Network And Controls Of Servomotors.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

NETWORK AND CONTROLS OF

SERVOMOTOR

Report submitted in accordance with partial requirements of the Universiti Teknikal Malaysia Melaka for the Bachelor of Manufacturing Engineering

(Robotics & Automation)

By

Teng Guat Theng

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PSM

JUDUL:

NETWORK AND CONTROLS OF SERVOMOTOR

SESI PENGAJIAN:

Semest er 2 2007/ 2008

Saya TENG GUAT THENG

mengaku membenarkan laporan PSM / t esis (Sarj ana/ Dokt or Falsaf ah) ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :

1. Laporan PSM / t esis adalah hak milik Universit i Teknikal Malaysia Melaka dan

penulis.

2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan

unt uk t uj uan pengaj ian sahaj a dengan izin penulis.

3. Perpust akaan dibenarkan membuat salinan laporan PSM / t esis ini sebagai bahan

pert ukaran ant ara inst it usi pengaj ian t inggi.

4. *Sila t andakan ( )

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdar j ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan di j alankan)

i

DECLARATION

I hereby declare that this report entitled “NETWORK AND CONTROLS OF

SERVOMOTOR” is the result of my own research except as cited in the references.

Signature :

Author’s Name : NETWORK AND CONTROLS OF

SERVOMOTOR

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Robotics and Automation). The members of the supervisory committee are as follow:

Mr. Ahmad Yusairi Bin Bani Hashim

iii

ABSTRACT

ABSTRAK

v

DEDICATION

ACKNOWLEDGEMENTS

vii

1.2 Statement of Problems 2 1.3 Scope 3 1.4 Organization 3 2.0 LITERATURE REVIEW 4 2.1 Programmable Logic Controller (PLC) 5

2.1.1 PC Hardware Structure 6 2.1.2 Input/ Output System 7 2.1.3 Memory Units 8 2.1.4 External Data Communications 9

2.1.5 PLC Programming 10 2.2 Servo Motor 12 2.2.1 Introduction to the Servo Motor 12

2.3 Wire 17

2.3.1 Standard Wiring Colours 17

2.3.2 Gate Rating 19

2.3.2.1 Detailed Instructions for using the Wire Size Calculator 20

2.3.2.2 Full-Load Currents in Amperes, Single-Phase

Alternating-Current Motors (From 1999 NEC) 21

2.3.2.3 Full-Load Current Three-Phase Alternating-Current

Motors (From 1999 NEC) 22

2.4 Application Formula 26

2.4.1 Angular Distance 26

2.5.1 Response Characteristics and System Configuration 32

2.5.1.1 Input and Output 32

2.5.1.2 Open-Loop Systems 33

2.5.1.3 Closed-Loop (Feedback Control) Systems 34 2.5.2 Control Engineering: Analyze and Design 36

2.5.2.1 Transient Response 37

2.5.2.2 Steady-State Response 37

2.5.2.3 Stability 38

3.0 METHODOLOGY 40

3.1 Methodology Flow Process Chart 41

3.2 Detail Description of Methodology Flow Chart 42

3.3 The Design Process 44

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3.4 The design process 47

3.5 Simulation (Calculation) 52

4.0 RESULT 54

4.3 Programmable Logic Controller (PLC) 60

4.3.1 Ladder Diagram 60

5.1.3 Selection of Coupling 71

5.2 Control box for Servo driver 72

5.2.1 Electrical Circuit (IEC Standard) for Control Box 72

5.2.2 The Function of electrical Diagram 73

5.2.3 Testing circuit for Control Box 74

5.3 Programmable Logic Controller 77

5.3.1 Ladder Diagram (CX-Programmer) 77

5.3.2 Electrical circuit between PLC and Servo Driver 80

5.3.3 Testing the PLC Training Kit 81

5.4 Components Analysis 82

5.4.1 Permissible Buckle Load and Tensile Compressive Load 82

5.4.2 Driving Torque 85

5.4.3 Servomotor Position 86

5.5.1 Servomotor Feedback Controller 88

5.5.2 Transfer Function for Servomotor 90

6.0 SUMMARY AND CONCLUSION 93

B-3 Programmable Logic Controller (OMRON SYSMAC CJ1M-CPU22)

APPENDIX C-1

C-1.1 Test waveforms used in control systems C-1.2 Response of a position control system showing effect of high

and low controller gain on the output response

APPENDIX C-2

C-2.1 Laplace Transform Table C-2.2 Laplace Transforms Theorems

APPENDIX C-3

xi

C-3.2 Block diagram of series RLC electrical network

C-3.3 Force-velocity, force-displacement, and impedance translational relationships for springs, viscous dampers, and mass

C-3.4 a. Mass, spring, and damper system; b. block diagram C-3.5 Torque-angular velocity, torque-angular displacement, and impedance

rotational relationships for springs, viscous dampers, and inertia

C-3.6 a. Physical system; b. schematic; c. block diagram C-3.7 a. Torques on J2 due only to the motion of J2; b. torques on J2 due

only to the motion of J1 c. final free-body diagram for J2

APPENDIX D

F-10 Engineering drawing for servomotor bracket 1 F-11 Engineering drawing for servomotor bracket 2

APPENDIX G

G-1 Coupling

APPENDIX H

LIST OF FIGURES

2.8 A Simple Ladder Logic Diagram 12

2.9 The duration of the pulse dictates the angle of the output shaft 13 2.10 Illustration of Servomotor Identifying the Armature 14

2.11 Examples of Duty Cycle Calculation 14

2.12 Typical dc servo motor system with either encoder or resolver 16 feedback. Some older servo motor systems use a tachometer and

encoder for feedback

2.13 BS 7671: 2001 Amendment No 2: 2004 18

2.14 Example of conductor marking at the interface for additions and 19 alterations

2.15 Angular velocity 27

2.16 Right hand rule direction of torque 28

2.17 Simplified description of control system 31

2.18 Elevator response 32

2.19 Block Diagram of Control System: Open-Loop System 33 2.20 Block Diagram of Control System: Closed-Loop System 35

3.1 Methodology flow Chart 41

3.2 Ball Screw Assembly 44

3.3 Types of Ball Screw Starts 45

3.4 Types of Ball Bearing 47

xiii

4.1 Final layout 55

4.2 Assemble of servomotor with lead screw mechanism by using coupling 55

4.3 Isometric 3D view for layout of project 56

4.4 Top view for 3D drawing of layout project 57

4.5 Front and side view for 3D drawing of layout project 57 4.6 Assemble of servomotor with lead screw mechanism by using coupling 57

4.7 Control Box of the servo driver 58

4.8 The solid work drawing for control box. 58

4.9 The electrical diagram for control box that draw by using 59 Automation Studio

4.10 Timer Base Ladder diagram of PLC to move the servomotor and lead 60 screw mechanism in CW and CCW direction

4.11 Normal jog Ladder diagram of PLC to move the servomotor and lead 62 screw mechanism in CW and CCW direction

4.12 The circuit diagram for the PLC and SMARTSTEP servo driver 63 4.13 Wire connection of the PLC and SMARTSTEP servo driver 64 4.14 Description the wiring connection for box that shows in figure 4.12 64

5.1 Assemble of servomotor and lead screw 69

5.2 L-brackets and support of the servo motor 69

5.3 A sample drawing for L-bracket 70

5.4 Coupling that used to two joining shaft for ball screw and servomotor 71

5.5 Electrical Diagram for control box 72

5.6 Testing the circuit of the control box 75

5.7 The ladder diagram for servomotor which move in clockwise direction 78 5.8 The ladder diagram for servomotor which move in CCW direction 79 5.9 The circuit diagram for the PLC and SMARTSTEP servo driver 80 5.10 The simple programming that use to test the function of PLC and 81

Training Kit

5.11 The testing result 82

5.12 Mounting Method for Ball Screw 83

5.13 Driving Torque Required By the Ball Screw to Move a Load 85

5.15 A Servomotor Feedback Controller 88

5.16 A Servomotor Feedback Controller 89

5.17 A Combination System Model 89

5.18 Servomotor (a) Schematic; (b) Block Diagram 90

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LIST OF TABLES

2.1 Full-Load Currents in Amperes, Single-Phase Alternating-Current 22 Motors

2.2 Full-Load Current Three-Phase Alternating-Current Motors 23

2.3 Wire Gage 25

2.4 List of Moments of Inertia 29

4.1 Standard Part BOM for Project 65

LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCLATURE

PLC - Programmable Logic Controller RTOS - Real Time Operating System

EPROM - Erasable Programmable Read-Only Memory

EEPROM - Electrically Erasable Programmable Read-Only Memory LAN - Local Area Networks

LLD - Ladder Logic Diagrams

ST - Structured Text

FBD - Function Block Diagrams SFC - Sequential Flowcharts IL - Instruction Lists

IEE - Institution of Electrical Engineers

IET - Institution of Engineering and Technology IEC - International Electrotechnical Commission

BS - British Standard

NEC - National Electrical Code AWG - American Wire Gage

1

CHAPTER 1

INTRODUCTION

Servo motors are best known for their rapid acceleration and deceleration capability, made possible by delivering high-peak torque in conjunction with a high torque-to-inertia ratio.Servo motors are famous for their high dynamic response and precision accuracy in traditional motion control applications, such as machine tools and robotics.

Nowadays, many servomotors are controlled by using some controllers such as PLC (Programmable Logic Controller), PAC (Programmable Automation Controller) and etc. Actually, this project will present about the network and controls of servomotors. The controller that will use in this project to control the servomotor is Omron brand’s PLC.

1.1 Objective

The purpose of this project is to install complicated servo motors networks to controllers according to the connection diagram on the operation manual. Through this project, students can understand about the equipment, device and component that used in this project. All this information and knowledge is very important to easier student install the complicated servomotors network to controller. After complete install the servomotor to controller, student should write a PLC’s program to control the servomotor. Through this, student will know how to apply the PLC programming to execute the servomotor. After that, student should verify the servomotor and investigate some analysis in control engineering such as speed of motor, stability of motor, movement of motor.

1.2 Statement of Problems

There have five sets of servomotor with controller are provided in this project. The servomotor does no function as a result of incomplete networking and installation. So, the important thing that should do in this project is find some suitable electrical connector or device to connect the wiring from PLC to servomotor. The electrical device that mention just now is start/stop button, emergency stop, relay, wire and so on. To connecting all the wiring of this project, student should study out the diagram that provided by the manufacturer (refer to Appendix A). Through this diagram, only students will know how to install and network the motor.

3

1.3 Scope

The focus of this report is on system investigation with some analysis in control engineering which is the engineering discipline that focuses on mathematical modeling of systems of a diverse nature, analyzing their dynamic behavior, and using control theory to create a controller that will cause the systems to behave in a desired manner. In this project, the control engineering such as speed, movement and transient response should take in consider to obtain an excellent result. After connecting all the wire connection and also finish assemble the mechanical part of this project, the analysis of control engineering should take in account to get the perfect result.

1.4 Organization

CHAPTER 2

LITERATURE REVIEW

5

2.1 Programmable Logic Controller (PLC)

Nowadays, almost all control applications require switching (on or off) which contain of various outputs as a function of a number of inputs [1]. The programmable logic controller is known as logic control or switching control. This switching control are quite simplicity that why it attractive for use in automatic machines where there is a requirement for the machine to follow a set sequence of operations to gives rise to the term sequential control by using switching control.

Normally, a PLC is an industrialized dedicated microcontroller. It is operation based primarily on sequential control of a process. Its Real Time Operating System (RTOS) scans a program in a repetitive cycle and actions are taken (outputs set) depending on logical relationships (specified by the programmer) between the inputs [1].

In fact, a PLC or Programmable Controller is a digital computer used for automation of industrial processes, such as control of machinery on factory assembly lines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or non-volatile memory. A PLC is an example of a real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result [2].

Figure 2.1: PLC – I/O structure [3]

Recently, PLCs have been gaining popularity on the factory floor and it will probably remain predominant for some time to come. Most of this is because of the advantages they offer. The advantages of the PLCs are:

§ Cost effective for controlling complex systems

§ Flexible and can be reapplied to control other systems quickly and easily.

§ Computational abilities allow more sophisticated control.

§ Trouble shooting aids make programming easier and reduce downtime.

§ Reliable components make these likely to operate for years before failure.

2.1.1 PLC Hardware Structure