Development Of Control System For EMU Braking Wheels Automatic Assembly Line

With the rapid development of EMU in China, the wheels of the EMU have been introduced to manufacture in China. However, due to the short developing time and the limitation of the special characteristics, there has no yet a suitable automatic equipment for the assembly between the wheels and the braking discs, and it stills to be accomplished by manual work.This project comes from the demand of the enterprise, aiming to solve the low efficiency, high labor intensity and other problems in the manual assembly of wheels and braking discs presently, based on the assembly technology requirements and assembly process, then design a assembly production line of wheels and braking discs that satisfies the production demand and has high degree of automation. It can realize a series of automatic process including feeding, assembly and unloading material. In this paper, the control system of the automatic assembly line is mainly developed and the following work is carried out:Firstly, the topic has analysed the function realization scheme combined with the mechanism design, then devided the assembly line to several units and designed the specific process and completed the timing planning of every unit. By taking them into consideration, the topic determined the distributed control system that the configuration software i FIX works as the master PC, the programmer controller(PLC) works as the core controller to realize the control of servo unit, manipulator and other actuators.Secondly, the hardware system of the control system has been designed accordind to the overall scheme, including the design and selection of the hardware structure, the PLC system, servo system, sensor system and the communication design between the equipments. At last completed the design and drawing of the control system electrical schematic.Thirdly, the software of the control system has been accommplished based on the hardware structure, including the design of the PLC ladder diagram, the phase detection and the automatic program of KUKA manipulator, etc. Through the upper configuration software iFIX, the signal interaction between PLCs and equipments have been realized and the human machine interface has been developed to realize the monitor, control and management of the whole system.Finally, completed the installation and wires connection of the electrical control cabinet and the on-site equipments. In order to test the reliablity and stability, the topic has carried out repeated debugging, and analyzed, optimized, improved the control system to solve the appearing problems. The operation results show that this automatic assembly line is stable and reliable to accomplish the task, the expected design target is achieved and has high use value.