM Cortex-A9 CPU、667M主频；运算采用64位双精度浮点数进行运算，确保运算精度。

Equipped with high-precision 64 bit motion calculation, dual core ARM Cortex-A9 CPU, 667M main frequency controller using ARM Cortex-A9 CPU and 667M main frequency; 64 bit double precision floating point number is used for operation to ensure the accuracy of operation.

运动控制器

Motion controller

设备由触摸屏、MC运动控制器和伺服系统组合成一个开放式运动控制系统，根据折弯工艺要求由MC运动控制器对各个输出点、伺服单元进行控制，送料伺服单元收到命令后驱动伺服电机进行送料，实现铝条折弯机的运动控制和逻辑控制。控制流程如下图：

The equipment is composed of touch screen, MC motion controller and servo system to form an open motion control system. According to the bending process requirements, MC motion controller controls each output point and servo unit. After receiving the command, the feeding servo unit drives the servo motor to feed, realizing the motion control and logic control of the aluminum bar bending machine. The control process is shown in the following figure:

控制流程图

Control flowchart

实现的功能及效果

Implemented functions and effects

经过实际运行效果得出，此控制系统实现的功能如下：

After actual operation, it can be concluded that the functions implemented by this control system are as follows:

弯角速度自动调节

Automatic adjustment of bending speed

铝条自动连接，矩形框接头智能避让

Automatic connection of aluminum strips, intelligent avoidance of rectangular frame joints

有独特的自动接料装置，接料工作稳定，对连续工作无任何影响；

Equipped with a unique automatic material receiving device, the material receiving work is stable and has no impact on continuous operation;

自动断料，断口毛刺微小且易，不影响下道工序和美观

Automatic cutting, small and easy to remove burrs on the fracture surface, without affecting the next process and aesthetics

加热功能，可以用于暖边条折弯，且暖边折弯每个折弯角部采用独立的加热控制，保证折弯质量；

The heating function can be used for bending the warm edge strip, and each bending corner of the warm edge bending adopts independent heating control to ensure the bending quality;

打孔功能，打孔配置可在折弯时在间隔框上加工充气孔,用以中空玻璃加工完毕后人工充氩气工作；

Punching function, punching configuration can process filling holes on the spacing frame during bending, used for manual argon filling work after the processing of hollow glass is completed;