HO CHI MINH UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF INTERNATIONAL EDUCATION Graduation Project Assignment Group members: Trần Xuân Thắng Studen’s ID:19142105 Nguyễn Hoàng Sơn
INTRODUCTION
Background of research
The use of automation has seen a steady rise in several sectors, notably manufacturing and assembly, during the last few years The use of automated technology and robots in production lines may enhance productivity, reduce mistakes, and improve efficiency Production line automation enhances productivity and decreases expenses by mechanising tasks that were previously performed manually, enabling quicker and more accurate execution of the activity
Industry classification has evolved significantly due to the introduction of picking and identifying systems, leading to increased output, improved efficiency, and faster processes Engineers can improve their ability to design secure products by using industry-specific retrieval and identification methods These systems can analyze large amounts of data and identify potential adverse effects or interactions Future advancements are expected to capitalize on these trends, leading to more innovations in other sectors.
Reason to select this project
Because of this, engineering students who are in charge of monitoring and maintaining the production system—which mostly uses a PLC controller and a system for picking up and identifying—need to study and do research in technical areas
Indeed, it is evident that user safety need to be the first concern in production Large-scale product manufacturing and delivery necessitate extreme precision Faulty products must be swiftly discarded by sorting them into packaging, verifying barcodes, looking for mistakes, identifying product names, and determining expiration dates Implementing such sequential challenges with labor is nearly impossible and requires a significant investment of time and money Thus, using cutting-edge technology in production will assist in resolving those issues Our team's goal is to complete
2 the industrial system for identifying and picking up cosses heads based on that.
Research objective
Set communication between devices in the project through SSCNET III, Ethernet and CC-Link including Q03UDECPU, QD75MH4, QY80 QJ61BT11N, Driver Servo: MR-J3-10B, MR-J3-40B; and Servo Motor: HF- KP43, HG-KR13, HG-KR053B, Driver Brushless Motor BLED6C; and Brushless Motor BLEM46-GFS, digital sensors, Camera Cognex 1100 Interpolation of Positions Manage and function as needed completing the system's mechanical and electrical panels, as well as turning on the model's motors to move the cosses heads onto a conveyor and then place them on a rotating table so that Camera Cognex can precisely sort and arrange them according to axes XYZ
Utilizing SoftGOT 2000, control and observe the industrial system for identification and picking up.
Research the contents
In light of the aforementioned goal, the following is how our graduation thesis is put together:
This chapter provides information about the project's background, justification for doing the study, goal, content, design, and boundaries
Describe the theoretical foundation for the system's devices: Mitsubishi PLC Q series; AC Servo sensors, barcode technology, SSCNET III, Ethernet, and CC-Link communication networks, as well as motor and control techniques using Driver Servo and encoder
- Chapter 3: Design and construct the model
This chapter describes the equipment arrangement in the panel and the appropriate model We make the decision to choose the system's gadgets after computing The project's detailed description covers every step of the process, from mechanical construction to electrical wiring, and then controls the entire system from setting up parameters to completing programs that activate in response to difficulties
- Chapter 4: Algorithm and Control Program
The project's system for locating and recognizing the cosses head needs a certain algorithm to govern and a control program to carry out step-by-step instructions The chapter describes the system's software component for selecting and identifying projects
This chapter summarizes the research findings and compares them to the initial goals It also highlights issues that arose during the research process, which led to the development of lessons learned and observations made at the end of each section
After the model is completed, draw conclusions, talk about the benefits and drawbacks of the project as a whole, and offer suggestions for further development.
The limitation of project
The project was conducted using a medium-sized model, which is smaller than the real automation line in any industry, and it merely controls in accordance with the specifications provided
Because of the low rotational table speed and the camera lens's inability to detect pattern, the system only accepts cosses heads with pattern that are properly positioned within the camera detecting region
THEORETICAL BASIC
PLC introduction
Programmable Logic Controller is referred to as PLC It is a digital computer that is utilized in control and industrial automation systems PLCs are used in power plants, water treatment facilities, manufacturing assembly lines, and many other industrial settings to monitor and control equipment and operations Receiving input signals from sensors and other devices, processing the information, and producing output signals to operate actuators, motors, and other machinery are the main tasks of a PLC Because PLCs can be programmed, their operation can be altered by creating logic and sequencing instructions in a programming language of choice
The central processing unit (CPU) serves as the primary processing unit, or "brain," of the programmable logic controller (PLC) It processes instructions, coordinates the operations of other components, and facilitates data interchange with other devices
PLC CPUs have varying processing speeds, memory capacities, and communication capabilities, depending on the model and manufacturer Some advanced CPUs can multitask, enabling simultaneous execution of multiple programs or sharing processing time across programs
The CPU carries out a range of tasks, such as executing programmes, processing data, handling communication and input/output operations, managing timing and synchronisation, performing system diagnostics, and managing memory
A Programmable Logic Controller (PLC) has two primary memory forms: program memory, which contains user-programmed instructions, and data memory, which stores variables, timers, counters, and other data used during program execution, ensuring efficient and reliable program execution
Depending on the particular model and manufacturer, a PLC's memory size can change When building PLC programs, it is crucial to take the available memory capacity into account to make sure the programs fit inside the allotted memory space
Additional memory expansion options, like memory cards or modules, may also be available for PLCs These can be utilized to expand the amount of data or program storage More comprehensive programs or the storing of past data and logs are made possible by these extension possibilities
The signals from different sensors, switches, and other field devices are received by these modules These modules transform the analog input signals into digital data that can be processed by the CPU of the PLC
A list of these features can include hot-swapping, wiring connection support, signal conversion, different input kinds, signal isolation, and multiple input channels
Output modules communicate with field devices and actuators To run the output devices, they transform the control signals produced by the PLC into the proper format Digital output cards, analog output cards, solenoid valves, motor drives, and other components are examples of output modules
The following features could be listed in the same order as input modules: hot-swapping, short-circuit and overload protection, output status indicator, current and voltage ratings, wire connection support, output kinds and channels, signal conversion, and so on
It is crucial to correctly map the output channels to the necessary variables or addresses in the PLC program when configuring the PLC's output modules By doing this, the PLC is guaranteed to transmit the proper control signals to the relevant output devices, allowing the industrial processes to operate and be controlled as intended
One part of a PLC (Programmable Logic Controller) that is in charge of giving the entire PLC system the electrical power it needs is the power supply It guarantees the PLC's dependable and constant operation Usually, the power supply receives an input voltage from an external power source and transforms it into the proper voltage levels that the PLC system needs Depending on the PLC model and application, the precise voltage levels may change, but typical input voltage ranges are 110–240 volts AC (alternating current) or 24 volts
AC Power Supply: Usually sourced from the main power grid, this kind of power supply accepts an AC voltage input Transformers, rectifiers, and voltage regulators are among the parts that it consists of to change the AC input voltage into the necessary DC voltage levels that the PLC requires
DC Power Supply: DC voltage is employed by some PLC systems, particularly those used in industrial automation In these situations, a
DC voltage input - typically 24 volts DC - that is frequently utilized in industrial control systems is accepted by the power supply It might have parts like voltage regulators and filters to guarantee a steady and pure power supply for the PLC
PLCs frequently include integrated communication interfaces that allow them to link to networks or other devices For inter-device communication, these ports enable data exchange with programming devices, other PLCs, supervisory control and data acquisition (SCADA) systems, and human-machine interfaces (HMIs)
Depending on the model and manufacturer, a PLC's specific communication port types may differ, but the following are some typical types: Ethernet ports; USB ports; wireless communication; fieldbus ports; expansion ports; serial ports (RS-232 or RS-485 connections, for example)
The control program and PLC configuration are created using a programming device, such as a laptop or handheld programmer It offers a PLC system interface for testing, programming, and troubleshooting
Servo motor and servo driver
A servo motor is a kind of rotary actuator that is frequently employed for accurate angular position control in a variety of applications It is a closed- loop system that continuously modifies its torque, speed, and rotating position via feedback signals
A servo motor's primary parts are its motor, position sensor (often an encoder or potentiometer), and control circuit A control signal that indicates the intended position or speed is sent to the control circuit This signal is usually in the form of a pulse-width modulation, or PWM, signal The control circuit
19 uses this input to compare the motor's actual position - as detected by the position sensor - with the desired position, then modifies the motor's output as necessary A servo motor's built-in amplifier amplifies the control signal and moves the motor to the intended position through the control circuit The motor itself is typically a brushless DC motor or a DC motor with high torque and accurate control
Servo motors are widely employed in many different applications, including robotics, industrial automation, CNC machines, radio controlled vehicles, and more, that call for precise and controlled motion Their high torque-to-size ratio, quick response time, and accurate position control are just a few of their many benefits
There exist various varieties of servo motors, including but not limited to DC,
AC, brushless, linear, continuous rotation, high-torque, and micro servo motors Yet, AC and DC servo motors are the two primary types of servo motors that are becoming more and more common in industrial settings
A rotor (the revolving part) and a stator (the stationary element) make up a DC motor Field coils are often found in the stator, and permanent magnets or windings are found in the rotor
A position sensor is built into a DC servo motor to give feedback on the motor's real location Potentiometers and encoders are among the motors whose positions are compared and adjusted using this feedback data to get the desired position
The control circuit is in charge of processing the position sensor's feedback and receiving the control signal It creates a control signal to move the DC motor in accordance with the comparison between the desired and actual positions Analog or digital control methods might be used to create the control circuit
Applications requiring strong torque and accurate control at lower speeds frequently choose DC servo motors
The majority of electrical systems use an AC power source, which is required for AC servo motor operation
Compared to DC servo motors, the control circuit for AC servo motors is frequently more intricate To attain exact position and speed control, it might make use of complex control algorithms and methods
Position sensors, such as resolvers or encoders, are frequently used by
AC servo motors to provide feedback on the motor's real position Precise control and placement are made possible by this feedback information Good torque characteristics are provided by AC servo motors over a broad speed range They are also capable of producing a lot of torque at fast speeds
When compared to DC servo motors, AC servo motors often have higher power efficiency For a given input power, they can produce more power
Applications requiring high-speed operation, dynamic control, and a larger speed range are better suited for AC servo motors
A variety of servo motors are available from Mitsubishi Electric to meet different industrial needs:
HF-KP/KP2R Series: High-speed, high-precision control is offered by these lightweight, compact servo motors, which are ideal for applications with limited space
HF-KP/HF-JP Series: These are small servo motors with great torque and high speed capabilities that are appropriate for applications needing exact control
Servo motors from the HG-KR/KRT/KP/KPN Series: These tiny motors have a high torque output and are ideal for robotics and automated machines, among other uses
Figure 2 5 Series HF Servo Motor
Position Control: The purpose of the AC servo system is to precisely maintain or hold a given position After receiving the required position signal, the control system compares it with the encoder's feedback signal
Velocity Control: The motor's velocity can also be managed via AC servo systems The control system modifies the motor's functioning to reach and maintain the required speed by establishing a desired velocity
Control of Acceleration and Deceleration: To produce fluid and accurate motion, AC servo systems have the ability to regulate the motor's acceleration and deceleration
Feedback Loop and PID Control: To continuously monitor the motor's position, velocity, and acceleration, the AC servo system makes use of a feedback loop A Proportional-Integral-Derivative (PID) control algorithm compares the feedback signal to the intended values, adjusting the motor's operation to minimize discrepancies
Feedforward control: This type of control entails sending out extra signals to offset expected disruptions or modifications to the system
Trajectory Planning: Motion profiles or preset trajectories can be followed by AC servo systems The control system determines the intended course for the motor to take and modifies its operation accordingly
Stator: The stator is the motor's stationary component It is composed of a laminated steel sheet core It has a set of stator windings that are arranged in a particular configuration These windings are usually three phases
Encoder
An encoder, sometimes referred to as a shaft encoder or rotary encoder, is an electromechanical device that outputs an analog or digital signal based on the angular position or motion of a shaft By counting the number of shaft revolutions, the encoder is used to determine the motor position, travel direction, speed, etc
Despite the fact that there are many different kinds of encoders, including half effect, optical, magnetic, capacitive, inductive, and inductive encoders, they are all based on two basic categories of encoders:
Incremental Encoders: An incremental encoder reports changes in position or relative motion When the shaft or object being measured spins or moves, it produces pulses or counts Typically, an encoder consists of a disk with marks or slots spaced equally apart, or pulses, and a sensor to identify the pulses The encoder's resolution is based on the number of pulses per unit of linear motion or per revolution The system can calculate the project's relative position or speed by counting the pulses
Absolute encoders: An absolute encoder gives data regarding the shaft's or object's exact position while being measured Every place along its range results in a different binary or digital code that it creates The various bits of the binary code are often represented by one or more tracks on the encoder The code varies as the object spins or moves, allowing the encoder to pinpoint the exact location Absolute encoders can hold onto positional data even in the event of a power outage
The use of homing or reference point initialization is no longer necessary thanks to absolute encoders, which offer accurate and straightforward absolute position information This functionality is vital in applications where it is necessary to keep precise position data, particularly in the event of a power outage or system restart It makes positioning quick and precise without requiring recalibration possible
AC servo positioning control
Unit setting: When the axis is controlled by a lead screw, the first setup for positioning control uses mm; when the axis is controlled for rotation, it uses degrees
Number of pulses per rotation: The control must be set to the desired number of pulses per rotation in order to obtain the desired precision This is the number of pulses needed, which varies based on the number of pulses fixed on the encoder disk, for the servo motor to complete one revolution It is 2 18 for the motors' 18-bit encoder, or 262144 fixed pulses on the encoder disk
Movement amount per rotation: Define the distance at which a mechanical device, such as a turntable, linear slide, or lead screw, links to the motor shaft
In unusual circumstances, the setting unit may be direct systems pulses, degrees for rotary motion, or millimeters for reciprocating motion
Reverse rotation command Forward and reverse rotation pulse train
- The number of revolutions as well as the rotation speed depend on the pulse signal
- The reversible rotation signal is independent of the command pulse to control the direction of rotation
- When port A receives pulse then the motor rotates follow clockwise, input B receives pulse then opposite
- By choosing the dimension to follow can be installed in parameter or transmit command from control to servo driver
A-phase pulse train b-phase pulse train
- Direction of rotation control difference between 2 pulse output - Turn forward when phase B phase delay than phase A 90 degrees - Reverse rotation when phase A phase delay than B phase 90 degrees
Input signal logic: Two forms of logic are available for selecting the digital input signal: positive logic and negative logic
Value for the speed limit: Determined by the servo motor's maximum capability, which may be less when specified in the parameters but not more
Rotation direction setting: The servo motor's default rotation direction is not actually in reverse A clockwise or counterclockwise indication indicates the correct orientation
OPR method: Select the position to begin working, which includes the count, data set, and near-point dog methods
Figure 2 14 Go home use Near-point dog method
Establish a system limit: In order to avert harm and unforeseen consequences that arise from improper control
Figure 2 15 Setting limit for system
Sensor
A sensor is an apparatus or part that is used to monitor or identify physical events or environmental factors and then translate those measurements into electrical signals Numerous industries, including consumer electronics, science, engineering, and medicine, use sensors
- Photoelectric Sensors Motion and Position
- Ambient Light Sensors Humidity and Moisture
- Thermal Conductivity Humidity Sensors Gas Sensors: - CO sensors
- Volatile Organic Compound (VOC) Sensors pH Sensors: - Glass Electrode pH Sensors
- Ion-Selective Field Effect Transistor (ISFET) pH Sensors
Force and Load Sensors: - Strain Gauge Sensors
- Piezoelectric Sensors Magnetic Sensors: - Hall Effect Sensors
- Magnetometer Sensors Chemical Sensors: - pH Sensors (also mentioned earlier)
- Gas Sensors (also mentioned earlier)
- Biosensors Imaging Sensors: - CMOS Sensors
2.5.2 NPN and PNP types – sensor
Figure 2 18 NPN and PNP type
The output device of an NPN sensor is an NPN (Negative-Positive-Negative) transistor.The base, emitter, and collector make up the three layers of a three- layer semiconductor device called an NPN transistor When it comes to sensors, an NPN sensor usually comprises of an NPN transistor and additional parts like a detector or sensing element The sensing element generates an electrical signal when it detects a specific physical amount or environmental situation
When a PNP (Positive-Negative-Positive) transistor is used as the output device, the sensor is referred to as a PNP sensor The base, collector, and emitter of a PNP transistor are the three layers that make up this semiconductor device
Pattern
A pattern is a form, a form, or a model that can be used to make or create things or parts of an object
Patterns are widely used to identify samples or products From there, machines can read and receive data to reduce operator errors
Memory area to determine patterns: because the camera's memory area is limited, it will have a certain memory area to determine patterns in that area
Read and remember patterns based on the camera: It will capture an image of the pattern to decode the product's shape, size and delivery characteristics.
Vision Technology
Cognex is a business that specializes in using technology to set industrial goods apart Cognex scanners swiftly and precisely read and write data on a range of surfaces, including labels, packaging, and parts, by utilizing cutting- edge image capture and processing techniques Cognex scanners have a reputation for being quick, dependable, and able to read codes that are poorly written or broken
They can be incorporated into production lines, handheld devices, or fixed- mounted systems and frequently have an ergonomic design Additionally, certain models have networking features like Ethernet, USB, and wireless ports
Inspection: Examine components for damage, missing features, surface imperfections, and assembly faults Determine the features' and objects' orientation, shape, and location
Measure/Gauge: Measure or gauge parts for sorting and classification procedures, or check important dimensions
Align/Guide: Direct robotic devices and automation equipment Align components to ensure precise assembly processes
OCR/OCV: Alphabet letters printed on labels and directly marked on parts should be read and verified
Barcode Reading: As part of a comprehensive inspection, read 2-D matrix codes and 1-D barcodes
For automated inspection, measurement, identification, and robot guiding applications on the manufacturing floor, the In-Sight® vision system is a small, standalone machine vision system that is network-ready With an easy- to-use user interface, any model may be remotely set across a network with ease
Ethernet network
For local area networks (LANs), Ethernet is a commonly used technology that enables wired communication between devices It offers a standardized technique for data packet transmission between network-enabled devices, including PCs, servers, routers, switches, and other devices
Ethernet networks have a number of benefits, such as dependability, scalability, minimal latency, and fast data transmission speeds They are frequently utilized in data centers, industrial settings, and homes and offices
Typically, an Ethernet network is made up of the following parts:
By using these setups, devices may connect to the internet and the larger network, ensuring effective communication
CC – Link
A collection of open fieldbus and industrial Ethernet technologies used for communication in industrial automation systems is called CC-Link, commonly referred to as CC-Link Industrial Networks Since its first development by Mitsubishi Electric Corporation in 1997, it has grown in popularity all around the world Programmable logic controllers (PLCs), human-machine interfaces (HMIs), sensors, actuators, and other automation components are just a few of the gadgets that CC-Link is made to link in an industrial or manufacturing setting It offers a dependable, fast communication network for controlling and exchanging data in real time Several CC-Link variations are available, such as:
CC-Link (Control & Communication Link)
CC-Link IE (Industrial Ethernet)
Figure 2 24 Industrial network of CC – Link
In a system, CC - Link has the following outstanding features:
Openness: This promotes interoperability and enables the integration of devices from many suppliers, giving consumers freedom and options
High Performance: CC-Link ensures real-time device control and synchronization by providing deterministic data transfer and high-speed connection
Dependability: In industrial settings, CC-Link is renowned for its resilience and dependability It enhances the system's overall stability by offering fault-tolerant communication, automated error detection and recovery procedures, and reduced latency when handling massive volumes of data
Scalability: CC-Link networks may be extended to handle an increasing number of devices due to its scalability They include a range of network topologies, including as ring, line, and star configurations, which provide designers and developers more freedom when designing and growing their systems
Flexibility: CC-Link provides a variety of wiring choices, enabling network connections to be made using both copper and fiber optic cables
Safety Integration: One of CC-Link's variants, Safety, enables the smooth integration of safety systems and devices into the network
Simple Maintenance: CC-Link networks are intended to be simple to use and maintain
Worldwide Adoption: CC-Link is sponsored by a large number of manufacturers and organizations and has become widely adopted internationally
SYSTEM CALCULATION, DESIGN AND CONSTRUCTION
Requirement of the system
An industrial automation system utilizes a Cognex camera system to detect the heads of cosses, which are then sorted and placed into pre-prepared boxes The system used in this research offers a labor-free, precise, and synchronized method of managing an industrial production line.
Calculation
- The screw rotates 1 revolution will make the table translate: 2cm (20000𝜇𝑚)
- Servo have max speed is: 3000 (rpm), but rotate 1 revolution make table translate: 2cm
- We have speed limit value is: 3000 (rpm) x 2 (cm) = 60000 mm/min
- The screw rotates 1 revolution will make the table translate: 1 cm (10000𝜇𝑚)
- Servo have max speed is: 3000 (rpm), but rotate 1 revolution make table translate: 1 cm
- We have speed limit value is: 3000 (rpm) x 1 (cm) = 30000 mm/min
- The screw rotates 1 revolution will make the table translate: 0.5 cm (5000𝜇𝑚)
- Servo have max speed is: 3000 (rpm), but rotate 1 revolution make table translate: 0.5 cm
- We have speed limit value is: 3000 (rpm) x 0.5 (cm) = 15000 mm/min
Figure 3 1 Set up speed limit value for each axis
Calculation and design for system
The system consists of two main components: the electrical and mechanical parts In order to establish the project as a genuine component of an industrial automation line, we installed and adjusted the mechanical and electrical components of the system All the mechanical parts are constructed exclusively from aluminum, while the electrical components are affixed to an aluminum composite panel
The system has three Mitsubishi servo motors and one Oriental brushless motor Three servo motors operate the three major axes simultaneously Hence, to fulfill the mechanical requirements:
- Camera mounting product with an aluminum base
- Bars and frames are used to install equipment on the conveyor panel
- The components include an engine support structure, a conveyor belt, and a product stop bar
- Drive belt, often known as a conveyor belt
- Mechanical axes and pedestals designed for the installation of X,
- The limit sensor is designed to detect the presence of a bar, when they pass the sensor and the system will stop
3.3.1.2 Block Diagram of mechanical part
Figure 3 2 Mechanical part block diagram
3.3.1.3 Design drawing and model parameters
The mechanical properties are chosen based on the specifications of the system
- 84x98x1 (cm): Aluminum plate for the entire system
- Aluminum Plate: 41x22x1.2 (cm) for XYZ axes
- Center of the CPU: 24.3 x 10.5 cm
Figure 3 4 The lead screw's X-Axis parameters
Figure 3 6 Lead screw Y: Axis specifications
Figure 3 8 Lead screw Z - Axis specifications
The electrical component of the model consists of many key modules, including the power block, central processing unit, position control block, CC-Link module block, driver servo motor block, driver brushless motor block, sensor block, and camera block
The system has many blocks, each serving a specific function The functions of each component are outlined below:
The power block consists of a 220VAC source that will provide power to both the motor driver and the PLC Additionally, it has a 24VDC switching source that supplies power to the control circuit, which includes sensors, relays, and I/O modules
The system utilizes proximity sensors to provide information on the position of the upper limit, lower limit, Home of the Servo Linear motor, and the position of the medication container on the conveyor The sensor block will consist of the Azbil APM-D3A1 and Omron EE-SX674A proximity sensors These sensors operate with a supply voltage ranging from 10VDC to 24VDC and have an NPN output type They will be connected to the input of the module positioning system
The central processing block serves the purpose of generating control signals for the other blocks The calculation and processing algorithms pertain to the synchronized operation and communication with peripheral devices, including sensors, cameras, and motor control pulse output The Q03UDECPU is the specific model of this block It serves the purpose of managing peripheral devices connected to the system, such as a camera
The Motor Driver Block is responsible for synchronously driving the shaft to facilitate movement of the axes in the model The QD75MH4 module transmits pulses to this block
Servo motor block: This block serves as the central component of the system
The block will be equipped with three motors affixed to the shafts Utilize the MR-J3 10B and MR-J3 40B drivers This driver utilizes the SSCNET network to receive communication pulses and carry out control requests
3.3.2.3 Select a device and construct a system
Device Q61P Q03UDE QD75MH4 QJ61BT11N QY80
Table 3 1 Modules in PLC station
The Q61P is compatible with both the Q3xP unit base and the Melsec Q- Series, providing power supply for PLC modules It needs just one power source Furthermore, the module is capable of accepting a broad variety of input voltages, ranging from 100 to 240VAC, making it acceptable for usage in households with a voltage of around 220 VAC
6.6A/5VDC Overload voltage protection: 5.5 to 6.5V
The Q03UDEHCPU programmable logic controller (PLC) offers support for functional modules and has a high maximum number of I/O inputs Additionally, it has an SD card backup capability, making it suitable for expanding analog systems Furthermore, the integration of Remote I/O and
53 industrial CC-Link IE Field Network connection offers a very manageable and efficient means of operating equipment inside the plant
Ethernet Memory: SRAM card, Flash card, ATA card Built-in many high-speed CPUs
Our system utilizes four servo motors, requiring a positioning module capable of controlling four drivers Furthermore, the system is capable of running locations using both millimeters and degrees, and it utilizes interpolation control
2/3/4 axes linear interpolation, 2 axes circular interpolation
Control unit: mm, inch, degree, pulse
Control system: Point to point control, control, path control, speed control, speed-position switching control, position-speed switching control in incremental and absolute system
In speed-position switching control/position-speed switching control:
In speed-position switching control
Other axis is in operation: 1.5
Table 3 4 Positioning Module QD75MH4
The output module is used to regulate the electromagnet in order to position the cosses head in an upward or downward orientation The module utilizes a 24V DC power source, which is consistent with the power supply used by other modules
3.3.2.3.6 CC-Link module QJ61BT11N
Figure 3 13 Module CC-Link QJ61BT11N
The Auto Cad 2D drawing of the PLC modules is constructed with a power supply module and five modules on the right side, based on the hardware arrangement
Mounting the devices on the base is essential Our company has selected the Q38B base unit, which is compatible with the required slots and Q series
Brand: Mitsubishi Series: Melsec Q Series
The station is equipped with a total of three Servo Drivers, consisting of two modules of Servo MR-J3-10B and one module of Servo MR-J3-40B
Control System: sine wave PWM/ current control
Table 3 7 Servo Driver MR-J3-10B Parameters
Control System: sine wave PWM/ current control
Table 3 8 Servo Driver MR-J3-40B Parameters
Based on the dimensions of the Driver Servo modules, our team has created a 2D model of the Driver Servo This module is connected to the positioning module QD75MH4 and three AC Servo motors using SSCNET III control
The system utilizes Servo motors that must be compatible with the Driver Servo According to table 3.9, the servo motors selected are as follows:
Model Servo HF-KP43 HG-KR13 HG-KR053B
1 phase 220V AC 1 phase 220 VAC 1 phase 220VAC
Encoder (bit) 18 bit 22 bit 22 bit
Figure 3 19 Camera Cognex In – Sight 1100
Speed rating 4x based on In-Sight Micro 1020
Model Stainless Steel Availability Not Available according to the In-Sight
Dimensions 30mm (1.18in) x 30mm (1.18in) x
60mm (2.36in) without mounting block
30mm (1.18in) x 38.2mm (1.50in) x 60mm (2.36in) with mounting block Temperature Operating: 0°C to 45°C (32°F to 113°F)
Humidity 90%, non-condensing (Operating and
Vibration (Shipping and Storage) 10 G with 50 gram or lighter lens attached 2 hrs/axis (10-500 Hz) per
Figure 3 21 Driver Brushless Bled6C-CC
Table 3 11 Brushless DC Driver BLED6C-CC parameters
The model incorporates multiple soft limits to restrict the working distance of the xyz axes and establish the home position of the axes and turntables Additionally, the system utilizes a total of nine proximity sensors to detect
70 objects on the conveyor Specifically, the x and y axes require two limit sensors and one near-point dog sensor, while the z axis necessitates two limit sensors to accurately position the cosses head on the conveyors
Name Proximity Azbil APM-D3A1 Proximity Omron EE- SX674A Figure
Type NPN transistor open collector NPN transistor open collector
NO Light-On/Dark-On
The Omron EE-SX674A sensor will be used for the limit sensor and the x- axis near-point dog sensor, while the Azbil APM-D3B1 sensor will be used for all the other axis
Figure 3 22 2D Sensors connecting QD75MH4
Module for positioning with a cable for controlling the driver servo:
The distance between Positioning Module QD75MH4 and Driver Servo in the model is rather short The team selected a cable length of 0.5 meters The chosen cable is identified by the model MR- J3BUS05M
The SSCNET III cable is a standard cord used for connecting components inside an interior panel
Model: MR-J3BUS_M ( _ represents the cable length)
System Construction
Figure 3 39 Conveyor and aluminum frame construction
Figure 3 40 Soft limit switch for X-Axis
Figure 3 42 Camera cognex in – sight 1100 construction
Figure 3 43 Mechanical part after construction
Once the mechanical part is completed, the aluminum composite panel is used to house all electrical equipment The electrical structure is shown below Prioritize completing the CB block before proceeding to connect the AC lines for the Drivers, PLC, and switching source
Figure 3 46 Sensor, each axis with domino
Figure 3 47 Complete the mechanical and electrical parts for system
ALGORITHMS AND PROGRAMS
System description
The system consists of two primary components:
Control devices such as Q03UDEHCPU, QD75MH4, QY80, QJ61BT11N, Driver Servo MR-J3-10B, MR-J3-40B, as well as other electrical equipment like circuit breakers, relays, dominos, switching sources, and network switches are positioned on the composite panel Meanwhile, the camera is installed on the aluminum base product
The following servo motors are used: HF-KP43 for the X-axis, HG- KR13 for the Y-axis, and HG-KR053B for the Z-axis Additionally, a brushless DC motor is also used The BLEM46-GFS motor is mounted on an aluminum base
The Programmable Logic Controller (PLC) is used to regulate the movement of three servo motors via the Positioning Module and Driver Servo, using the SSCNET III network Additionally, a DC Brushless motor is controlled by the QJ61BT11N module and Driver Brushless, connected via the CC-Link network The brushless motor is connected to the conveyor shaft through an intermediary shaft for power transmission The product will be recognized using the recorded camera, In-Sight 1100, which will be situated beyond the working range of the xyz-axis The Programmable Logic Controller (PLC) will receive the signal from the camera, retrieve the pattern and the name of the item, and instruct the position control module QD75MH4 to control the axes and move to the precise location of the product on the conveyor for sorting Mitsubishi's SoftGot display manages all operations.
System operation and Algorithms
The conveyor model has three operational modes: Stop, Manual, and Auto In Stop mode, the servo and other devices are inactive In Manual mode, the operator inputs speed and position using data and jog modes to verify motor and equipment functioning In Auto mode, the motor is returned to its home position to prevent incorrect movements or accidental contact with the limit switch The operator then initiates conveyor movement by pressing the "Run" button
4.2.2 Algorithms used by the system
The project utilized insight explorer support software to identify and interpret patterns and read product characters After training, items were transported on a conveyor belt until a camera detected them The arm mechanism moved the product to classification position, where it was analyzed for pattern, format, and character The product was then sorted into pre-arranged compartments, restoring the arm structure to its former location
4.2.2.1 An algorithm designed to analyze and extract information from photographs depicting various things
The camera scans an item on a conveyor, transmitting the object's cosses head and product pattern to a PLC The data is preserved in a device array arranged according to XYZ axes Once the item is absorbed and released by a magnet mechanism, its information is withdrawn from the data array, indicating processing
Position control interpolation is a technique that synchronizes the movement of multiple axes using the speed of a chosen axis as a reference point, with a manufacturer developing a position control module with separate parameters
3-axis linear interpolation involves specifying the destination coordinates
(X2, Y2, Z2) and the speed of the main axis (measured in mm/min) for the interpolation origin
The Positioning Module controls movement along X, Y, and Z axes, determining actuator coordinates relative to the reference origin A position interpolation run occurs when present position coordinates (X1, Y1, Z1), destination location coordinates (X2, Y2, Z2), and corresponding function call are present and destination respectively, in OPR mode
Figure 4 1 Linear Interpolation 3-axis algorithms
A flowchart is a crucial preliminary step prior to programming the model The group has created a control flowchart based on the control technique and control algorithm In this section of the flowchart, the stages are drawn in a manner that closely aligns with the programming requirements, taking into account the original requirements
The main function serves as the central control mode in the system, including three primary components: Manual, Auto and Stop By including a multitude of buttons, we enable the seamless transition between different modes and facilitate the alteration of the screen mode on the HMI, hence enhancing operator convenience
The system is inactive until a manual or auto button is pressed It can transition between modes and switches to alarm mode if an error occurs It can restart operation and restart in Stop mode after rectification It also has Auto mode Stop function can be activated by pressing an emergency button, disconnecting devices Normal operation resumes after rectification and reset Stop mode refers to the situation in which the servo and all devices within the system are turned off
In manual mode, the operator has control over testing axes and devices The operator may input the required speed and velocity to run in this mode
The first automatic mode It is necessary to establish the initial position for the system (Home) Once the initial position is determined, the system may be activated and it will automatically operate at a speed of 14900mm/min
Software installation
The engineering software GX Works2 utilizes the well accepted principles of
"grouping" and "structuring" to enhance programming efficiency at its core
GX Works 2 is the starting point for the globally recognized engineering style
To Parameter → PLC Parameter → Establish I/O Assignment for the system
The system consists of four modules: the PLC Q03UDECPU, the servo QD75MH4, the output module QY80, and the CC-Link module QJ61BT11N The QD75MH4 and QJ61BT11N modules have 32 points, while the QY80 module has 16 points
A connection has been established between module QJ61BT11N and Bled6C-
Select the CC-Link folder in the Network Parameter section and specify the number of interconnected modules, remote input, output, registration placement, relays, and registers
Figure 4 9 Setup for CC – Link
Next, we designate the station for driver BLED6C-CC as CC-Link Configuration Setting We next choose the intelligent device station for driver BLED6CC-C and the master station for the CPU
Figure 4 10 Setup master station for CC – Link
Figure 4 11 Basic parameters to control the speed of the motor after connecting to the PLC
In order to manipulate the conveyor's direction of rotation, it is necessary to provide a value to Y, which corresponds to the remote input specified in the CC-Link module and driver configuration segment
With BLE series, we setting speed for conveyor is 100 r/min
Establish a connection and define the settings for Modules QD75MH4 and
In intelligent function module → chose QD75MH4 → chose parameter
Figure 4 13 Setting parameters for PLC
GX Works2 offers a wide range of settings to facilitate user control In this project, we need to focus on certain parameters, namely:
The following parameters need to be determined: unit, the number of pulses needed for one revolution, the amount of movement per rotation, the speed limit, the software stroke limit, and the jog speed value
When the parameter "home" is specified, we must also specify the parameters for OPR direction, OPR speed, Creep speed, and OPR retry
Figure 4 14 Setting OPR (Home), Creep and OPR retry for project
In servo parameter: Setting MR – J3 – B series for axis 1, axis 2 and axis 3, forced stop input will change by invalid
Figure 4 15 Setting servo series and forced stop
Regarding the positioning axis, there are many methods to get the data used in the project:
The operation pattern consists of three modes: End, Cont, and
The "End" mode signifies the conclusion of data, whereas the "Cont" mode initiates the data and continues running until the data reaches its conclusion
Control system: The control system offers many modes such as ABS
(absolute), INC (increment), linear, and linear interpolation This project utilizes the ABS and INC of linear functions to regulate the movement of each axis
Positioning address refers to the specific location where the required axes move at the speed specified in the Command speed
Dwell time refers to the duration of the delay between each occurrence of data
Figure 4 16 Setting function in positioning axis mode
To call data and save values in a register, use the memory range specified in the handbook Access desired numbers using axis 1, which spans from 2000 to 7999, axis 2, which covers 8000 to 13999, and axis 3, which covers 14000 to 19999
Figure 4 17 Call data for each axis
In order to visually track the movement of the axes and identify any operational issues, it is necessary to record the register values and use them to show on the screen for convenient viewing and troubleshooting, as well as error rectification:
QD75MH4 → Chosse auto refresh → declare current feed value and axis error No
In order to reset the error, the following steps must be taken:
Figure 4 19 Call “K1” to reset error
GT Designer3 is a software application designed for Mitsubishi Electric HMIs, specifically for the GOT2000 series, as part of the GT Works3 package, allowing for easy creation of well-structured displays
Displayed below is the screen layout of GT Designer3 The screen is partitioned based on function, facilitating rapid identification of the desired object To get specific information on each feature, see the GT Designer3 (GOT2000) Screen Design Manual
Figure 4 21 Layout of GT designer 3
In GT Designer3, you may position switches, numerical input, numerical displays, or other components on the screen design area These components on the screen are often known as "objects"
The configuration options in a project are categorized under the "Project",
"System", or "Screen" tab To see the configuration items in each tab, you have the option to flip between the tabs This allows you to efficiently locate a certain configuration option
Figure 4 23 Project, screen and system tab
Choose from available screen design options for all displays, eliminating the need for individualized configurations Adjust gradation to enhance visual appeal and easily apply to base, window, and mobile screens
Choose an item and left-click on any location within the screen layout to position the item To adjust the advanced options, simply double-click on the item The state of the light, switch, or other items may be verified by examining the displayed picture in the configuration dialog
Design the HMI screen for the project:
Next, proceed with the instructions for creating buttons and the interface page mentioned above:
Figure 4 27 Create switch for each function, numerical input and numerical display
Figure 4 28 Background and interface for project
Once we have finished, we will proceed to create a central interface for seamlessly transitioning between desired settings
The central screen offers three distinct pages for user convenience: automated, manual, and introductory modes, allowing easy navigation between pages and configuration of desired values for control process initiation
The manual screen allows for input of location, speed, and modes like ABS, INC, and JOG Speed It also regulates magnetic conveyor belt functioning, detects errors, and relocates the Servo Positions are displayed visually, and a taskbar allows navigation between sites, displaying date and real-time information
When in Auto mode, the buttons will have a similar appearance but will be more intuitive This will allow the operator to effortlessly navigate the screen without needing to focus on the model
GX Works2 uses temporary variables to represent operational progress, with a monitor screen showing patterns and a camera reading and returning characters The PLC provides Servo position information, and light illuminates according to modes and goods, with green light activated when the system halts or detects a product
GT SoftGOT2000 is a HMI program for personal and panel computers, enabling data surveillance and control from industrial equipment It allows users to access shop floor data on their office computer, while GT Works3 offers HMI/GOT Screen Design Software for convenient access
RESULTS, COMMENT AND EVALUATION
Results
The control system fulfils the following criteria:
Run Jog and run Data to the standby position
The XYZ axis system will automatically return to the standby position (home) after the object processing is finished, in order to proceed with the next step
The conveyor operates via the CC-Link network, allowing for independent adjustment of the speed
Press servo off to turn off the XYZ – Axis
The system operates smoothly and stably
While operating, the system and conveyor belt function at the predetermined velocity
The camera has the capability to rapidly scan things within its field of view, but it lacks the ability to scan damaged goods
My crew accurately adjusted the distance and velocity to successfully transfer the article from the conveyor onto the turntable
The products (cosse head) are arranged in the positions in the box
The SoftGOT display actives well, which contains all simple information for regulation users
Comment and evaluation
Following an extensive period of study, design, and programming, our team has successfully gathered predefined findings for the functioning supervision of the model The model has the accompanying benefits and drawbacks:
My group controls 3 servo motors for 3 axes and can run all 3 - Axis smoothly
Camera works stably, no interference
The axes operate with stability, ensuring that the items are accurately deposited into the boxes
Flexible model can run many different modes
Minor variations in mechanical specifications might result in operations that lack complete precision Nevertheless, minor mistakes might be disregarded
The camera's hardware restrictions restrict its capacity to catch things beyond a distance of 30cm This is due to the camera's tiny active area and the limited processing power of its tools, resulting in a somewhat slow sensor response for capturing objects
There is a restricted vertical distance for the suctioning and placement of items onto the box
The operational velocity is not substantial
The range at which the object recognition and dog sensors can detect is limited
There is a latency in the system's communication and data transmission from camera pictures to the PLC Consequently, if the XYZ axis does not get the product, the magnetic will not have sufficient time to attract the item
CONCLUSION AND RECOMMENDATION
Conclusion
The team successfully achieved their original objectives by constructing a model with a rapid and stable control algorithm The method is versatile and can be used across various domains However, challenges such as product categorization based on patterns and other sector issues persist Despite some mechanical deficiencies, the team has made efforts to minimize them
The team gained a thorough understanding of servo motors' operating principles and position control theory, Encoder theory, and modern device communication They also learned to read mechanical drawings and process metal while building mechanical models, enhancing their skills in the field
Upon comprehending and constructing the model, the team has successfully achieved the basic objectives The control method for the model exhibits rapidity and a reasonably consistent state, making it applicable across many domains Issues related to product categorization based on patterns and several other challenges encountered in the sector Despite certain remaining deficiencies in the mechanical framework, the team has made efforts to minimize them
The program has been fully developed and is user-friendly The SoftGOT display system provides a handy means of monitoring the functioning state of the device by presenting speed and location information
Recommendations
Improve the mechanical framework to enhance the precision of the model
To enhance the responsiveness while moving objects at high speed and reduce reaction time, it is advisable to switch to a more modern image processor
To enhance the operational efficiency of the model, we propose implementing speed synchronization between the pick-and-drop mechanism and the conveyor during product categorization This would allow things to be captured off the conveyor without interrupting its movement
It is possible to use motors with larger capacity and change the sliders accordingly to increase the load capacity
REFERENCE http://dl.mitsubishielectric.com/dl/fa/document/manual/ssc/ib0300117/ib0300117b. pdf https://www.mitsubishielectric.com/fa/vn_vi/download/manual/pdf/cnt/plc007.pdf https://www.mitsubishielectric.com/fa/vn_vi/download/manual/pdf/cnt/plc005.pdf https://catalog.orientalmotor.com/item/all-categories-accessories-peripherals/ac- motor-accessories/cc05if-usb https://oriental-motor-co-ltd-cc05if-usb-driver.software.informer.com/download/ https://www.mitsubishielectric.com/fa/download/cad/cnt/plc/plcq/io/index.html https://support.cognex.com/en-gb/downloads/detail/in-sight/4531/1033