Development And Design Of Monitoring System Of Electrolyte-plasma Processing Machine

Electrolyte-plasma technology has a number of advantages, such as wide range ofapplications and pollution-free, it also can efficiently reduce the value of the surfaceroughness of metalwork. It is particularly suitable for the fine polishing of themetalwork which is with complex surface shape. Electrolyte and plasma polishingtechnology has a great demand in the market. So, developing a high reliability and goodstability electrolyte and plasma polishing equipment has great social and economicbenefit.Two tasks of this paper, one is developing a control system of the50KW typepolishing equipment according to its function and process requirements. Another isprogramming and forming a dedicated appliction software of the polishing equipmenttrough the configuration design.Firstly, the paper selects the IPC as the core of the control scheme by comparingand analysing the mainstream control systems and considering the actual requirements.The control scheme samples the analog signal such as processing voltage，current andtemperature by the PCI bus analog signal sampling card. It also based on the PCI busdigital IO card to control the relays and capture the digital input signal from theproximity swithes. As to the control mode of the servo motor, the paper achieves thepositioning and jog function by writing to the internal registers of the motor drive andreceived the motor’s running state by reading the registers. All of these are achievedthrough the modbus communication between the IPC and the motor drive by connectingthe serial port of IPC to the driver’s communication port CN3.Secondly, all the type of the electrical components of the monitoring system havebeen selected and the interface circuit between these electrical components has beendesigned in this paper. It also has completed the functional tests of the key componenetsbefore their installation and it comes up a installation type with before and after twomounting plates according to the function and type of the electrical components anddesigns the electrical control cabinet.Finally, the configuration design are finished, including the human-machineinterface configuration, database configuration, modbus and other equipments configuration by using the Forcecontrol6.1configuration software. It also hascompleted the system functionality test, such as positioning and jog function test,analog signal sampling function test, digital input and output function test. Theprocessing temperature’s real time curve and the XY curve of the temperature andcurrent and the LAN web release function of the engineering application has beenachieved.The electrical hardware and appliction software of the50kw type polishingequipment have been varified by the process tests that they can reach the desiredprocess requirements, and they made up the final monitoring system. In the conclusionpart of this paper, some suggestions about the polishing equipment’s improvement areput forward.