全自动铝条折弯机归属于玻璃加工行业，主要用于真空玻璃外侧密封铝条的生产。近年来随着对建筑要求的提高，中空玻璃市场需求不断扩大。

The fully automatic aluminum strip bending machine belongs to the glass processing industry and is mainly used for the production of vacuum sealed aluminum strips on the outside of glass. In recent years, with the increasing demand for building environmental protection, the demand for insulated glass in the market has continued to expand.

本文分析了铝条折弯机设备组成和工艺流程，构建以和利时MC运动控制器+RTEX总线系统+松下A6N交流伺服系统为核心的铝条全自动折弯机控制系统，实现上料、接料、进给、折弯等全过程的自动化生产，提高了生产效率和折弯质量。

This article analyzes the composition and process flow of aluminum strip bending machine equipment, and constructs a fully automatic aluminum strip bending machine control system with the core of Hollysys MC motion controller+RTEX bus system+Panasonic A6N AC servo system, realizing the automation of the entire process of feeding, receiving, feeding, bending, etc., improving production efficiency and bending quality.

关键词：折弯机、MC运动控制器、RTEX总线、中空玻璃

Keywords: bending machine, MC motion controller, RTEX bus, insulated glass

国内高端铝条折弯机市场一直都被国外所垄断，国内铝条的加工主要以手动折弯和铝条拼接方式为主。手动折弯存在铝条刚度差、四角漏气、生产效率低下等问题，使用的折弯机存在铝条精度不足、折角不美观等问题。因此，铝条自动折弯机的国产化，尤其是控制系统国产化已迫在眉睫。

The domestic high-end aluminum strip bending machine market has always been monopolized by foreign brands, and the processing of aluminum strips in China mainly relies on manual bending and aluminum strip splicing methods. Manual bending has problems such as poor rigidity of aluminum bars, air leakage at the four corners, and low production efficiency. The bending machine used has problems such as insufficient accuracy of aluminum bars and unsightly bending angles. Therefore, the localization of aluminum strip automatic bending machines, especially the localization of control systems, is urgently needed.

设备组成与工艺流程

Equipment composition and process flow

铝条折弯机的设备组成：

Equipment composition of aluminum strip bending machine:

该设备本体由机身机架、铝框背板、自动接料装置、步进给料机构、折弯机构、自动断料机构、电气控制系统、动力控制系统、控制箱及触摸屏人机界面等结构组成。

The device body consists of a body frame, an aluminum frame backplate, an automatic feeding device, a stepper feeding mechanism, a bending mechanism, an automatic 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

Composition diagram of aluminum bar fully automatic bending machine equipment

自动接料装置：

Automatic feeding device:

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。

Composed of joint positioning components and aluminum strip positioning components, when the signal is sent out at the tail of the aluminum strip, the feeding system will automatically locate the tail of the aluminum strip 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 feeding is executed by the system.

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 precisely adjusted and controlled.

自动断料机构：

Automatic cutting mechanism:

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。

When the initial loading or bending of a frame is completed, the cutting mechanism will automatically cut off the aluminum strip.

自动断料机构：

Automatic cutting mechanism:

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。

When the initial loading or bending of a frame is completed, the cutting mechanism will automatically cut off the aluminum strip.

电气控制系统：

Electrical control system:

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。

The electrical control system is the core part of the entire equipment, and the control software of the equipment is installed in the MC motion controller. All control instructions, computational work, input/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 high cost performance ratio. By adopting the RTEX bus control system, customers can significantly reduce wiring and installation work without increasing motor costs. The 100M network bandwidth and excellent stability of RTEX ensure that the control cycle between MC1002R and various A6N servo drives in the system can reach 0.5ms, greatly improving the control accuracy of customer machines.

动力控制系统：

Power control system:

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。

The pneumatic power system consists of several pneumatic solenoid valves, corresponding pneumatic circuits, numerous pneumatic components, and control signal circuits, responsible for completing complex programmable actions of the equipment.

触摸屏软件界面：

Touch screen software interface:

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。

The use of equipment by operators, the large amount of data input required, and the information about equipment operation that operators need to know are all completed through touch screens.

铝条折弯的工艺流程

Process flow of aluminum strip 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, the aluminum frame graphic parameters are input through the touch screen, and the foot switch is pressed to start running. The control system determines whether the raw material position selects the automatic feeding process or directly enters the automatic bending process, and automatically judges whether the current position of the remaining material joint is outside the prohibited bending zone. The step feed material 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 a situation where the currently processed aluminum strip is about to run out at any time. Through the system's automatic judgment, subsequent aluminum strips can be automatically connected to the tail of the current aluminum strip without interrupting the forming work of the current aluminum strip.

控制方案

Control scheme

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

MC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。

MC has high-precision 64 bit motion calculation, dual core ARM Cortex-A9 CPU, and a 667M main frequency controller using ARM Cortex-A9 CPU and 667M main frequency; The operation is performed using 64 bit double precision floating-point numbers to ensure accuracy.