Trang 1 MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT ELECTRONICS AND ELECTRONIC ENGIN
OVERVIEW OF THE PROJECT
Problem
Servo motors play a crucial role in motion control systems and are extensively utilized in industrial production and automation Despite their higher cost, the advantages they offer, including precise positioning, rapid reversing, and exceptional performance, make them an invaluable investment for various applications.
Nowadays, together with science and technology, Servo motor technique is also widely applied and plays an important role in automatic control systems
Objectives of the topic
➢ Can communicate with devices of the model: PLC Mitsubishi Q series, Driver MR- J4-B, Servo,
➢ Machine design capable of polishing all-round surface
➢ Precise operation control according to the specified requirements
➢ Use related software: programming software, HMI software,
Research Methods
In order to complete the topic in the best way, the group was guided in the clearest way from the instructor
The team has extensively researched various online sources and conducted observations of real machines, enabling them to identify key requirements and establish research directions for their model.
✓ Get advice and guidance from instructors and learn from real-life models that give you the best direction
✓ Research and learn programming to control Servo motors
✓ Perform mechanical processing, assemble the model from which to give an idea for the movement and operation of the model
✓ Modify hardware to suit the intended use of the model, install electrical assembly (control cabinet components)
✓ Connect the devices as well as connect to the source (wiring the devices)
✓ Iterate the driver to achieve the desired result
✓ Run test and observe the results
✓ Edit and optimize the system
Project limit
✓ The subject only stops at the model mode Polishing only the available material does not cover all materials
✓ The polishing speed and gloss of the product do not meet the actual needs
✓ Controlling the 3-axis according to direct deviations by software.
Research subjects
- Structure of lead screw (X, Y, Z axis)
- Other hardware details: support table, pedestal,
THEORETICAL BASIS
Overview of polishing machine
A Polishing machine is a type of machine that treats metal, making materials shiny With the following advantages:
- Can work with high hardness metals such as aluminum,
- High polishing quality, many levels of polishing, can work on variety of materals
- Crankshaft and slider control mechanism
Figure 2 1: Polishing machine in industry
The principle of the polishing machine is the circular motion created by the motor, using the impact force to combine the friction with the material to create the product
Currently on the industrial market, factories are using different types of polishing machines, each with different uses
Three-dimensional vibrating polishing machine is also known by other names such as: Vibrating shock machine, vibrating machine With this machine has improved working efficiency many times
Figure 2 2: 3-way vibrating polishing machine
The three-dimensional vibrating polishing machine is ideal for processing small parts in bulk, offering the significant advantage of allowing direct product inspection while the machine is in operation.
The rotary cage polishing machine features a sturdy A-shaped support, ensuring exceptional stability It operates on the principle of a vertically rotating cage, making it ideal for polishing small-sized products with flat surfaces and shapes.
Figure 2 3: Rotary cage polishing machine
• Polishing machine using abrasive belt:
The machine employs a high-speed abrasive belt to effectively remove rust and polish metal surfaces, making it ideal for finishing tubes, boxes, and metal plates.
2.1.4 Advantages and disadvantages of polishing processing a) Advantages of polishing machine
- Polishing all material surface, used to remove sharp edges on small products
- Products are stable in quality
- Saves processing time, takes less labor, optimizes production costs
- High economic efficiency, less waste in production b) Disadvantages of polishing machine
- Complicated parts can’t be treated
- Gloss can’t be consistent and can’t last a long time
- Could be vulnerable to corrosion
- The mechnical strength of the surface is weaked.
AC servo motor overview
2.2.1 General introduction about AC Servo motor a) Introduction to Servo
A servo motor utilizes an encoder to provide feedback signals to the control driver, enabling precise adjustments in speed, torque, and position to achieve specific outcomes This feedback mechanism allows the motor to self-adjust for varying torque, speed, or inertia based on the load it carries, particularly when faced with obstructions or impacts that may slow the motor shaft In the event of external forces, the servo motor and its connected mechanical structure may shift from their positions, as they are inherently inclined to do so without external constraints.
6 of a control signal Mechanically, the servo will go back to the place where it was before becoming out of alignment
Figure 2 6: The example of servo motor
The AC Servo Motor is a 3-phase electric rotating motor that operates on the principle of permanent magnets, similar to motors used in pumps and fans Unlike conventional motors, AC Servo Motors are equipped with advanced electronic tools and sensors, including amplifiers, controllers, encoders, and monitors, which enhance accuracy and control This integration is crucial for meeting the demands of industrial production in the era of Industry 4.0.
AC Servo Motor system is composed of 3 main parts
The AC Servo Motor controller features screens and buttons that facilitate the reception and transmission of information, including speed, position, and torque This data is displayed on the main screen, allowing users to easily adjust parameters and configure the PLC for optimal motor performance tailored to specific tasks.
A servo amplifier is a specialized electronic device designed to receive command signals from control systems, amplify them, and deliver current to servo motors, enabling precise control over speed, torque, and position By continuously monitoring feedback signals from encoders, servo amplifiers can correct any deviations, ensuring the servo motor operates with high accuracy In a well-designed control system, the servo motor's performance closely matches the control signal received from the control system, achieving precise control and desired outcomes.
The amplifier receives encoded information from the encoder and transmits it to the controller for display on the screen Its main function is to continuously adjust the actual outcomes to reduce discrepancies before instructing the motor to operate.
7 great automation capabilities of the AC Servo Motor, which result in the precision we can see in the results of CNC cutting machines, are its defining characteristic
Figure 2 7: The principle of servo amplifier
Each type of Servo motor usually comes with a dedicated Servo Amplifier, sowhen choosing a Servo Amlifier, we must also choose a suitable Servo motor
The MR-J4B Servo Amplifier series stands out in the market as a cutting-edge solution for motor control technology, featuring advanced anti-vibration capabilities, rapid and precise response times, and straightforward installation This innovative amplifier includes a torque limiter and clamping circuit designed to safeguard the main circuit's power transistor from overcurrent issues arising from acceleration, deceleration, or overload situations.
The torque value can be adjusted to meet specific control requirements Powered by the MR-J4B servo amplifier, SSCNET III enhances communication speed and reduces interference through the use of optical fiber technology.
The AC Servo Motor consists of two main components: the motor and the encoder, which are interconnected by wires The motor features a rotor and stator, incorporating secondary windings made of aluminum or copper, a magnet, an electromagnetic brake, and a drive shaft that operates on the principle of permanent magnet application The encoder plays a crucial role by receiving information from the motor, converting it into a coded format for processing, and vice versa Additionally, AC Servo motors are equipped with a regenerative brake that not only reduces speed when necessary but also regenerates current for reuse, making them one of the most advanced energy-saving options available on the market today.
An encoder is an electromechanical device that transforms the angular position or movement of a shaft into an analog or digital output signal It plays a crucial role in monitoring the position, direction, and speed of a motor by counting the revolutions of the shaft.
+ 1 rotating disc with hole for mounting on the motor shaft
+ 1 LED used as light source
+ The circuit board helps amplify the signal
The number of pulses counted and incremented is calculated by the number of times the light is cut off
As the encoder moves, the transducer captures this motion and transforms it into electrical signals These signals are then sent to PLC control devices, where they are processed to accurately represent the values measured by an external program.
Figure 2 8: Encoder image installed behind Servo motor d) The function of AC servo motor
AC Servo motor works on the principle of pulse width modulation, also knownas PWM Basically, their rotation is related to the duration of the pulse
Motor control modes operate through three primary mechanisms: speed, position, and torque Depending on the intended application, users can select the most suitable installation mode for optimal performance.
A servo motor operates similarly to a conventional motor, featuring a rotor made of a permanent magnet and a stator with separate windings powered by precise timing and current The rotor's rotation is influenced by the frequency, phase, polarity, and current in the stator windings Additionally, servo motors utilize closed-loop feedback systems, where the output signal is linked to a control circuit This setup allows for real-time monitoring of speed and position, enabling the control circuit to adjust for any discrepancies in achieving the desired position, speed, or torque, ensuring optimal performance.
Figure 2 9: Servo motor closed feedback loop
The servo drive acts as a controller that receives control command signals, either in pulse or analog form, from the PLC It transmits these commands to the servo motor, ensuring it operates according to the specified instructions Simultaneously, the servo drive continuously receives feedback signals regarding the current position and speed of the servo motor from the encoder One notable example of a servo amplifier is the MR-J4-B.
The MR-J4-B servo amplifier enhances servo system performance by connecting to controllers through a high-speed synchronous network, enabling direct position data reading This setup allows for precise control over the rotation speed and direction of the servo motor, utilizing data from the command module for accurate positioning Additionally, the MR-J4-B's integration of an optical communication system significantly boosts communication speed and noise resistance compared to previous SSCNET versions.
Figure 2 10: Driver Servo and Servo Motor
+ Autotuning for settings, fast and accurate
+ High-speed control for ultra-short positioning times, medium frequency response rate of 900Hz
Figure 2 14: The image shows the Servo Driver name
Figure 2 15: The image of the internal structure of the amplifier driver MR-J4-B
- Ability to control and suppress vibration
- Ability to automatically adjust the load
- Switch operation in modes b) SSCNET (Servo System Controller Network)
Smooth, High-Speed and High-Accuracy Operation
SSCNET realizes high-performance and high-accuracy devices that could not be attained with conventional pulse train command or analogue command
Analog and pulse-train commands offer high-speed and high-accuracy control; however, they face challenges such as limited pulse frequency, susceptibility to line noise, voltage drops due to cable length, and temperature drift.
Introducing PLC MELSEC-Q Mitsubishi
a) General characteristics of Mitsubishi PLC Q series
- Mitsubishi PLC Q series is a compact, high-performance PLC series It integrates new techniques that break the limitations of traditional programmers
The multi-processor technique enables simultaneous processing by four CPUs, significantly enhancing time features and increasing program cycle scan times to just 0.5 to 2 milliseconds This advanced system streamlines machine control, position control, and communication processes, while also allowing users the flexibility to select control direction, perspective, and programming language, all within a single platform.
- Suitable for high-end control applications
- Mitsubishi Q series PLC offers a wide range of solutions for different applications
- Applications of Mitsubishi PLC Q series: Beer and beverage industry, semiconductor technology, packaging, waste incineration
Figure 2 18: Q03UDCPU b) Main features of Mitsubishi PLC Q series
- Mitsubishi PLC Q series has processing speed up to 34ns/LD
- High-precision A/D-D/A unit, applied in temperature control, position control
- CIP (Chanel Isolated Pulse) input, built-in high-speed pulse counter
- Full support in MELSOFT software applications
- Full range of network applications such as: CC-link, MELSECNET-H, …
Figure 2 19: Placement of PLC module
Positioning Module QD77MS4
Figure 2 20: : The figure of QD77MS4
(2) Wide variety of positioning control functions
(3) Large amount of data Up to 600 positioning data (combinations of data, such as control system, positioning address, and command speed) per axis can be set
(4) The synchronous control and electronic cam control can be performed
(5) The mark detection to latch any data by the external command signal [DI1 to
(6) Support of intelligent function module dedicated instructions
(8) Connection between the QD77MS and servo amplifier with high speed synchronous network by SSCNET (/H)
(9) Easy application to the absolute position system
(10) Easy application to the absolute position system
(11) Addition of forced stop function b) Communicating signals between QD77MS4 and each module
Figure 2 21: Communicating signals between QD77MS4 and each module
Figure 2 22: Communicating between QD77MS4 and each module
Theoretical basis of polishing materials and pressing torque
2.5.1 Classification of materials used for polishing other materials
Polishing materials are essential in manufacturing processes, particularly for metal products, stainless steel, and wood, as they enhance the surface quality, making it smoother and shinier This term encompasses a variety of polishing materials used across different industries today.
Polishing felt wheels, also referred to as polishing pads or polishing wheels, are abrasive tools made from a combination of industrial fabric fibers, abrasive particles, and adhesive These wheels feature a coarse surface, enabling them to effectively create friction, which results in shiny surfaces that enhance aesthetics and increase product value.
Figure 2 23: The figure of steel polishing
The fleece seal is designed specifically for polishing motorcycles and intricate details, including auto glass, lights, narrow corners, air conditioners, refrigerators, furniture, stainless steel, composite materials, and plastic For optimal results, use polishing step 1 to eliminate minor scratches after sanding, ensuring a brilliant initial shine.
Figure 2 24: The figure of fleece seal
Sandpaper is an efficient material that often surprises investors with its effectiveness It is composed of three main components: the abrasive material, the backing paper or fabric, and a special adhesive Depending on their specific functions, sandpapers are categorized into different types, each with varying densities, offering a wide range of choices for users.
When polishing metal, sandpaper is categorized by its abrasive material, with a preference for harder abrasives like zirconia, aluminum oxide, and ceramic beads These materials enhance the efficiency and effectiveness of the polishing process.
Round sandpaper is composed of Ceramics, Pearl…
Using this type of sandpaper significantly enhances sanding efficiency, effectively eliminating scratches on metal surfaces and restoring their smoothness.
Figure 2 25: The figure of round sandpaper
Roll sandpaper is a high-quality, ultra-fine sanding tool known for its self-sharpening properties, making it highly effective for sanding abrasive metal surfaces Leading brands such as NCA, JB5, and Starcke are recognized in the market for their exceptional performance and convenience, delivering impressive results in surface polishing.
Figure 2 26: The figure of roll sandpaper
Sandpaper is manufactured for manual handling of hard-to-grind areas such as edges, contours, and rough spots
Sandpaper sheets are sold a lot and used very popularly, you can trust using domestic and foreign manufacturers
Figure 2 27: The figure of sheet sandpaper
2.5.2 Calculating the pressure for the metal piece
Pressing the material is essential to stabilize objects and ensure that the polishing material effectively enhances the surface luster It is crucial to apply adequate pressure to avoid overloading the motor during operation The three primary objectives of compression are to maintain stability, achieve optimal polishing results, and protect the equipment from excessive strain.
- Create stability between the speed and pressure of the machine In order not to create an overload situation
- For transmission of transmission and braking force
- To ensure the gloss and smoothness of the surface
The force at this point is referred to as the pressing force, aimed at applying appropriate longitudinal tension While controlling longitudinal tension is essential, it can be challenging to measure shaft difficulty Therefore, torque control is utilized as an effective alternative, enabling precise management and facilitating ease of operation.
Figure 2 28: The figure of force acting on the aluminum
Pressure on the piece of aluminum
Utilizing a force sensor allows for precise measurement of the force exerted on the surface of a polished product This measurement provides an estimate of the relative compressive force, enabling the calculation of mass and the determination of the impact force acting on the polished surface.
+ Step 1: Carry out the force test
Figure 2 29: The example of testing Force
To ensure safe polishing operations, it is essential to assess the force applied to the measurement table at a constant speed This evaluation helps identify the optimal pressure values for the machine, establishing a secure working area for effective polishing.
+ Step 2: When measuring the impact force parameters through the loadcell, make a statistical table from which we can see the linearity of the force
From the theory, can calculate the Force acting on the polishing surface
T: Torque ( kg.F) m: mass of the motor of Z-axis acting on the surface (kg)
Besides, when calculating the force through measuring the value at the loadcell, there are many other influencing factors, such as: step parameters, default load of the machine
The result of calculation of process through loadcell
1st measurement method 2nd measuring method
Table 2.2: The measurement results through load cell
GX Works 2 and GT designer 3 software
Modern PLC product lines offer a diverse range of options, requiring businesses to develop specific programming software for each type For instance, Mitsubishi employs GX-Works2 or GX-Works3, while Siemens utilizes the TIA Portal for programming their PLCs Mitsubishi PLCs support various CNC programming software, with GX-Works2 designed to replace the older GX Developer software This versatile software accommodates multiple PLC series, including FX, Q, L, A, S, and CNC, enabling the programming of controls for CNC drills, cutters, breakers, and stamping machines, among other applications.
GX Works2 is a programming tool for designing, debugging, and maintaining programs
GX Works2 has functionality and operability and easy-to-use features
Figure 2 30: GX Works 2 software interface
➢ Create a program and execute it in a programmable controller CPU
6 Connecting the programmable controller CPU
7 Writing to the programmable controller
Mitsubishi's HMI consoles utilize GT-Designer 3, which simplifies user manipulation and control, even without a realistic screen This software is compatible with both GT SoftGOT1000 and GT SoftGOT2000, allowing operators to easily adjust parameters before production GT-Designer 3 supports both old and new HMI line designs, making it essential for designing surveillance screens.
Figure 2 31: GX Works 2 software interface
1 Create a project according to the new project wizard
2 [New Project Wizard] is displayed Check the description and click [Next]
3 Set the GOT type information in [GOT System Setting] →Click [Next]
4 Check the settings configured in [Confirmation of GOT System Setting] →Click [Next]
5 Set the controller to be connected in [Setting of Controller] →Click [Next]
6 Set the interface of the GOT to be connected with the controller→Click [Next]
7 Set a communication driver to be used→Click [Next]
8 Check the configured settings in [Confirmation of Communication Setting] →Click [Next]
9 Set a device used to switch the GOT screen in [Screen Switching Device Setting]
10 Confirmation of system environment settings→Click [Finish]
PROJECT DESIGN AND CONSTRUCTION
Introduction to the project
- The mechanical part must be firm, ensuring stability when the machine is running
- Install the correct mechanical system and arrange it properly for wiring
- Electrical wiring is safe and properly arranged
- Reasonable distribution and arrangement between the parts on the support table
Figure 3 1: Model of polishing machine
The machine runs stably with high speed
Ability to polish all surfaces
The gloss of the product after polishing reaches 80-90%
The screen is close and the control is precise
Device comparison and selection
Since the model leverages laboratory equipment that is already in place, it saves money and is simple to locate and replace during project execution due to the dense factor
Chose Mitsubishi PLC Q series: Q03UDCPU
Figure 3 2: Q03UDCPU a) Components in Q03UDCPU
Table 3 1: Names and applications of components in the Q03UDCPU
- Control method: Stored program repeat operation
- I/O control mode: Refresh mode (Direct access I/O is available by specifying direct access I/O (DX , DY ).)
- Sequence control language: Relay symbol language, logic symbolic language,
MELSAP3 (SFC), MELSAP-L, function block and structured text (ST)
- Max number of intelligent function module parameters:
- No of I/O device points (No of points usable on program.):8192 points (X/Y0 to 1FFF)
- No of I/O points (No of points accessible to the actual I/O module.): 4096 points (X/Y0 to FFF) c) Advantage
- Mitsubishi Q Series PLC programmable controller belongs to the line of high-quality automatic control devices
- High-speed, high-precision data processing
- Easy to change working mode
- Save time for control work
- Connect with other smart devices easily There are 2 USB and RS-232 jacks for connecting to peripheral modules
- Simplicity in installation and programming
Chose Servo Driver: MR-J4-20B (Mitsubishi)
+ Voltage/frequency: 3-phase or 1-phase 200 to 240VAC, 50/60Hz
+ Permissible voltage fluctuation: 3-phase or 1-phase 170 to 264VAC
- Control System: Sinewave PWM control, current control system
+ Voltage, frequency: 1-phase 200 to 240VAC, 50/60Hz
+ Permissible voltage fluctuation: 1-phase 170 to 264VAC
+ Power supply capacity: 150mA or more
The MR-J4-20B features comprehensive protective functions, including overcurrent shut-off, regenerative overvoltage shut-off, and overload shut-off through an electronic thermal relay It also offers servo motor overheat protection, encoder error protection, regenerative error protection, undervoltage protection, instantaneous power failure protection, overspeed protection, and excessive error protection These safety measures ensure optimal performance and reliability in various applications.
- MR-J4: Series of Servo Driver
Chose Servo HR-KR053,Servo HG-KR13 and servo HR-KR23
Figure 3 8: Describe what each block of the HG-KR type model name indicates
3.2.4 Select some other device a) Select positioning Module QD77MS4
Quantity: 2, of which one is used for X,Y axis and 1 is used for Z axis
Figure 3 9: Positioning Module QD77MS4
Table 3 2: Specifications of positioning Module QD77MS4 b) Select power supply module
- Max input Apparent power: 105 VA
IV Select output module QY42P
Table 3 3: Specification of output module QY42P
- Hysteresis: 20% or less of operation distance
- Current consumption: 15mA or less
Figure 3 13: Wiring diagram of sensor(NPN transistor)
- Name: Relay MY2N DC24 Omron
- Safety standard : CE / UL / CUL
- Dimension depth (mm) : 124.5 Figure 3 15: Source 24V DC
The 24V source provides voltage to the sensor and a brake
VII Noise filter WYFTH20T1BD
- Type: 3 Phase AC500V High Quality type
Protect electrical equipment during control from short circuit, short circuit, etc
- Manually close the circuit breaker
The mechanical system of the polishing machine consists of 3 main axes X, Y, Z
• Includes AC Servo motor connected to Vitme
• The X-axis is a horizontal axis along the table and is raised by two aluminum pillars on both sides
• AC Servo Motor: HG-KR053
• Is the bearing shaft for the Z-axis mechanism to perform polishing
• The Y-axis is the axis along the table and is placed on an aluminum
• The Y-axis is driven by a 100W HC-KFS13 AC Servo motor with a lead screw with a lead screw pitch of 12 mm and is limited by 2 sensors on both sides
• An aluminum worktable with dimensions of 265 x 210 mm and a thickness of 8 mm is placed on the slide of the Y axis
+ The Z axis is attached to the slider of the X axis so that it is perpendicular to the X axis in the same plane and perpendicular to the Y axis
The Z axis is powered by a 100 W HC-PQ13 AC Servo motor, featuring a lead screw with a 5 mm lead pitch and constrained by two sensors at either end, allowing for a limited travel distance of 95 mm Additionally, the spindle consists of a servo motor that is mounted in the spindle bearing and connected to the Z-axis slider.
Electrical design
The system uses 220V single-phase AC power to power the MR-J4-20B to control the motor 24V DC power supply to power the PLC and active sensors
The polishing machine includes 4 motors, each motor will have 1 driving wire and 1 encoder wire
Figure 3 22: Block diagram of polishing machine circuit
+ Power Supply: including 220 VAC and 24 VDC power for the system (computers,
PLC modules, Servo drivers, X, Y, Z-axis motors, and limited sensors)
+ Programable motion controller: Execute control commands, read the sensor value, and relay to process output signal
The Servo Driver Block for the X, Y, Z, and Main Axis features AC Servo motors equipped with signal pins that serve multiple functions These pins connect to the control system, enabling the reception, amplification, and transmission of control signals to the AC Servo motors.
+ Servo motor block X, Y and Z axis: Directly control the mechanical axes of the machine according to the signal transmitted to
The central processing block receives signals from the sensor upon touch, enabling it to process the information effectively.
CONTROLLER PROCESS
Control Algorithm
The code runs in the following order
2 Press the Z axis to polish the product
3 Move the axis left then right.
Setting the parameters on the GX-Work2
The initial step into the controller requires checking the vitme step of the 3-axis X, Y, and
The Z turntable, equipped with MR Configurator2 software, enables precise 3-axis movement based on coordinates inputted into the control computer By utilizing GX Works2 software, users can accurately manage the servo motor's driver by configuring essential parameters like gear ratio and pulse frequency.
To be able to use GX Work 2 software to control, we must declare the types of equipment used in the polishing process
Firstly, we have to choose the correct PLC module that we have In our case it is Q03UDCPU
Figure 4 1: The interface of choosing type of CPU module
The second step, we configure the whole system that have many modules with different function in PLC parameter
To declare the control modules, in “Paramter” => “PLC Paramter” => “I/O Assignment” Choose the location of the modules in the correct order on the hardware Choose “New Module” and declare
Figure 4 2: The interface of I/O Assignment
Figure 4 3: The intleginent Function Module Detailed Setting
Set the parameters for modules of position QD77MS4
Next, to install the parameters for module QD77MS4, click: “0000” => “Parameters” declared the same as the figure
Figure 4 4: The intleginent Function Module Detailed Setting
+ Unit setting: In the system using Vitme, the unit will be millimeters
+ No of pulses per rotation: Number of pulses for the motor to make one revolution
+ The system uses an 22-bit motor, so the number of pulses for the motor to rotate 1 revolution is 𝟐 𝟐𝟐 = 𝟒𝟏𝟗𝟒𝟑𝟎𝟒 𝒑𝒖𝒍𝒔𝒆𝒔
Figure 4 5: Setting parameter for Driver Servo
• Input signal logic selection: Lower limit
• Input signal logic selection: Upper limit
Figure 4 6: Setting parameter for Driver Servo
Figure 4 7: Setting parameter for Driver Servo
After finish the installation in the “ Servo parrameters” =>
Figure 4 8: The figure of setting parameters interface
+ Operation pattern: Working model of the axes It can be performed singly or in combination with data
+ Control system: Types to control the system
+ Axis to be interpolated: This function is to coordinate the operation between 2 axes
+ Positioning address: The address of the location we want to move there
+ Arc address: Addressing the arc when we want the system to move in a circular motion
+ Command speed: Speed of AC Servo motor
+ Dwell time: Rest interval between two consecutive data
Figure 4 10: Settings parameters for servo of Y-axis
Figure 4 9: Settings parameters for servo of X-axis
Figure 4 11: Settings parameters for servo of Z-axis
Figure 4 12: Current value for speed and error in the system
Desgin the HMI on the GT Desginer3 sofware
• Create the interface for the system
Figure 4 13: The interface when starting the software GT Desginer3
After that, click Next => Set up the interface for next screen, as shown
Figure 4 14: Set the screen size and display type
Press continue, choose the manufacturer and type of control to suit the PLC => Next
Figure 4 15: The manufacturer display interface and the PLC type of the system
Continue, press Next until see the figure below => Finish
Figure 4 16: The display when the installation finish
After configuring the values and accessing the main screen, the interface will be displayed as illustrated below In this section, we will proceed to create buttons, indicators, alerts, and display parameters that correspond to the variables programmed in GX Works2.
Figure 4 18: The figure of setting button for servon on
Figure 4 19: The figure of JOG speed display
And after configuring all displays, buttons, variables, warnings, etc., we get a screen interface as shown below
At this screen, the parameter value of electricity, machine load, and pressure value when pressing Aluminum pieces will be displayed
This screen displays sensor signals whenever the machine exceeds its limits or encounters a device error, allowing users to easily and conveniently monitor the system's status.
Control process
To begin the process, securely position the aluminum piece on the designated area of the machine, ensuring that the power source is disconnected and the circuit breakers are switched off for safety.
Figure 4 25: Insert the aluminum into the workpiece table
+ Step 2: Take a sandpaper ( P600) install into motor
+ Step 3: Check again the connection of wire, sensor, check the normall status of all devices, then power on the control system
Close the CP 24VDC to discharge the electromagnetic brake of the servo motor driving the polishing tool
+ Step 4: Turn on all driver by press the button “Servo ON” on HMI screen
Figure 4 26: Turn on servo driver
+ Step 5: To control to the position to be polished, we choose 1 of 2 methods displayed on the HMI screen (Supervisor or User)
Figure 4 27: User interface on HMI
+ Step 6: Move the axis and set the desired point to be original point
+ Step 8: Enter the speed of movement of the coordinate axes
Figure 4 30: Speed of movement of the coordinate axis
+ Step 9: Enter the position of object for polishing
Figure 4 31: Enter length and width of object
+ Step 10: Click “Run” for the system operate and observe the process
Figure 4 32: Press “Run” for polishing material
+ Step 11: After the polishing process is finished, press “ Home” to return the coordinate axes to their original position and continued for the next polishing with the fleece seal
Figure 4 33: Press “ Home” for go to the initial point
+ Step 12: Shaft speed values, rotation speed remains the same as the initial setting, press "Home" to continue polishing and observe the process
Figure 4 34: Polishing with polishing felt
+ Step 13: After the process is done , press “Home” Then turn off the servo by click
“Servo OFF” on the HMI screen Turn off all the CBs
+ Step 14: Remove the finish product from workpiece table
RESEARCH RESULTS AND ASSESSMENT
Hardware
Successfully designed and manufactured a model including an electrical panel, a machine model consisting of 3 axes X, Y, Z The model is solid, sturdy, does not shake when polishing at high speed
Sofware
+ Control the polishing machine to run stably with the high accuracy with the Manual and Auto mode
+ Calculating algorithms like Jog, auto mode, and torque
+ Complete programe, must operator in accordance with the process
+ HMI monitoring system shown full speed, position parameters, easy to manage.
Conclusion
The team successfully achieved the initial objectives by developing a responsive and stable control algorithm for the model Throughout the implementation, they faced challenges, particularly in calculating pressure and optimizing polishing rotation speed for the surface Despite some mechanical structure shortcomings, the team worked diligently to minimize these issues.
During the implementation of our graduation project, our group gained valuable insights into the automatic polishing machine model, identifying both its advantages and disadvantages.
+ Complete programe, must operator in accordance with the process
+ The system can run in many modes, can change the value to suit different requirements
+ The control panel is easy to understand so anyone can control the polish if they don't know about automatic polishing
+ The mechanical still limited in term of precious
+ The polishing machine still has a slight vibration when polishing
+ The system still restricts the materials used for polishing and the materials that need to be polished
+ The control panel is easy to understand so anyone can control the polish if they don't know about automatic polishing
+ No actual control screen yet and only control operator computer
+ Due to small are of the table and short stroke it can only use for small material.
Development orientations
+ Designing an actual control screen instead of using a control computer screen creates convenience and can be applied in practice without the need for a programmer's computer
+ Improving the polishing machine in the direction of operation with continuous operating frequency and less errors can be put into practical use
+ Improved a device that can be used to apply glue, polishing wax during implementation
+ Improved polishing cycles of different styles and different polishing mechanisms for each material
+ Expand the model range to be applicable to large materials
+ Further improve the problem of using equipment that can change the workpiece through the automatic system and limit the manual manual
Main Code
Device comment
Device Comment Device Comment Device Comment
M0 SERVO ON M116 STEP 3 D74 Torque CMD
M1 SERVO OFF M117 STEP 4 D76 Z Speed Limit
M3 JOG X- M120 RUN AUTO D86 Effect load ratio
M4 JOG Y+ M122 Sand paper D88 Ins Torque
M6 JOG Z+ SM400 Allways ON D92 D_linear
M7 JOG Z- SM401 Allways OFF D94 Motor current A
M8 SET HOME X Y SM402 ON ONE TIME D96 Ins Torque A
M9 HOME SM403 OFF one times D100 CHIEU RONG
M10 HOME Z Y0 PLC READY D102 CHIEU DAI
M11 ERROR RESET Y4 Stop X D104 LENGTH STEP
M17 POSION MODE Y0B JOG Y- D200 M CODE VALUE
M18 SPEED MODE Y0C JOG Z+ T0 TIMER STOP A
M20 STT SPEED MODE Y21 BRAKE T2 TIMMER 2
M21 STT TORQUE MODE D0 Feed value X T4 LOOP
M22 INC X BUTTON D4 JOG SPEED INPUT T5 DELAY 0.5 S
M23 INC Y BUTTON D8 MOVE SPEED T6 STOP X
M33 ALLARM LIGHT D14 Error A C0 CONTER LOOP OUTPUT
M40 MANUAL BUTTON D16 SPEED A INPUT U0\G1502 RST X
M45 M_ABS X D20 Feed value Y U0\G1518 JOG SPEED X
M54 M_Go A D26 SET HOME Y U0\G1618 JOG SPEED Y
M65 M POSION MODE D31 SET HOME Z U0\G1718 JOG SPEED Z
M66 M SPEED MODE D33 DISTANCE X U0\G1775 MODE value
M88 M TIMMER 2 D40 Feed value Z U0\G2006 DISTANCE ABS X
M100 Linear Button D45 D_ABS X U0\G2016 DISTANCE INC X
M101 Linear STT D46 D_ABS Y U0\G8004 SPEED ABS Y
M103 M CODE STT D49 D_INC Z U0\G8014 SPEED INC Y
M111 SET TIMER 3 D55 D_INC X U0\G14016 DISTANCE INC Z
[1] MISUBISHI ELECTRIC CORPORATION (2021) “I/O Module Type Building Block User's Manual,”
[2] MISUBISHI ELECTRIC CORPORATION (2005) “Servo amplifiers and motors Instruction Manual,”
[3] Mitsubishi Electric, GT Designer 3 Screen Design Manual
[4] Mitsubishi Electric, Mitsubishi Programmable Logic Controller Training Manual
[5] Mitsubishi Electric, Mitsubishi Programmable Controller Training Manual Q series basic course (for GX Works2)
[6] Screws in TOHNICHI TORQUE HANDBOOK VOL.9
[7] Mitsubishi Electric, MELEC-Q QD77MS Simple Motion Module User Manual
[8] Electronicscoach “AC Servo motor.” Electronicscoach.com
[10] MELSEC-L SSCNET III/H Head Module User's Manual
[11] QCPU User's Manual(Hardware Design, Maintenance and Inspection)
[12] GXL SERIES Micro-size Inductive Proximity Sensor Manual