飛剪機台定尺裁切技術改善之個案研究

Case Study on Cut to Length Rotary Shear Machines

陳明助(Ming-Chu Chen)

指導教授 ： 洪一薰

國立臺灣大學/工學院/工業工程學研究所/碩士(2020年)

https://doi.org/10.6342/NTU202002217

摘要

飛剪裁切(rotary shear)系統是為定尺裁切(cut to length line)產線的先進控制系統，廣用於金屬片材加工及配銷業。本文從鋼板產品的規格需求面，在連續生產的條件下分析製程技術，於每一個運轉週期內，建構同步、異步區控制的運轉模式。同步裁切模型，使裁切線筆直並垂直於產線方向。以定尺長度(特定長度)控制數學模型，在非同步區調整裁刀之加減速以符合長度要求。整合兩種控制方法，建立電子凸輪控制韌體，達到定尺裁切的訴求。在整條產線的同步規劃考量；定轉矩控制(torque control)可使設備可用於更薄的板材裁切。穩定的張力控制，使得鋼板整平效果更佳。並研究運作的邊界條件，導入PLC程式中，達到全線同步伺服控制系統。其次，採用綠能電源回收系統，電源供應選用整流模組(Rectifier Module)，其輸出之直流電能連結至直流公共匯流排(common DC bus)，並供應電能給各軸主機驅動器。系統內，以張力控制模式取代機械煞車。將剎車機械能轉換之回生電能，回饋至直流公共匯流排上，可以讓各軸的能源能夠共用，或由其他機台的電容器吸收，達到環保節能的效果。

關鍵詞：飛剪、同步裁切、電子凸輪、定尺裁切、電能回生、控制韌體化

關鍵字

定尺裁切 ； 飛剪 ； 同步裁切 ； 電子凸輪 ； 電能回生 ； 控制韌體化

並列摘要

The Rotary shear system is one of the major components in advanced cut-to-length machines which are widely used by sheet metal products manufacturer. This research aims to analyze the demand and specification of metal sheet products by constructing a synchronous cutting model, where cutting period contains both synchronous zone and asynchronous zone under the condition of continuous production process. Furthermore, the synchronous cutting model leads the cutting line perpendicular to the direction of the production line. On the other hand, the fixed length control model allows to adjust the speed of the cutting knife respectively within the asynchronous zone to meet the desired length of the material. Integrate two control methods and establish the firmware of electrical cam to meet the requirements of cut-to-length production.
From the perspective of full production line planning, torque control allows the equipment to operate on thinner metal sheet. The stable tension control further enhances the leveling of the condition of the metal sheet. On the other hand, we further study the boundary condition and implement such method into the Programmable Logic Controller (PLC) to achieve full synchronous speed line of the Servo control system.
A green energy power recovery system is adopted for the power supply system. It uses a Rectifier Module, and its output DC power is connected to the DC link, and then connected to the host of each axis to form the structure of the Common DC Bus. The regenerative electric energy comes from the Uncoiler, which continuously generates electricity in the form of a generator, and the Rotary Shear machine, which varies in repeated speeds. The regenerative electric energy is fed back to the Common DC Bus and shares electric energy to the main drive of each axis, achieving the effect of environmental protection and energy saving.

Keywords： Cut to length Line, Rotary Shear, Synchronous, Asynchronous, Electrical Cam, Regeneration

並列關鍵字

Cut to length Line ； Rotary Shear ； Synchronous ； Asynchronous ； Electrical Cam ； Regeneration

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