With the rapid development of science and technology in the world today, new knowledge, new technologies, new processes, and new products are emerging. The traditional motor drive system is constantly being updated and transformed. The following introduction is based on the application of servo systems in the electrical transformation of cross-cutting machines.
Some cross-cutting machines are products of the 1970s, which are mainly used to cut some paper products with gram lines. The original equipment was driven by a main DC servo motor with a mechanical gear transmission device, and a part of the mechanical device pulled the paper roll so that it could send the specified paper length to the cutter according to the paper cutting requirements.
The other part drives the cutter roller for slitting. At the same time, the original equipment also has a small power DC servo motor. Its main task is to fine-tune the position of the cutter to make the cutting accuracy more accurate. However, due to the long operating time of the original equipment, the mechanical gears have different degrees of severe wear and aging of the original electronic components, so that the control accuracy of the original equipment cannot meet the requirements of the product.
Based on this, we used two AC servo motors to replace the main DC servo motor and mechanical gear transmission of the original equipment, replaced the fine-tuning motor of the original car with a positioning module and another servo motor, and realized the machine through PLC and human-machine interface. Soft adjustment of gears to meet production needs.
1 System control requirements
(1) Sensor collection part. The sensor is required to transmit the code signal collected on the paper to the PLC when the locomotive is running, and the PLC transmits the interruption processing and corresponding calculation to the positioning module, so as to control the fine-tuning of the motor's running direction and rotation speed.
(2) Servo amplifier. The servo amplifier is required to collect pulse signals in real time, and then cooperate with the parameters set by it to complete the purpose of controlling the motor.
(3) Terminal man-machine dialogue operation control. Since there are many types of paper produced, the distance between different paper gram lines is very different. Therefore, the actual length between two gram grams of the paper needs to be input for each type of paper produced, which can reduce the running speed of the fine-tuning motor. Number improves production accuracy.
(4) Encoder acquisition part. Adopt l3-bit absolute value type encoder, used to reflect the cutter position in real time, in order to adjust the fine-tuning motor.
(5) The precision of paper cutting should be within 0.5mm.
2 System hardware configuration
According to the system control requirements, the servo system is used to form the hardware configuration of electrical control.
(1) PLC uses Mitsubishi FX2N series FX2N-64RM, positioning module uses Mitsubishi FX2N-10GM.
(2) The servo amplifier adopts Mitsubishi MR-J2S-A series, the servo motor adopts Mitsubishi HC-KFS series 7kw, 5kW, 1.5kW each.
(3) Codegram sensor adopts German Gram CS1 color sensor, which has the characteristics of accurate detection.
(4) The encoder adopts the 13-bit absolute value encoder produced by German P + F company.
(5) The man-machine interface is a workstation specially designed for the application of PLC. It has the ability to connect with various brands of PLC for monitoring and control, and uses text and graphics to display the internal contact status and data of the PLC simultaneously. It is an interactive workstation. Equipped with LCD touch screen, communication interface, intelligent operation panel, printing interface, etc. It replaces the traditional key control system and terminal display system, not only saves the PLC I / O module, indicating device, but also can display the required information in real time.
3 Design of the hardware system
(1) The traction servo system adopts the speed control mode, and the speed given mode is given by the potentiometer of 2KQ and 5W.
(2) The cutter servo system adopts the position control mode, and the traction servo system adopts a cascade control mode, that is, the cutter servo system follows the traction servo system. This control method can accurately synchronize the speed of the two systems.
(3) The control mode of the fine-tuning servo system is calculated by PIE, and the required pulse number is transmitted to the positioning module, and then the positioning module sends a pulse command to the fine-tuning servo amplifier to control the operation of the fine-tuning servo motor. The positioning module sends out the pulse train + symbol mode, so the fine-tuning servo amplifier also needs to be set accordingly to accept the pulse command of the positioning module. [next]
4 Software design of the control system
The software of the control system includes the PLC control program, the positioning module control program and the touch screen operation terminal monitoring system. The former performs real-time control tasks, and the latter implements human-computer interaction functions.
(1) PLC control program
It consists of data sampling, data calculation, data processing, control signal processing and other programs.
â‘ Data sampling: The program collects the signal of the encoder while collecting the signal of the code sensor to determine the deviation of the current position of the cutter.
â‘¡Data operation and data processing: In order to accurately control the cutting precision and cooperate with the terminal display, process the data in the data area, and use various calculation methods such as addition, subtraction, multiplication and division. Compensate the position deviation of the cutter. It also controls some control signals of the servo system.
(2) The control program of the positioning module
(3) Monitoring procedures
The monitoring software design is composed of a group of screens. In addition to the dynamic simulation device current running screen, 1/0 status display screen, fault display screen, and fault query screen, the system is also designed with control and operation screens, which can be directly input from the touch screen. The given length of the paper can also display the given pulse required for fine-tuning the motor. The design of static graphics uses the general controls provided by the drawing software, such as lines and text boxes. Dynamic graphic design, through the data collected by the sensor and the processing of PIE to follow the changes, realize the dynamic connection of data and graphics, when the monitoring screen is running, the graphic properties change at any time.
(4) Servo amplifier parameter setting
The traction servo motor adopts the speed control method, the cutter and the fine-tuning servo motor adopt the position control method, and each motor sets its electronic gear ratio and acceleration / deceleration time, etc. accordingly.
5 running results
After the system is installed, commissioned, and put into operation, the system runs stably, has a high degree of automation, and the control accuracy meets the production requirements. At the same time, the incidence of electrical failures has also been reduced and significant economic benefits have been achieved.
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