Machine Control System Research Articles

Design and application of double closed loop weight control system for cigarette maker

In order to solve the problem that the precision of cigarette weight control system is not high enough in cigarette machine production, a double closed loop weight control system of cigarette machine is designed according to the characteristics of cigarette machine control system. This system takes IPC as the control core. Firstly, the current cigarette weight is obtained, then the weight deviation is calculated, and then the distance to be moved by the actuator is calculated based on the deviation. Then the current position of the actuator is obtained, and the target position of the actuator is calculated. The results show that the long-term deviation of the weight control system using the double closed-loop control method can be reduced to less than 4.0mg during the production of the target weight of 490mg cigarette, which is 0.8mg lower than that of the single closed-loop control method. This technology can improve the quality of cigarette process and reduce the overall consumption.

Design of Self-service Car Washing Machine Control System Based on ARM

With the cars in our country’s rapid increase, the limited quantity of traditional car washing shop has been unable to satisfy people’s needs. Responding to this problem the author designed a set of self-service car washing machine control system based on ARM, and a set of remote monitoring system based on 4G mobile network. The terminal control system adopted high speed, low power microcontroller LPC4350 as the control core; adopted RFID read-write module to realize IC card consumption; adopted EM770W 4G module for the washing machine terminal could connect to 4G mobile network. Through MODBUS protocol, the remote monitoring system based on KINGVIEW6.55 could communicate with the terminal system, and realized the real-time monitoring and recording the washing machines’ working parameters regularly. Because the designed system realized the unattended self-service washing, so it greatly reduced the maintenance workload, and improved the work efficiency.

INFORMATION SYSTEM OF MINIMIZATION CONSUMPTION REACTIVE POWER IN ASYNCHRONOUS ELECTRIC DRIVE WITH VECTOR CONTROL

It is known that the energy performance of asynchronous electric drives is extreme nature. However, when stabilizing the mag-netic flux of the asynchronous machine at the nominal level and reducing the load moment on the shaft, the power factor becomes less than the nominal, and this reduction can be significant. Therefore, the paper proposes to improve the energy performance of asynchronous electric drives with a fan mechanical characteristic of the production mechanism by changing the magnetic flux as a function of the moment of resistance forces on the shaft of the asynchronous machine. Thus, to optimize the energy processes in the electric drive when regulating the performance of turbomechanisms, it is necessary to build a system with independent speed control and magnetic flux of an asynchronous machine. Since the control systems of turbomechanisms are designed to stabilize the speed in long-term operation, it is first necessary to ensure the maximum energy performance in steady-state operation. In this work, the in-crease in energy efficiency is achieved by implementing a vector field-oriented control system of an asynchronous machine with the addition of an extreme control circuit. In the article the information system of two-channel vector control of the asynchronous electric drive with the fan moment of loading which contains a contour of extreme regulation on criterion of a minimum of consumption of reactive power is developed. The dependence of the values of the magnetic flux of the rotor, which are extreme for the reactive pow-er function, mainly on the moment of loading and insignificant on the speed, is substantiated. A synthesized state observer, which estimates the moment of static load, is needed to determine the extreme values of the magnetic flux of the rotor on the basis of the obtained functional dependence. Thus, the idea is to use the reactive power channel of an asynchronous machine not to stabilize the magnetic flux, as was the case in classical vector control systems, but to adjust the modulus of the magnetic flux vector as a function of static load by the minimum stator reactive power. A mathematical model in the Matlab/Simulink environment has been developed and the efficiency of the synthesized information system of minimization of reactive power consumption by an asynchronous electric drive with vector control has been confirmed by mathematical modeling.

FOC-Droop control strategy for PMSM fed paralleled multi-inverter power systems oriented to aeronautical applications

This paper proposes a Field Oriented Control (FOC) for a Permanent Magnet Synchronous Machine (PMSM) which is supplied by a Parallel Multi-Inverter System. The parallelization of the Voltage Source Inverters is safely achieved using a V-f Droop Control strategy as a distributed generation system would be considered like in Smart-Grids. This novel technique is the combination of the previous mentioned both strategies, and will be key when answering to the need of modularity, scalability, redundancy and parallelization for electrical machine control systems. Theoretical and experimental analysis are provided in order to validate the new combined control strategy which fulfills the motor control requirements while current balancing is safely achieved between individual parallelized inverters.

Application of PLC in Automatic Tapping Machine Control System

Aiming at traditional equipment’s problems, such as low tapping efficiency, poor reliability, a set of special automatic tapping machine control system is designed. The system can tap five workpieces at the same time by using Siemens S7-200 series CPU226 AC/DC/Relay PLC technology. The system will carry out technical reform of traditional equipment. The paper describes the control system scheme, work flow chat, I/O wiring diagram and program design of PLC. The operation results meet the use requirements. The system has the characteristics of good maneuverability, high operation safety and high production efficiency, which can greatly reduce the production cost.

Knowledge representation model for intelligent power supply control system of special purpose control machines

The problem of automating the process of reconfiguring the power supply system of onboard radio-electronic equipment in special-purpose control machines in different operation modes is considered. It covers power supply from different power sources, both while parked and when moving by developing and introducing the intellectual management to the structure of an electric power supply system. The analysis of the existing devices used to provide mobile objects with electrical energy of a direct current is carried out. Their advantages and drawbacks are highlighted. The conclusion is drawn on the necessity of new product development – the P910 power supply control panel with an integrated intellectual power supply management system. The model of representation of knowledge of the intellectual management system offered by authors is based on the classic productional model specified regarding the mechanism of forming and creating the database and rule base structures. The process of synthesizing managing influences that are based on analysis of information that describes a system status of control machines’ power supply is formalized. The operation algorithm of the intellectual power supply management system is developed and the chart illustrating its work is provided. The 1887BE7T domestic microcontroller is offered for the implementation of the model.

Design Control Systems of Marking Machine and Total Length Check Damper Assembly Based on Programmable Logic Controller

This research was conducted at an automotive manufacturing company in Indonesia that produces shock absorber (damper). Case study was conducted on the front shock absorber of the motorcycle (front fork). This new product will be given special marking at the designated place. Previous Front Fork products did not have a marking process at the Front Fork Assembly Line. We designed the marking machine control system. This machine control system uses the main MC2000N machine actuator and MC2000T Controller². The machine design is then added to the total length check function. The results obtained are the traceability of the damper made easier and faster in handling claims from the customer. The damper becomes in accordance with the standard.

A multi-DOF rotary 3D printer: machine design, performance analysis and process planning of curved layer fused deposition modeling (CLFDM)

Purpose The purpose of this paper is to design and develop a rotary three-dimensional (3D) printer for curved layer fused deposition modeling (CLFDM), and discuss some technical challenges in the development. Design/methodology/approach Some technical challenges include, but are not limited to, the machine design and control system, motion analysis and simulation, workspace and printing process analysis, curved layer slicing and tool path planning. Moreover, preliminary experiments are carried out to prove the feasibility of the design. Findings A rotary 3D printer for CLFDM has been designed and developed. Moreover, this printer can function as a polar 3D printer for flat layer additive manufacturing (AM). Compared with flat layer AM, CLFDM weakens the staircase effect and improves geometrical accuracy and mechanical properties. Hence, CLFDM is more suitable for parts with curved surfaces. Research limitations/implications Double extruders have brought improved build speed. However, this paper is restricted to complex process planning and mechanical structures, which may lead to collisions during printing. Meanwhile, the rotation range of the nozzle is limited by mechanical structures, affecting the manufacturing capability of complex curved surfaces. Originality/value A novel rotary 3D printer, which has four degrees of freedom and double extruders, has been designed and manufactured. The investigation on the prototype has proved its capability of CLFDM. Besides, this rotary 3D printer has two working modes, which brings the possibility of flat layer AM and CLFDM.

Machining of directed energy deposited Ti6Al4V using adaptive control

Additively manufactured (AM) components possess microstructures different from conventional forms in the same material and as a consequence, the mechanical properties and machinability of components produced using these technologies differ. Also, the microstructures from these processes are often anisotropic and as such different regions possess varying properties and hence varying response during post process machining. An adaptive control (AC) machining system for addressing this variation in microstructures during post process machining is developed here and its use demonstrated in this paper.The adaptive control system is used in milling and drilling trials for machining components manufactured by Directed Energy Deposition (DED). Surface roughness and residual stress analysis in the ‘as built’ state and after post process machining with the prevailing cutting forces are also presented here. Microstructures of the deposited material and the subsurface effects at the machined region due to the action of the cutting tool is also analysed.Milling trials are investigated from the standpoint of the use of adaptive machining for the removal of the outermost layer of DED produced Ti6Al4V and in the machining of bulk regions after preliminary machining of the undulating layer. Drilling experiments are carried out for investigating the effects of the machining process on the resulting surface condition, comparing the process with and without adaptive control. The effects of variation in cutting forces during drilling through the different material systems comprising of the DED region and the wrought substrate is also discussed. The effect of periodic changes in cutting forces during machining due to the variation in microstructure along the build direction is analysed and discussed. The use of adaptive control machining for post processing is shown to improve surface finish as it reduces the initiation and generation of chatter marks on the machined surface resulting from material anisotropicity.

Automatic Melting-casting-palletizing Production System for Miniature Batch/Mass Metal Based on Robot Technology

In metal recycling and smelting, especially precious metal recycling and smelting, a novel production system is put forward for the automatic and intelligent control of the melting-casting-palletizing processes based on the systems engineering principle with multi-robots. The system is optimally designed and consists of five fundamental function modules, the melting-casting robot sub-system, over-turning robot subsystem, palletizing robot subsystem, vibration-demolding table, and the ring-like rotating table. By using the modern cybernetics and intelligent control method in the whole machine control system with machine vision, location and gravity sensors and the corresponding algorithm, into to the PLC control system, achievement of energy saving and environmentally friendly small batch/mass metal recycling and ingot-making is gained with automation and intelligence.

A Dynamical Machine Control System using Simple Processing Unit Based-on FPGA

This paper aims to design a dynamic machine control system device. The proposed dynamic device models are a combination architecture of memory and Arithmetic-Logic Unit (ALU). The configuration of the memory has used a random access memory (RAM), and the configuration of ALU is the core of the central processing unit (CPU), which consists of two functions, namely the arithmetic unit and the logical unit. In this paper, the arithmetic unit consists of addition, subtraction, multiplication, and division, whereas the logical units are AND, OR, NOT, and XOR. The shifter circuit in this paper was also applied to complete the programming code instructions in a software approach. The arithmetic unit and logic unit selector path in the ALU configuration employed a multiplexer circuit. This paper used a top-down design technique by determining the components in implementation. By knowing the function and work of these components, it is much easier to combine the components employing the configuration code of the hardware description language, namely a Very High-Speed Integrated Circuit Hardware Description Language (VHDL). The implementation of the VHDL code was configured into the Xilinx Spartan-3E Field Programmable Gate Array (FPGA) to determine the component consumption and the resulted delay time. The results obtained from the configuration of the ALU components consume 26 slices, 50 4-input look-up table (LUT), 17 input/output (I/O), and 17 Bonded IO, while the component delay time is 11,413 ns.

4D modeling of soil surface during excavation using a solid-state 2D profilometer mounted on the arm of an excavator

The aim of this research is to create a 4D point cloud map from a trench through a solid-state 2D profilometer. The profilometer is integrated with an 8.5-ton medium-size excavator's machine control system with pose calculation. Accordingly, the point cloud was transformed to a work coordinate system. We used a recently developed pulsed time-of-flight laser light detection and ranging profilometer, which makes possible simultaneous depth measurements to 256 directions in an angle range of ±20° and measurement range from 1 m to 8 m with a frame rate of 25 frames per second under sunlight conditions (≈50 Klux). The analysis is based on a 4D map, which consists of 3D data (XYZ) and intensity information. The XYZ coordinates give the position of an object, and the intensity data can be used to roughly identify materials and recognise surface markings, such as texts. An analysis of the results shows that the detection accuracy of the profilometer is better than ±10 mm. The main advantages of our method are accuracy, high update rate, compact size, real-time measurement and a construction without moving parts. Our technique has a great potential in construction applications, where accurate measurements of a surface shape are needed.

Design of a control system for a mini-automatic transplanting machine of plug seedling

In China, vegetable production system has been dominated by small and medium-sized agricultural facilities over the open-field cultivational practices. Low ceiling height and narrow width are dimensional attributes associated with most of these facilities. Due to these dimensional parametric constraints, the application of available field transplanting machinery in such facilities is a problematic subject which leads the vegetable growers towards manual transplanting. In order to meet the needs of small and medium-sized agricultural facilities for automatic vegetable transplanting, a smaller size wireless remote-controlled automatic transplanting machine was designed, which can transplant seedlings quickly in the greenhouse and by considering the stainability of environment electric power was adopted to drive all the mechanisms. In the process of agricultural production, the control system of agricultural machinery plays an important role in the degree of automation of mechanical equipment. Therefore, this paper focuses on the design of the control system of the newly premeditated automatic transplanting machine. The hardware of the control system is separated into three portions: the sensors for signal acquisition, the programmable controller for signal processing, and the driving elements for specific actions. PLC (Programmable logic controller) is adopted as the central control system of the transplanting machines which controls the automatic movement of seedlings tray carrier, seedlings extraction and feeding, and seedlings transmission to the planting units automatically. In order to control the overall movement of seedling transplanting machine, a microcontroller is adapted to control the hub and steering motor. The key driving elements of the control system are solenoid valves and electric motors which controls the action of pneumatic air cylinders and linear movement of different parts of machine respectively. The overall software design of the control system is accomplished, together with coordinated motion between components, control flow design and control program writing. In order to test the motion coordination of each component and the rationality of the control system of the Mini-Automatic transplanting machine, different planting frequencies were set to record the success rate of seedling collection and transplanting. The results of the trials exhibited that at the planting frequencies of 40, 50 and 60 plants/row/min the overall success rates were noted 98.6%, 97.2% and 96.5% respectively. It shows that the key parts of the transplanting machine are synchronized in motion, accurate in positioning, reasonable in assembling the control system and stable in operation, which meets the requirements of transplanting seedlings in the dry land.

Control of bearingless electric machines dedicated for aviation

Purpose The paper presents the results of work on control systems of bearingless electric motors. Authors proposed the applications of bearingless electric machines for aircraft actuation system. Suggested solution characterizes novel concept of on-board equipment design such as More Electric Aircraft. Magnetic suspension technology allows elimination of friction force and the negative performance features of classic bearing system. However, to achieve all these purposes appropriately, dedicated control system must be also applied. Design/methodology/approach The development of a control system of bearingless electric machine is presented in detail. Mathematical model and construction of induction bearingless motor are widely discussed. Then, proportional–integral-derivative controller algorithm designing for BEM control system was presented using the well pole placement method. Simulation model of BEM control system with use of Matlab-Simulink software was shown. Finally, experimental studies on laboratory stand were introduced. The paper presents design methodology of conventional and advanced control system of bearingless motor. Findings The presented concept of the bearingless electric machines could be applied in the on-board actuation system. During research, full control system of bearingless electric motor was designed and tested. This system consisted of two subsystems. The first responded for rotary speed stabilization and second one was designed for position control of the rotor in the air gap. Practical implications The presented concept of the bearingless electric machines could be applied in the on-board actuation system. During research, full control system of bearingless electric motor was designed and tested. This system consisted of two subsystems. The first responded for rotary speed stabilization and second one was designed for position control of the rotor in the air gap. Originality/value The idea of active magnetic suspension system will be implemented for aviation on technology readiness level V. The paper presents unique laboratory stand with bearingless electric motor and experimental studies. The stable time responses of designed control system were presented and discussed. In addition, preliminary considerations of advanced control system with robust controller were introduced as well.

Интеллектуальное управление технологическими системами в условиях цифрового производства

This paper presents an analysis of the development of adaptive control systems for CNC machines. It is shown that the construction of systems for optimal control of machining processes is based on such approaches as artificial intelligence, genetic algorithms for optimizing processing modes, expert systems for knowledge accumulation, cloud technologies and the development of digital twins of the equipment. An adaptive system of intelligent control of a CNC machine is developed based on training of a neural network model, which can improve the quality of machining parts and reduce the wear of the cutting tool.

Development of an Automatic Water Injection Control System of Peristaltic Transport Machine for Excavated Soil Vertically Transportation

Development of an Automatic Water Injection Control System of Peristaltic Transport Machine for Excavated Soil Vertically Transportation

Computer simulation of kinematics of parallel mechanisms

The paper deals with the kinematic analysis of a planar parallel mechanism. The use of parallel mechanisms makes the tasks of controlling the arms on the basis of these mechanisms difficult, since the solutions of the problems of kinematics and the dynamics of mechanisms are complicated. This leads to more complex control systems for such machines. Therefore, it becomes important to develop appropriate templates for solving certain problems of kinematics and dynamics for certain types of parallel mechanisms. In this paper, a planar parallel mechanism in the form of a tripod with three rotational pairs in each leg is considered.

Operator-based nonlinear fault detection and fault tolerant control for microreactor using one-class SVM

This paper proposes a method of nonlinear fault detection scheme using one-class support vector machine (SVM) and operator-based fault tolerant control system for a microreactor with Peltier device. This method requires only one-shot training data for the normal condition of the plant. The data is used to learn for the SVM, it realises nonlinear fault detection without the known fault condition of the plant. Also, the control system that consists of the nonlinear model of the microreactor system and operator-based controller designed by the model is introduced as the fault tolerant control system using compensation operator to remove the sensor fault. The usefulness of the method is shown by an experiment of the temperature sensor fault case for the temperature control system of the microreactor system.

Operator-based nonlinear fault detection and fault tolerant control for microreactor using one-class SVM

This paper proposes a method of nonlinear fault detection scheme using one-class support vector machine (SVM) and operator-based fault tolerant control system for a microreactor with Peltier device. This method requires only one-shot training data for the normal condition of the plant. The data is used to learn for the SVM, it realises nonlinear fault detection without the known fault condition of the plant. Also, the control system that consists of the nonlinear model of the microreactor system and operator-based controller designed by the model is introduced as the fault tolerant control system using compensation operator to remove the sensor fault. The usefulness of the method is shown by an experiment of the temperature sensor fault case for the temperature control system of the microreactor system.

Machine control systems for leveling areas for road investments

Earthwork is an essential stage in road construction. The proper and efficient performance of earthwork is a necessary condition of a successful execution of a road building project. Earthwork is carried out with suitable machines and implements, which allow mechanisation and acceleration of the task. In order to fully implement these machines, control systems are employed, as these improve the accuracy of the earthwork done, enable machine operators to carry out their work more easily, and support the processing of data. This article describes automated and laser systems used for this purpose. The situation on building sites where such systems are deployed has been analysed. The article contains the results of this analysis.