Design And Realization Of The Control System For The High Speed Terminal Insertion Machine

Teriminal insertion machine is the one widely used in connector production, lifting speed of insertion machine can do the effect of raise efficiency and cost down. Every connector company cost energy to lift the machine's speed. Fortunately I join in the high speed insertion machine team as an electrical control system design and realization.The project's aim is to develop a standard high speed terminal insertion machine, its speed requirement is 800 RPM. The main cam and two screw balls are transferred by three servo motors. They are named main axis,slave1 and slave2. when the machine is running , the main cam finish terminal feeder,terminal cut and terminal insertion ; slave1 and slave2 feed housing alternately .The paper has a design and realization of the control system for the high speed terminal insertion machine, the major job is as below:1.At first the paper has a research on the insertion machine and its common control method, especially on high speed counter interrupt control system in detail including its hardware system,software system and parameter setting in PLC and servo driver. Then it gives a detailed analysis on the wasting time using the high speed counter interrupt control method, and draw a conclusion that cannot realize 800 RPM using the common control method.2. The paper has a control proposal design as requirement , identify the controller including HMI, I/O module and ACOPOS motor. It also has a feasibility evaluation on the system and motion control, so draw a conclusion the system can realize insertion machine 800RPM.3. The paper has a control program design based on software platform Automation Studio. Because B&R PCC uses time-sharing multi-task operation system, control program uses modularization concept, and it makes different program to realize different function, also it makes different cycle time according to the importance. And it also has an electric cam design and high speed insertion machine cam follow configuration,program architecture,program logistic analysis and touch screen interface design. Finally I realize the control of high speed insertion machine and attend the design requirement using ANSI C program.4. High speed insertion machine control need a better control requirement to the servo motor, so I also have a research on the servo control system, and give a analysis on the position loop,speed loop and current loop. Performance requirements of the servo-control system in the high speed insertion machine mainly include the accuracy of the steady state, stability and swiftness of the dynamic response, and robustness to the varying parameters and uncertain disturbance. High performance can be achieved through the selection of actuators, sensors, and control strategies. The study and application of advanced control strategies is very important to the improvement of the performance of systems. In this paper, I analyze the PID control. The performance of the control strategies is studied through simulation, which provides a guide line for the practical applications. Furthermore, this paper also explores the application of the intelligent control theory to the servo system. A fuzzy PID controller is designed for the position control. Simulation results show that advanced control theory can improve the steady state accuracy and the dynamic performance of the system.