Application of Programmable Controller (PLC) in Inner Circle Cutting Machine
1. INTRODUCTION The micro-control internal circular cutting machine is the main product of our company's semiconductor industry. The annual sales volume is about 50~60 sets, and the annual sales volume is increasing. However, the internal circular cutting machine manufactured by our factory mainly used single-chip microcomputer. To control, because the circuit board is manually welded, the error rate is quite large, the maintenance rate is also very high, and customers have many problems in reflecting the equipment. Therefore, we have reconstructed the electrical parts of the machine. PLC control, text display for parameter setting and display. Through production and sales, users responded well and improved the reliability of the equipment.
2. PLC's structural design PLC is called the programmable logic controller. Its operation is reliable and its failure rate is low. Has become a major industrial control products, its powerful, internal timers, counters and other auxiliary registers. It can trigger the output relays and other signals through the external signal. To complete the control of the whole machine. PLC mainly has relay type and transistor type two kinds.
The internal circle cutting machine uses a Mitsubishi FX1s-30MT-001 transistor type PLC, which is a 16-point input, 14-point output, transistor type, and its supply voltage is AC 220V. Its internal DC 24V power supply is available. Input part of the sensor switch for its power. The output Y0 port is set as a fixed stepper motor pulse output port, and Y1 port is set as a fixed stepper motor direction output port. The two signals are input to the stepper motor driver to control the feed of the stepper motor. At the same time equipped with RS232 port, data exchange with the text display. And through the text display to set and display the data parameters in the PLC.
The inner circle cutting machine produced by our company mainly includes the following: 1. The manual/automatic mode selection, the manual mode is mainly used for the knife before the cutting process, the inner circle cutting process, manual The tool setting method is a must; the automatic method is mainly for the automatic cutting process after the knife setting process is completed. After reaching the set number, the machine stops automatically. 2. Run/Stop is mainly to send signal and stop signal to automatic cutting process. 3. Spindle/Cooling is mainly used to start the spindle motor and cooling motor. 4. The left, right, forward, and backward movements of the jog are mainly used to adjust the machine during manual tool setting. These buttons only work in the manual mode. 5. The front limit, rear limit, left limit, and right limit. The motor return position is mainly a switch detection signal, providing limit position protection. 6. The return is the confirmation of the alarm signal. The main control output points include: 1. Stepping pulse, stepping direction, offline signal, etc. 2. Spindle motor, cooling motor, spindle brake. 3. Control fast forward and rewind lateral motor left and right relays. 4. Alarm lights, button indicators and other signals.
The above is the control input and output points of the PLC. The hardware control circuit diagram we draw here is as follows:
Figure 1 3. PLC program control design for internal circular cutter 3.1 Control program for counting the number of pieces in the cutting process The requirements for the cutting process of the internal circular cutter require that the first cutter cannot count the number of cut pieces, so it is necessary to avoid After cutting the number of sheets to the set value, the alarm machine stops. Its program control is as follows:
After the LPDm9//* auto run is turned on, the ///ANDX013//* will automatically run at the right limit*//
OUTm10//* set the first knife mark *//OUTm10//* set the first knife mark *//
DMOVD520D522//* Transmits no slice value *//LDm10//* Takes the first knife start cut mark *//
LDm10//* takes the first knife start cut mark *//ANDX013//* right limit to the end *//
The LDm11//* has set a cut flag and started preparing for counting*//
ANDPX013//*Right limit rising edge*//
DSUBD522K1D522//*Remaining unsliced ​​count minus 1 count*//
3.2 Set the slice thickness control program during the cutting process The requirements for the cutting process of the inner circle cutting machine are that the slice thickness requirements are very high, and the parallelism and the degree of consistency are very demanding, so that preparations for the subsequent process grinding process are required. When the film thickness is high, the precision is high. A three-phase reactive stepper motor is used, which is low in cost and stable in operation. Use subdivisions to eliminate low-frequency oscillations of the motor. Increases the output torque of the motor and improves the resolution of the motor.
The step distance calculation process is as follows: set the slice thickness to D516 (PLC digital unit) unit is mm, the step angle of three-phase stepping motor is 0.75°/1.5°, set the number of subdivisions to 10, after subdividing The step angle is 0.75°÷10=0.075°, then the number of pulses required for a stepping motor rotation is 360°÷0.075°=4800 pulses, and the feed uses a stepper motor with a ball screw drive. When the stepping motor rotates one revolution, the screw rotates one revolution, and the pitch of the lead screw is 4mm, then the pulse number of the stepper motor corresponding to 1mm is 4800÷4=1200. The thickness D518 is two bits with a small value, so the D516 is used The pulse number of the stepper motor is D516*K12. It is the number of pulses required to control the stepper motor output.
The step speed calculation process is as follows: Set the speed to D520 (PLC digital unit) unit is mm/min, D520 ÷K60 convert to unit mm/s to D522. The number of pulses corresponding to a stepper motor 1mm is 1200, corresponding to the number of pulses corresponding to D520 speed in one second is D522*K1200. Then pulse period T = 1/d522*K1200. Then the pulse frequency F=1/T=D522*K1200. That is to control the output frequency of the stepper motor.
The above two calculation process control procedures are as follows:
DMOVD516D518//* Send slice thickness setting value*//
DMULD518K12D518//*Convert sheet thickness value to required pulse number*//
DDIVD520K60D522//* transmission speed setting value*//
DMULD522K1200D522//* Convert speed value to required pulse frequency*//
PLSRD522D518K100Y000//* The slice thickness setting value is set at the specified speed. The pulse frequency is D522KHz, the pulse number is D518, the acceleration/deceleration time is 100ms, and the output port is Y000*//Note that the pulse frequency value cannot exceed 100KHZ.
3.3 Control procedure when the machine moves forwards and backwards during jogging The jogging process is an essential process in the cutting process of the internal circular cutter. By setting the frequency, the walking speed of the longitudinal screw can be changed to improve the efficiency. Through the jog operation to adjust the phase before and after the stroke, and adjust the right and left cutting process through the stroke.
LDm8//* is in manual mode*//
DMOVK0D0//* sets the number of pulses 0, that is, the number of pulses output from the stepper motor is not controlled. Infinity*//
DMOVD530D532//*Manual pulse frequency*//
The PLSRD532D0K100Y000//* moves around manually, the frequency is D532, and the number of pulses is 0, which means there is no limit to the number of pulses. Acceleration/deceleration time is 100ms, output port is Y000*//
4. Structure Design of Text Display The text display selects Delta's TP04G-AS2 series of products. This product displays up to four lines of text with operating keys and LCD display, which has a long service life and is safe and reliable. It carries on the data transmission with the PLC through the special RS232 data line. The text display mainly shows the following parameters in the cutting process of the internal circular slicer:
The setting of the slice thickness value, the setting of the slice value, the setting of the cutting speed value, the setting of the brake time value, the display of the total slice value, and the display of the remaining slice number.
The parameters that need to be set and displayed are designed through special software. After the software is organized, it is downloaded to the TP04G-AS2. After entering the operating mode, the PLC and the text display can be connected through a dedicated data cable to run. Parameters can be set and displayed.
5. Concluding remarks Through on-site commissioning, we proved that the use of PLC and text display in the internal circular cutting machine is feasible, it has changed some of the ills of our company's previous internal circular cutting machine, and improved the reliability and market share of the equipment. It provides a good platform for our company's equipment. The application of this model is a leading level in the industry, and the cost has not been correspondingly increased.
2. PLC's structural design PLC is called the programmable logic controller. Its operation is reliable and its failure rate is low. Has become a major industrial control products, its powerful, internal timers, counters and other auxiliary registers. It can trigger the output relays and other signals through the external signal. To complete the control of the whole machine. PLC mainly has relay type and transistor type two kinds.
The internal circle cutting machine uses a Mitsubishi FX1s-30MT-001 transistor type PLC, which is a 16-point input, 14-point output, transistor type, and its supply voltage is AC 220V. Its internal DC 24V power supply is available. Input part of the sensor switch for its power. The output Y0 port is set as a fixed stepper motor pulse output port, and Y1 port is set as a fixed stepper motor direction output port. The two signals are input to the stepper motor driver to control the feed of the stepper motor. At the same time equipped with RS232 port, data exchange with the text display. And through the text display to set and display the data parameters in the PLC.
The inner circle cutting machine produced by our company mainly includes the following: 1. The manual/automatic mode selection, the manual mode is mainly used for the knife before the cutting process, the inner circle cutting process, manual The tool setting method is a must; the automatic method is mainly for the automatic cutting process after the knife setting process is completed. After reaching the set number, the machine stops automatically. 2. Run/Stop is mainly to send signal and stop signal to automatic cutting process. 3. Spindle/Cooling is mainly used to start the spindle motor and cooling motor. 4. The left, right, forward, and backward movements of the jog are mainly used to adjust the machine during manual tool setting. These buttons only work in the manual mode. 5. The front limit, rear limit, left limit, and right limit. The motor return position is mainly a switch detection signal, providing limit position protection. 6. The return is the confirmation of the alarm signal. The main control output points include: 1. Stepping pulse, stepping direction, offline signal, etc. 2. Spindle motor, cooling motor, spindle brake. 3. Control fast forward and rewind lateral motor left and right relays. 4. Alarm lights, button indicators and other signals.
The above is the control input and output points of the PLC. The hardware control circuit diagram we draw here is as follows:
Figure 1 3. PLC program control design for internal circular cutter 3.1 Control program for counting the number of pieces in the cutting process The requirements for the cutting process of the internal circular cutter require that the first cutter cannot count the number of cut pieces, so it is necessary to avoid After cutting the number of sheets to the set value, the alarm machine stops. Its program control is as follows:
After the LPDm9//* auto run is turned on, the ///ANDX013//* will automatically run at the right limit*//
OUTm10//* set the first knife mark *//OUTm10//* set the first knife mark *//
DMOVD520D522//* Transmits no slice value *//LDm10//* Takes the first knife start cut mark *//
LDm10//* takes the first knife start cut mark *//ANDX013//* right limit to the end *//
The LDm11//* has set a cut flag and started preparing for counting*//
ANDPX013//*Right limit rising edge*//
DSUBD522K1D522//*Remaining unsliced ​​count minus 1 count*//
3.2 Set the slice thickness control program during the cutting process The requirements for the cutting process of the inner circle cutting machine are that the slice thickness requirements are very high, and the parallelism and the degree of consistency are very demanding, so that preparations for the subsequent process grinding process are required. When the film thickness is high, the precision is high. A three-phase reactive stepper motor is used, which is low in cost and stable in operation. Use subdivisions to eliminate low-frequency oscillations of the motor. Increases the output torque of the motor and improves the resolution of the motor.
The step distance calculation process is as follows: set the slice thickness to D516 (PLC digital unit) unit is mm, the step angle of three-phase stepping motor is 0.75°/1.5°, set the number of subdivisions to 10, after subdividing The step angle is 0.75°÷10=0.075°, then the number of pulses required for a stepping motor rotation is 360°÷0.075°=4800 pulses, and the feed uses a stepper motor with a ball screw drive. When the stepping motor rotates one revolution, the screw rotates one revolution, and the pitch of the lead screw is 4mm, then the pulse number of the stepper motor corresponding to 1mm is 4800÷4=1200. The thickness D518 is two bits with a small value, so the D516 is used The pulse number of the stepper motor is D516*K12. It is the number of pulses required to control the stepper motor output.
The step speed calculation process is as follows: Set the speed to D520 (PLC digital unit) unit is mm/min, D520 ÷K60 convert to unit mm/s to D522. The number of pulses corresponding to a stepper motor 1mm is 1200, corresponding to the number of pulses corresponding to D520 speed in one second is D522*K1200. Then pulse period T = 1/d522*K1200. Then the pulse frequency F=1/T=D522*K1200. That is to control the output frequency of the stepper motor.
The above two calculation process control procedures are as follows:
DMOVD516D518//* Send slice thickness setting value*//
DMULD518K12D518//*Convert sheet thickness value to required pulse number*//
DDIVD520K60D522//* transmission speed setting value*//
DMULD522K1200D522//* Convert speed value to required pulse frequency*//
PLSRD522D518K100Y000//* The slice thickness setting value is set at the specified speed. The pulse frequency is D522KHz, the pulse number is D518, the acceleration/deceleration time is 100ms, and the output port is Y000*//Note that the pulse frequency value cannot exceed 100KHZ.
3.3 Control procedure when the machine moves forwards and backwards during jogging The jogging process is an essential process in the cutting process of the internal circular cutter. By setting the frequency, the walking speed of the longitudinal screw can be changed to improve the efficiency. Through the jog operation to adjust the phase before and after the stroke, and adjust the right and left cutting process through the stroke.
LDm8//* is in manual mode*//
DMOVK0D0//* sets the number of pulses 0, that is, the number of pulses output from the stepper motor is not controlled. Infinity*//
DMOVD530D532//*Manual pulse frequency*//
The PLSRD532D0K100Y000//* moves around manually, the frequency is D532, and the number of pulses is 0, which means there is no limit to the number of pulses. Acceleration/deceleration time is 100ms, output port is Y000*//
4. Structure Design of Text Display The text display selects Delta's TP04G-AS2 series of products. This product displays up to four lines of text with operating keys and LCD display, which has a long service life and is safe and reliable. It carries on the data transmission with the PLC through the special RS232 data line. The text display mainly shows the following parameters in the cutting process of the internal circular slicer:
The setting of the slice thickness value, the setting of the slice value, the setting of the cutting speed value, the setting of the brake time value, the display of the total slice value, and the display of the remaining slice number.
The parameters that need to be set and displayed are designed through special software. After the software is organized, it is downloaded to the TP04G-AS2. After entering the operating mode, the PLC and the text display can be connected through a dedicated data cable to run. Parameters can be set and displayed.
5. Concluding remarks Through on-site commissioning, we proved that the use of PLC and text display in the internal circular cutting machine is feasible, it has changed some of the ills of our company's previous internal circular cutting machine, and improved the reliability and market share of the equipment. It provides a good platform for our company's equipment. The application of this model is a leading level in the industry, and the cost has not been correspondingly increased.
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