Machine Control System Research Articles

A Study and Development of the Control System of Fruit Dehydration Machine by Biomass Energy

This article presents the study and development of the control system of fruit dehydration machine by biomass energy in which manual control system was upgraded to the Auto one. Study results revealed that Auto control system required less operation time for as much as 1.30 hour. By comparing energy consumption of the two systems, the upgraded system required less energy approximately 751.30 baht/month and 9,016.32 baht/year. When the break-even point is taken into consideration, this system upgrade could payback after 3.33 year. The author really hopes that this study can be used as a guideline for those interested or involved in the development fruit dehydration machine.

Design of an Adaptive Scheduling Algorithm for a Warp Knitting Machine Industrial Wireless Network Based on Fuzzy Control

Aiming at resolving the technical bottlenecks existing in current warp knitting machine control systems, such as the distributed industrial wireless networked control system, in this study the architecture of a warp knitting machine industrial wireless networked control system based on the WIA-PA international standard is proposed which provides a design idea for building a „smart factory”. Secondly, according to the WIA-PA specification, an allocation plan of time slots in a super-frame for intra-cluster and inter-cluster communication is given. Third, in order to enhance the real-time access of equipment, expand the network capacity, and reduce the energy consumption of the system, based on the carrier sense multiple access (CSMA) mechanism supported by IEEE STD 802.1 5.4:2006, an adjustment algorithm of the super-frame structure based on fuzzy control was designed. The effectiveness of the design method was verified by simulation.

POSSIBILITIES OF USING SERIAL CNC EQUIPMENT AS A BASIS FOR BUILDING DIGITAL PRODUCTION SITES

The article addresses the problem of building cyber-physical control systems of metal machining based on commercial computer numerical machine control systems (CNC). The article provides an overview of possibilities of integrating third-party software into common CNC units. The analysis has revealed a universal way of integration and resulted in a diagram of the cyber-physical machining system.

Nonadaptive Rotor Speed Estimation of Induction Machine in an Adaptive Full-Order Observer

In the sensorless control system of an induction machine, the rotor speed value is not measured but reconstructed by an observer structure. The rotor speed value can be reconstructed by the classical adaptive law with the integrator. The second approach, which is the main contribution of this article, is the nonadaptive structure without an integrator. The proposed method of the rotor speed reconstruction is based on an algebraic relationship – the rank of the mathematical model of the observer system is not increased. However, the problem with the stabilization of the observer structure does exist. For near to zero rotor speed or in the regenerating mode of an induction machine, the speed observer structure can be unstable. Therefore, in this article, the new stabilization functions are proposed. The stability is provided by the Lyapunov theorem and the practical stability theorems in which the uncertainty of parameters is considered. In the proposed solution, the newly introduced stabilization functions guarantee observer stability during both the motoring and regenerating conditions at the chosen low rotor speed ranges and for different load torque values. All the theoretical considerations were confirmed by simulation and experimental tests during the chosen working modes and uncertainties of nominal parameters of the induction machine.

Analysis of WWER-1000 Fuel Deformation Using the Refueling Machine Control System

The analysis of the geometric dimensions of fuel assemblies, whose change may lead to mashing of the cassettes in the core, is performed at this stage only after removing the fuel assemblies from the reactor. This paper considers the possibility of analyzing the mashing of WWER-1000 cassettes using the control system of the reloading machine. Based on data from an industrial experiment at the Rostov NPP, a typical distribution of friction forces over the height of the WWER-1000 reactor core is assessed.

New Design of a Boost Drive Circuit with an Energy Recovery Function for the Piezoelectric Jacquard Needle

Aiming at the technical bottlenecks existing in the current warp knitting machine control system such as jacquard drive circuit, the design method of self-boosting power supply circuit integrated with jacquard driver is proposed for the embedded warp knitting machine jacquard control system for miniaturization design. The voltage boost circuit designed can boost the low voltage from the input of the working power supply to the high voltage for the output to drive the oscillation of the piezoelectric ceramic jacquard needles. Since the circuit adopts energy storage inductance instead of current-limiting resistor to optimize the driving circuit, it not only limits the forward charging current of the piezoelectric ceramic, but also effectively realize the energy recovery function. The effectiveness of the design method is verified by simulation.

Symmetrical Components Observer for LPMM Back EMF Based on Negative-Sequence Current Injection

Thrust force ripple, including no-load detent force and electromagnetic thrust ripple, worsens the precision of the linear permanent magnet machine (LPMM) control system. This article focuses on the elimination of electromagnetic thrust ripple caused by the finite length of the LPMM mover core. On the basis of the asymmetrical current controller for suppression of thrust ripple, the observation of asymmetry plays an important role. The extraction strategy, including the extraction of fundamental frequency current/voltage symmetrical components and an observer for positive- and negative-sequence back electromotive force (EMF), is derived. Compared with off-line data, the proposed control strategy has wider application. Experimental results based on an LVPMM are presented. It verifies that the asymmetrical current control strategy based on the back EMF observer reduces electromagnetic thrust ripple by more than 66%.

X-Ray machine control with wireless based on mA parameters

An x-ray machine is a medical device that is used as a diagnostic tool for patients. The conventional x-ray machine consists of a control system, high voltage and tube x-ray machine. The control system on conventional x-ray machines uses too many cables so it looks less efficient. Control of the x-ray machine must be carried out in the same room as the equipment so that it can endanger the radiographer when it will be operated, because the radiographer will be continuously exposed to radiation. Therefore, an x-ray machine control system is designed that is safe for radiographers when operated and efficient in the use of cables. This research method uses the Arduino application to change the conventional control system to wireless, with the aim of providing the radiographer’s safety because he operates the device from a separate room and does not face the x-ray machine directly. Current selection uses several contactors at each different current. The contactor is controlled by a microcontroller connected by a series of drivers. The process of selecting voltage, current and time is carried out on a Personal Computer (PC) connected to the controller via Bluetooth. The test is done by measuring the output voltage of the filament transformer using an AVO meter, then comparing it with the voltage calculation results obtained from the x-ray machine tube specifications. Based on the tests that have been done, it is found that the correction value is small and does not deviate much, which is 0.01 V when selecting mA 50 and 0.09 V when selecting mA 60. The x-ray machine can be controlled wirelessly using a PC with a distance 6 meters in conditions blocked by a 9 cm thick wall.

Use of the CANopen protocol in vibration control systems of rotary machines

Currently, most accidents and disasters at power plants are associated with fatigue failure of machines, mechanisms and assemblies caused by vibration. To prevent real threats of man-made disasters, there is an urgent need for objective monitoring of the current technical condition of mechanisms without disassembling them, during operation, repair and adjustment. The article proposes to use innovative approaches in the design of reliable and high-speed communication systems for the control of diagnostics and vibration monitoring of rotary-type machines in the form of a high-level network protocol running on top of the physical interface CAN (Controller Area Network). The aim of the study is to develop proposals for the use of the CANopen protocol in vibration control systems for rotary-type machines. The authors of the article analyzed the causes of man-made accidents at energy enterprises, identified the goals and objectives of vibration control of rotary machines and substantiated the possibility of using the CANopen protocol in vibration control systems. This will allow the exchange of data between devices from different manufacturers and ensures the interchangeability of devices. Thus, the authors concluded that the use of the CANopen protocol in vibration control systems for rotary-type machines is a promising direction that allows engineers to solve the necessary technical problems using modern methods.

Research on key technologies of intelligent control system of bucket wheel machine in enclosed stockyard

Research on key technologies of intelligent control system of bucket wheel machine in enclosed stockyard

Development of gear dynamic performance testing machine

With the development of gears towards high temperature, high pressure, high speed and high stress, gear measurement, in which only the static geometric accuracy is considered, is unable to meet the current application requirements. While, the low precision and single function gear tester constrains the measurement of gear dynamic performance. For the resolution of this problem, based on the principle of gear system dynamics and several precision mechanical design techniques, a gear dynamic testing machine has been developed, providing new instruments for gear testing. On the basis of research of the principle of dynamic performance test, the primary measurement items of the testing machine have been determined. The measuring principles of each item and the driving and loading form of the testing machine have been examined. The measurement and control system of the testing machine and its corresponding software have been developed. The instrument can not only obtain the static precision index of the gear, but also obtain the dynamic performance index of the gear in variable working conditions. According to the actual test, the uncertainty of instrument is 3.8 μm and the external disturbance caused by the shaft vibration is less than 0.6 μm, which can meet the 5–6 grade precision gear testing requirement.

Real-Time Human Detection in a Restricted Area for Safety in Truck Dumper Control System Using Deep Learning

A process to receive raw materials from suppliers in an animal feed industry utilizes both automatic and semi-automatic machine control systems. The process called “truck dumper system” is the procedure that the suppliers provide raw materials carried by trucks; then, their tailgates open, and the raw materials are discharged by raising front end part of a truck to gather raw materials in a collection area. In general, the truck dumper system has been controlled manually by staff in a control room, not by a truck driver. However, serious accidents may occur during the process because when the dumper lifts up, the staff's vision has been blocked by the raised part of a truck. Therefore, if the staff controls the dumper to lift down by lacking safety awareness, people in the restricted area can be endangered. In this study, we proposed a framework of automatic human detection to prevent any accident that may occur from the truck dumper in the restricted area. The human detection model was developed to detect humans possibly in different blind corners that are difficult for staff in a control room to monitor these unseen areas for safety-awareness. The main technology of the proposed framework was the real-time human detection with fully convolutional neural network architecture called You Only Look Once, or YOLO. The framework has been designed to send a signal to terminate the truck dumper system immediately after the model detects people in the restricted area. In experiments, we discovered that the model could detect a human in all blind corners, including the corners that the staff's sight was completely bloacked by some barriers. The overall efficiency of this framework in an aspect of speed was high. The average time to process per image was 397 milliseconds by using CPUs and only 52 milliseconds by using GPUs. The results also showed that the model was effectively applicable to detect human in real-time due to its high-speed process.

Design and implementation of laser marking machine control system

The laser marking control system based on STM32 microprocessor is designed. Combined with the advantages of high efficiency and low cost of embedded control system, the overall scheme design is described and the peripheral hardware and the underlying driver are analyzed and designed. The microprocessor controls the switch of the laser by receiving the marking data sent by the upper computer via USB, and at the same time, the simulated galvanometer control protocol (XY2-100) controls the scanning of the galvanometer. SDRAM is used to enhance the data storage and processing capacity of the microprocessor. In order to improve the security and reliability of data, symmetric encryption algorithm is designed. After testing, the designed system meets the requirement of actual marking precision and has good practical value.

5G as an enabler for cloud-based machine tool control

The new cellular network standard 5G is characterized by greater bandwidth, lower latencies, higher reliabilities, and a higher number of recipients per cell compared to industrial 4G or wireless networks. This makes 5G a promising technology in latency-critical applications in manufacturing, such as machine tool control systems. Today, machine tools are mostly controlled with on-site industrial PCs, which require space, are often heterogeneous, and have limited processing power. 5G potentially enables to migrate the machine control system to external computing resources. This paper aims at elaborating resulting potentials by conceptualizing and outlining an architecture that integrates the requirements and capabilities of 5G and a machine tool control system.

Combined Positioning Device for the Control System of the Microtunnel Boring Machine

The issues of developing a combined positioning device for the microtunnel boring machine control system are considered. A device combining laser and inertial methods of determining coordinates is proposed, which provides the possibility of determining the coordinates and spatial position of the tunneling shield during the construction of straight and curved tunnels by the pushing method. A method for connecting the positioning device with the microtunnel boring machine control system based on the RS-485 wired interface is proposed. A method for calculating coordinates has been developed that takes into account the rotation of the local coordinate system relative to the local geodetic coordinate system.

Digital twin control of multi-axis wood CNC machining center based on LinuxCNC

This paper presents an application of an open architecture control system implemented on a multi-axis wood computer numerical control milling machining center, as a digital twin control. The development of the digital twin control system was motivated by research and educational requirements, especially in the field of configuring a new control system by “virtual commissioning”, enabling the validation of the developed controls, program verification, and analysis of the machining process and monitoring. The considered wood computer numerical control (CNC) machining system is supported by an equivalent virtual machine in a computer-aided design and computer-aided manufacturing (CAD/CAM) environment, as well as in the control system, as a digital twin. The configured virtual machines are used for the verification of the machining program and programming system via machining simulation, which is extremely important in multi-axis machining. Several test wood workpieces were machined to validate the effectiveness of the developed control system based on LinuxCNC.

РАЗРАБОТКА ИНТЕЛЛЕКТУАЛИЗИРОВАННОГО СТАНКА ДЛЯ РАЗДЕЛЕНИЯ ПОТОКА ЖИВОТНЫХ ПО ЗАДАННЫМ ПРИЗНАКАМ

The Federal scientific Agroengineering center VIM has developed technical tools, algorithms and software for the intelligent automatic control system for milking animals “Stimul” on the “Herringbone” milking unit in three versions. The created system does not include automatic selection gates for effective management of zootechnical and veterinary services of animals. (Research purpose) The research purpose is in developing an intelligent machine for automatic sorting of animals for servicing and managing the herd according to specified characteristics. (Materials and methods) The article presents the development of control and management systems in dairy farming based on the conceptual principles of digital transformation. The digital control system is based on a multifunctional panel controller. The created control unit has a port for connecting to the RS 485 network and provides support for network functions via the Modbus Protocol. The programming of the control unit has been made in the SMLogix tool environment, which supports the FBD function block language. (Results and discussion) The article presents an intelligent machine for automatic sorting of animal flows for servicing and managing the herd according to specified characteristics with the unification of hardware, software modules and interface. The article describes the necessary parameters for the automatic remote animal identification system, the basic component of the control system of an intelligent machine for sorting animals according to specified characteristics. (Conclusions) The machine allows to automatically identify, sort and send animals to the specified areas for individual service.

Practical aspects of constructing a specialized control system for compact machines

In the presented article is considered the task of constructing a specialized system for implementing numerical control of various compact machine solutions that allows to process wood or metal or create parts from model plastic based on additive technologies. The control system must be flexible and, by its principles of construction and programming, be close to classical CNC systems, but not possess excessive functionality and corresponding price. The development of such compact machine-tool solutions will make it possible to use them both for small productions and for training specialized specialists in working with numerical control systems and in their programming.

Research on Automatic Control Mode of Profile Cutting Machine Based on PLC

Aiming at the constant need of cutting various metal profiles in industry, the control mode of automatic profile cutting machine is studied, which is based on PLC (Programmable Logic Controller) controller. MCGS (Monitor and Control Generated System) is used for monitoring and management, and the modular design of control layer is completed. The core of the control layer is that we have a cutting material database, which makes up for the fact that the current cutting machine control system only aims at a single cutting model or material, and the cutting speed and torque of the cutting machine need to be adjusted or designed manually. Based on this market demand, the automatic control mode of profile cutting machine based on PLC is established. Practice shows that this mode is based on the analysis and comparison of common cutting materials in the market, and the material database is consequently established. Users can choose the required cutting mode through the intuitive MCGS graphical interface, which improves the cutting efficiency of users and reduces the development cost of enterprises.

Wind-DFIG wireless controlled using EGPRS standard applied to the ancillary services in a smart grid environment

This paper presents an alternative topology analysis for reactive power control in wind farms with wireless communication link integration. The co-simulation environment with telecommunication, machine control, and power system demonstrate in this analysis, that it can be an useful solution for planning the operation of modern power systems and their ancillary services in a smart grid scenario. A low cost and easy implementation EGPRS standard wireless link was adopted to perform the communication from the smart grid operator and the wind farm with the objective of maintain the voltage levels under established limits. The wireless communication was used to send the value of measured voltage of one critical bar to the operator and to return the reactive power reference to the wind farm. The studied scenario is represented by a seven bar power system model connected to a DFIG wind farm. The results obtained by this co-simulation endorse this original proposal and show its operability.