Trang 1 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT ELECTRONICS AND ELECTRONIC ENGINEERING TECHNOLOGY Ho Chi Minh City,
MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT ELECTRONICS AND ELECTRONIC ENGINEERING TECHNOLOGY PROGRAMMING AND CONTROLLING AUTOMATIC TAPPING MACHINE MODEL ADVISOR : STUDENTS : LE HOANG LAM, MS HO NGUYEN THANH LONG NGUYEN DUC HUY SKL010600 Ho Chi Minh City, December 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT PROGRAMMING AND CONTROLLING AUTOMATIC TAPPING MACHINE MODEL Name: HO NGUYEN THANH LONG Student ID: 18142036 Name: NGUYEN DUC HUY Student ID: 18142025 Major: ELECTRICAL AND ELECTRONICS ENGINEERING TECHNOLOGY Advisor: LE HOANG LAM, MS Ho Chi Minh City, December 2022 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, December 28th, 2022 GRADUATION PROJECT ASSIGNMENT Student name: Long Ho Nguyen Thanh Student ID: 18142036 Student name: Huy Nguyen Duc Student ID: 18142025 Major: Electrical and Electronics Engineering Technology Class: 18142CLA Advisor: MS Lam Le Hoang Project title: Programming and controlling automatic tapping machine model Initial materials provided by the advisor: Content project: Final project: CHAIR OF THE PROGRAM ADVISOR (Sign with full name) (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, December 28th, 2022 ADVISOR’S EVALUATION SHEET Student name: Long Ho Nguyen Thanh Student ID: 18142036 Student name: Huy Nguyen Duc Student ID: 18142025 Major: Electrical and Electronics Engineering Technology Project title: Programming and controlling automatic tapping machine model Advisor: MS Lam Le Hoang EVALUATION Content of the project: Strengths: Weaknesses: Approval for oral defense? Overall evaluation: (Excellent, Good, Fair, Poor) Ho Chi Minh City, December 28th, 2022 ADVISOR (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, December…., 2022 PRE-DEFENSE EVALUATION SHEET Student name: Long Ho Nguyen Thanh Student ID: 18142036 Student name: Huy Nguyen Duc Student ID: 18142025 Major: Electrical and Electronics Engineering Technology Project title: Programming and controlling automatic tapping machine model Name of Reviewer: ……………………………………………………… EVALUATION Content and workload of the project Strengths: Weaknesses: Approval for oral defense? 5.Reviewer’ questions for project valuation Mark: ……………… (In words: ……….…………………………………………………….) Ho Chi Minh City, December…., 2022 REVIEWER (Sign with full name) DISCLAIMER Subject: PROGRAMMING AND CONTROLLING AUTOMATIC TAPPING MACHINE MODEL Instructor: MS HOANG LAM LE Student's name: Ho Nguyen Thanh Long Student ID: 18142036 Contact phone number: 0915224092 Email: 18142036@student.hcmute.edu.vn Nguyen Duc Huy Student ID: 18142025 Contact phone number: 0378790936 Email: 18142025@student.hcmute.edu.vn Promises: We (Long Ho Nguyen Thanh and Huy Nguyen Duc) hereby declare that the topic “PROGRAMMING AND CONTROLLING AUTOMATIC TAPPING MACHINE MODEL” is our research work under the guidance of MS Le Hoang Lam The results published in the Graduation Project are honest and not copied from any other works Ho Chi Minh City, December…, 2022 Group Representative’s Signature (Sign with full name) Long Ho Nguyen Thanh Huy Nguyen Duc ACKNOWLEDGEMENTS To complete this graduation thesis, it is impossible not to mention the help from the teachers where I studied and researched First, I would like to express my sincere thanks to the school for creating conditions for me to learn effectively and train myself as a future engineer Besides, the group would like to thank the teachers and teachers in the Faculty for high quality training in particular and the teacher of Ho Chi Minh City University of Technology and Education, in general up to the present so I can apply the knowledge learned to the research process and implement the graduation thesis In particular, my group would like to express their deepest thanks to the teacher instructor - Master Engineer Hoang Lam Le for guiding my group and imparting knowledge and experiences in the process of making projects for the group Students can best complete the graduation thesis The graduation thesis has been completed by my group for nearly months at Ho Chi Minh City University of Technology and Education During the process of making graduation projects, my group received a lot of support from teachers, friends, brothers, and sisters who were dedicated to teaching and answering the questions that the group was entangled with so that my group would be able to complete this graduation thesis However, due to the limited time and knowledge of the group, the group's graduation thesis is not without the existence of errors I look forward to receiving valuable comments from teachers, the council commented that this good project is better completed Finally, my group thank their families and friends for always supporting, accompanying, and encouraging the group of students throughout the process of making the graduation project Sincerely thanks! Ho Chi Minh City, December… ,2022 Group Representative’s Signature (Sign with full name) TABLE OF CONTENTS DISCLAIMER ACKNOWLEDGEMENTS LIST OF FIGURES LIST OF TABLES 13 ABSTRACT 14 ABBREVIATIONS 15 CHAPTER 1: PROJECT OVERVIEW 1.1 1.2 1.3 1.4 1.5 1.6 Content of the subject CHAPTER 2: THEORETICAL BASIS 2.1 CNC overview 4 2.1.1 Introduction to CNC machine 2.1.2 Working principle of CNC machine 2.1.3 Application and classification of CNC machines 2.1.4 Advantages, disadvantages and applications of CNC machines 2.2 Programmable Logic Controller 11 13 2.2.1 Introduction PLC 13 2.2.2 Advantages, disadvantages and applications of PLC 14 2.2.3 Basic structure of PLC 15 2.2.4 Working principle and structure of PLC [8] 19 2.2.5 Introducing PLC MELSEC-Q Mitsubishi 20 2.3 Overview of AC servo 25 2.3.1 General introduction to AC servo 25 2.3.2 Mitsubishi AC servo motor 28 2.3.3 General introduction of Driver Servo 31 2.3.4 Comparison of step motor and AC Servo motor 34 2.3.5 Encoder 35 2.3.6 Brushless 38 2.4 Positioning Module QD75D4 40 2.5 Overview of the control system 48 2.6 Mitsubishi communication network solutions 49 2.6.1 Ethernet/IP communication standard 49 2.6.2 CC-Link communication standard 50 2.7 Software used in the system 52 2.7.1 GX Works2 52 2.7.2 GT Designer3 53 2.7.3 AutoCAD 54 CHAPTER 3: DESIGN AND MODEL CONSTRUCTION 55 3.1 Introduction to the model 55 3.2 Mechanical component 56 3.2.1 Introduction mechanical 56 3.2.2 Steps for the construction of mechanical component 58 3.3 Electrical component 59 3.3.1 Introduction electrical 59 3.3.2 Block diagram 60 3.3.3 The devices are in the model 60 3.3.3.1 Base unit – I/O slot 60 3.3.3.3 Module CPU Q03UDV 62 3.3.3.4 Module Intelligent QD75D4 63 3.3.3.5 CC-Link communication module QJ61BT11N 66 3.3.3.6 Driver and Servo motor of X, Y, Z-axis 69 3.3.3.7 Brushless DC motor driver CC-Link BLED6C-CC 72 3.3.3.8 Brushless DC motor BLEM 46-GFS 73 3.3.3.9 Remaining devices 73 CHAPTER 4: CONTROLLER PROCESS 80 4.1 Overview of the implementation process 80 4.2 Calculate and setting control parameters on the GX Work2: 81 4.3 Control parameters for Axes 83 4.4 Design the interface on GT Designer3 software and conduct machining 88 4.4.1 Create the interface for the system 88 4.4.2 Conduct machining 96 CHAPTER 5: RESULTS, CONCLUSIONS AND THESIS DEVELOPMENT 101 5.1 Successful results 101 5.2 Conclusion 101 5.3 Theme development directions 102 REFERENCE 103 APPENDIX 104 GRADUATION THESIS Step 5: Enter “Speed table Axis XY input”, “Speed Spindle”, “Speed Z Down”, “Distance Z” Step 6: Press “Start Data”, the progress will be started Fig 31: The result after the tap process arranged in the shape of the mitsubishi logo is done AUTOMATIC CONTROL SUBJECT Page | 117 GRADUATION THESIS Fig 32: The result after the tap process arranged in the shape of the circle is done AUTOMATIC CONTROL SUBJECT Page | 118 GRADUATION THESIS CHAPTER 5: RESULTS, CONCLUSIONS AND THESIS DEVELOPMENT 5.1 Successful results ● Successfully connected 220V and 24V power supplies for PLC, Driver, Motor ● Fabrication and installation of structural mechanical parts ● Read and understand wiring diagrams, manuals, catalogs of control devices, motors ● Successfully constructed a stable 3-axis automated tap machine model to make sure there are no problem during tapping progress ● The servo control panels match each other according to the preset data In particular, the brushless DC tap motor is controlled by the Driver through the CC-Link module and works simultaneously with the Z axis when tapping down the workpiece ● Successfully applied Cc-link communication network to the system ● The system runs steadily during operation ● Productive with the MELSOFT series GX Work2 and GT Designer3 applications ● Programmable Safety and Emergency Stop protects the system 5.2 Conclusion Our team has obtained a significant amount of knowledge about the project while carrying out the graduation project, and has identified the following benefits and drawbacks of the 3-axis automatic Taro model of the system: ❖ Advantages: ● Design and construction of the automatic tapping control system ● Servo motors control axis XYZ with high speed and precise position ● The DC brushless motor has a powerful gearhead that responds to tapping conditions with slow speeds and large torque ● Can tap workpieces with a thickness greater than 3mm ● Cc-link has a fast data transfer rate and can be expanded to connect many devices through the CC-Link module in the future AUTOMATIC CONTROL SUBJECT Page | 119 GRADUATION THESIS ● The tapping system uses AC servo motor and Brushless DC motor which is quiet and low noise ● The HMI display is designed to be simple and easy to use Simple system operation Alerts and displays most errors on the HMI screen ❖ Disadvantage: ● Must locate the exact borehole coordinates before the tap process is performed ● Taro hole after tapping with tap details inside is still not sharp ● Project has only performed tapping on thin and medium flat workpieces actual control screen yet and only control operator computer ● The tap system can drill but the drilling process is very slow ● Taro drill chuck is still difficult to change and there is no automatic tap change mode The system will lose its coordinate position when the power is suddenly cut off 5.3 Theme development directions After tapping many times on different types of workpieces with different thicknesses as well as taps with different thread pitches, the team found the following solutions and directions for developing the topic ❖ Solutions ● Get a backup PIN that the driver can memorize the location in order to avoid unforeseen power outages ● Design an external physical Emergency stop button to help us proactively stop the system when there is a problem ● Complete the mechanical part of the Z-axis lead screw shaft holder to make the tapping journey down more, it is easier to change the tap bit and tap the workpiece with a thicker workpiece ● Add a torque sensor to determine the "Subpoint" position more accurately ● Develop SCADA system to store data and monitor product’s data information AUTOMATIC CONTROL SUBJECT Page | 120 GRADUATION THESIS REFERENCE [1] MITSUBISHIELECTRIC “MR-J2-_A SERVO AMPLIFIER INSTRUCTION MANUAL.” Mitsubishielectric.com [2] AC Servos-MELSERVO https://www.mitsubishielectric.com/fa/vn_vi/download/index.html#manualArea [3] BLED6C, Brushless DC Motor Driver https://catalog.orientalmotor.com/item/es-shop-online-components-speed-controlcomponents/speed-controllers/bled6c [4] Monolithicpower “Brushless and Brushed Dc Motors : When and Why to Choose One Over the other.” Monolithicpower.com https://www.monolithicpower.com/en/brushless-vs-brushed-dc-motors [5] Robu “Brushless DC Motor Working Principle And Applications.” Robu.in https://robu.in/brushless-dc-motor-working-principle-construction-applications/ (Accessed April 28, 2020) [6] Wikipedia contributors “Numerical Control” En.wikipedia.org https://en.wikipedia.org/w/index.php?title=Numerical_control&oldid=1096784869 [7] Wikipedia contributors” CC-Link Open Automation Networks” En.wikipedia.org https://en.wikipedia.org/wiki/CC-Link_Open_Automation_Networks [8] Wikipedia contributors “Brushless DC electric motor” En.wikipedia.org https://en.wikipedia.org/wiki/Brushless_DC_electric_motor [9] Electronicscoach “AC Servo motor.” Electronicscoach.com https://electronicscoach.com/ac-servomotor.html [10] Tapping Explained: Type, Selection Principle, and Tapping Skills https://www.machinemfg.com/tapping-explained/ [11] Dynapar “Motor Encoder Overview.” Dynapar.com https://www.dynapar.com/technology/encoder_basics/motor_encoders/ [12] Brushless DC Motor Speed Control Systems https://www.orientalmotor.com/brushless-dc-motors-gear-motors/index.html [13] Drill and Tap Reference for CNC Machined Parts https://parts-badger.com/drill-tap-referencing/ [14] Thermal drilling processing on sheet metals: A review AUTOMATIC CONTROL SUBJECT Page | 121 GRADUATION THESIS https://www.sciencedirect.com/science/article/pii/S258884041930006X [15] What is CC-Link V2 https://www.cc-link.org/en/cclink/cclink/ver2.html APPENDIX APPENDIX 1: (Layout diagram of system electrical cabinets) AUTOMATIC CONTROL SUBJECT Page | 122 GRADUATION THESIS APPENDIX 2: (Controller circuit connection diagram) AUTOMATIC CONTROL SUBJECT Page | 123 GRADUATION THESIS APPENDIX 3: (Communication network circuit diagram) AUTOMATIC CONTROL SUBJECT Page | 124 GRADUATION THESIS APPENDIX 4: (Connection diagram of the motor circuit) AUTOMATIC CONTROL SUBJECT Page | 125 GRADUATION THESIS AUTOMATIC CONTROL SUBJECT Page | 126 GRADUATION THESIS APPENDIX 5: (Controller circuit connection diagram) AUTOMATIC CONTROL SUBJECT Page | 127 GRADUATION THESIS APPENDIX 6: (Working diagram) AUTOMATIC CONTROL SUBJECT Page | 128 GRADUATION THESIS APPENDIX 7: (Working diagram) AUTOMATIC CONTROL SUBJECT Page | 129 GRADUATION THESIS AUTOMATIC CONTROL SUBJECT Page | 130 S K L 0