PROGETTO del CONTROLLO di MACCHINE AUTOMATICHE per lIMPACCHETTAMENTO MOTION CONTROL for PACKAGING MA

1
PROGETTO del CONTROLLO di MACCHINE AUTOMATICHE
per lIMPACCHETTAMENTO(MOTION CONTROL for
PACKAGING MACHINES)
MECHATRONICS
Davide Borghi
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The Course

• Course characteristics multi-discipline contents
• Course Goal speak the same language and be
  able to design the machine as a whole (not
  mechanics and motors separately).
• Course Limitations no time to go deeply in each
  subject, so I will try to give you the tools and
  hints to investigate further not everybody is
  interested to deepen every subject, so dont
  worry if sometimes you miss some parts

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Index
(1/2)

• Mechatronics in the
• Packaging World
• Mechatronics on packaging machines
• bits of history
• Where is the Performance Limit? (motor gt
  electronics gt mechanics)
• Multiaxes systems (e.g. A3-Flex, DIMC, PT)
• Programming Interface RS-Logix5000
• IEC1131-3 Application Program Example
•  
• Brushless Motors
• Electric Motors Choice (kinematic chain, torque
  characteristics, field weakening - deflussaggio)
• Stator Re-Winding (riavvolgim. motore)
• Brushless motors technology
• Resolvers and Encoders
• Linear Motors
• Torque Motors

PID Control PID Theory Serial (Rockwell
Kinetix) and Parallel (Danaher SAM) PID Digital
PID Feed Forward Vibrations Analysis
Control-Motor-Load relationships Bandwidth PID
bandwidth relationships Vibration
measurements Sizing Planetary gearboxes versus
direct-drive Servo-System Design EMC
hints Trouble Shooting of a rig solution (in fase
di prima verifica) Packaging Machines Motion
Architecture
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Index
(2/2)

• Drives
• AC brushless drive
• DC brushless drive
• Resolver to Digital Converter
• Regenerative breaking (Recupero in rete)
• Control Strategies
• ClarkPark Transforms
• IPxx Protection
• Servo System TroubleShooting on the field
•  
•  

THE END
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Bibliography

• 1.     Luciano Bonometti Convertitori di
  Potenza e Servomotori Brushless,
• Editoriale Delfino, Milano, 1996
• 2.     Hughes "Electric Motors and Drives",
  1993, Heinemann, 348pp., codice RS 912076
• 3.   CYMEX Cyber Motion Explorer, CD-ROM, Alpha
  getriebebau GmbH info_at_alphagetriebe.de
• 4.     THE MOTION BOOK version 4.0, Rockwell
  Automation/Allen-Bradley 2004
  www.ab.com/motion
• 5.     DSP Solution for Permanent Magnet
  Synchronous Motor, Texas Instruments
• 6.     Ashish Tewari, Modern Control Design
  With MATLAB and SIMULINK
• 7.     Dean C. Karnopp, Donald L. Margolis,
  Ronald C. Rosenberg
• System Dynamics Modeling and Simulation of
  Mechatronic Systems
• 8.     D.M. Auslander, J.R. Ridgely, J.D.
  Ringgenberg, David M. Auslander
• Control Software for Mechanical Systems Object
  Oreiented Design in a Real Time World

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Bibliography internet links

• Bosch internet site http//app10.bosch.de//en/def
  ault.htm
• Danaher Motion internet site http//www.danaher.c
  om/
• Elau internet site http//www.elau.de/english/fra
  mesets/frhomenic.htm
• HDD internet site http//www.hdd.se/
• Kollmorgen internet site http//www.kollmorgen.de
  /, http//www.kollmorgen.com/
• Mektron Pacific Scientific internet site
  http//www.mektroninc.com/pacsci.html
• Pacific Scientific internet site
  http//www.industry.net/c/mn/017k3
• Parker internet site http//www.parker-emd.com/uk
  /
• Rexroth Indramat internet site
  http//www.indramat.com/
• Texas Instruments internet sites
  http//www.ti.com/, http//www.ti.com/sc/momentum/
  dm2sa2x6t4,
• BR internet site http//www.br-automation.com/we
  lcome.htm
• Baldor internet site http//www.baldor.com/
• Festo internet sites http//www.festo.com/,
  http//www.festo.com/food/eng/index.htm
• GE-Fanuc internet site http//www.gefanuc.com/ind
  ex.asp
• HydraForce Hydraulic Cartridge Valves internet
  site http//www.hydraforce.com/
• Rockwell Automation internet site
  http//www.automation.rockwell.com/
• SERCOS related links http//www.sercos.com/links.
  htm
• Siemens Machine Control Systems Packaging
  internet site http//www.aut.sea.siemens.com/mach
  ine/systems/packaging.html
• Stegmann encoders http//www.stegmann.de/english/
  html/produkte/index.html

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Why Automation?

• The machine makes FAULTS that can be
• Detected
• Measured
• Corrected
• Predicted
• Man makes ERRORS that, not always, can be
• Detected
• Measured
• Corrected
• Predicted

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Mechatronics whats in a name

• Mechanical system control is undergoing a
  revolution in which the primary determinant is
  becoming the control software. This is enabled by
  developments in electronics and computer
  technology.
• Mechatronics (Yaskawa Electric, 1970) new kind
  of mechanical system where the electronics take
  the decision-making function formerly performed
  by mechanical components
• Mechatronics (now, 2004) there has been a shift
  from electronics to software as primary
  decision-making software, the definition thus
  becoming
• The application of complex automatic
  decision-making to the operation of physical
  systems.
• Real time software differs from conventional
  software in that its results must not only be
  numerically and logically correct they must also
  be delivered at the correct time it must embody
  the concept of duration.

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Parts of a mechatronic system
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General Control System
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Analog Controller
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Digital Controller
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ANALOG vs. DIGITAL Controllers

• ANALOG
• Huge bandwidth (no sampling)
• Resolution
• Easy design
• Time-dep. Performances
• Temperature drift
• HW design no easy change
• Trimmers

DIGITAL Diagnostics Programmable (SW) Not
depending on environment (temp., pressure,
humidity, ) Deterministic behaviour Advanced
Algorithms Memory HMI Quantization (discr.
represent.) Truncation (16x1632bit) Limit
Cycles Register Overflow Sampling Rate
Pros
Cons
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Examples of Advanced Algorithms that can be
implemented on Digital Controllers

• Kalman Filters (optimal observer)
• LQR Linear Quadratic Regulator (optimal
  controller)
• Adaptive Control
• Possibility to handle non-linear systems
• Fuzzy Logics
• Neural Networks
• DNA Computing
• Time Sharing Multitasking
• FFT Fast Fourier Transform (time gt frequency)
• Debugging Functions
• HMI Human Machine Interface
• Data Logging
• Data Communications (Field Bus)
• Sensorless Algorithms

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Il Mondo del Packaging
Solid Food
others
Semi-Solid Food
Toys
Pastorized Liquid Food
Cigarettes
Tissues
Aseptic Liquid Food
Personal Care
Beve- rages
Chocolate
Beauty Care

• Pharmaceutical

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Raw Material Supply
(e.g. trees)
The Packaging Material
(e.g. carton layers)
Converting
T h e P a c k a g e
Card Board Packing
Fill
Cap
Palletize
Label
Food Treatment
(e.g. UHT, Past.)
The Product
Food Supply
(e.g. cows)
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Openings
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Filling Machine
animation
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Filling Machine (contd)
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Packaging Line
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Esempio di Packaging Line
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...at the customer site
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Distribution Equipment
Macchine automatiche situate dopo la macchina
riempitrice (filling machine)

• Accumulators
• Cap Applicators
• Card-Board Packers
• Film Wrappers
• Handle Applicators
• Straw Applicators
• etc..

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Mechatronics on Packaging Machines
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Packaging Line Monitoring System
modem
Automatic data logging Data transfer -
modem/diskette Data analysis - off line software
An excellent tool to analyse and improve
performance quality
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3 Generations of Motion Control

• I Generation
• Fully ANALOG
• II Generation
• ANALOG and DIGITAL
• III Generation
• Fully DIGITAL and INTEGRATED with STANDARD
  IEC1131-3 programming languages

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Bits of history
The TypewriterServo Packaging Machines
Electronics Typewriter

• Mechanical

• Electromechanical

• Electric

• Electronic

• Word Processor

• PC with impact Printer

• PC with laser printer

• PC with ink jet printer

• Email

chronology
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Where is the performance limit?

• First the limit was in the Motor due to the
  backlash in the key slot and/or other backlashes
  or static/starting friction (that is the same
  thing since with applied current theres no
  motion).
• Then the limit became the Electronics
• due to the low band-width.
• Now the limit is the system Resonance Frequency
  due to elasticity and inertias.
• 1) limit the gains (bw G/J)
• 2) Notch or Low Pass Filter
• 3) high stiffness (direct drive solution)
• In 2) and 3) I can have high gains high
  resolution sincos encoder (0.01 or
  1nm accuracy)

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Multiaxes Systems
Industry-wide Interface
Industry Guideline Compliant Machine Interface
Sensor Network
Machine Controller
Motion Network
OEM Core Competency
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Modular Software Software modeling
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Modular Software Software modeling (contd)
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Multiaxes Systems (contd)
animazione

• Packaging Machine 3-50 axes toward 100 axes
  machines on the long run (Human Body 150 axes,
  i.e. 300 muscles with 2 muscles to give one
  complete degree of freedom)
• Each motor has a
• winding (power) cable
• feedback cable (encoder or resolver)
• PTC temperature sensor wirings and, if present,
  brake wirings
• Each power cable is attached to a drive (one
  drive generally drives one motor).

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Multiaxes Systems (contd)

• The ideal partition line has to be found
• for having the field bus
• band-width as low as possible.
• Solution close every loop in the drive or
  integrate the electronics in the motor (but I
  would have the DC bus running through the whole
  machine for having breaking/acceleration actions
  balanced among all axes, as a mechanical shaft
  would do).

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Programming Interface
With a field bus, the axis becomes only an object
of the bus I can connect the PC to any bus
point for monitoring/accessing any bus device
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HW Architecture example 1
4ms coarse update rate (7 axes)
125ms pos. loop
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HW Architecture example 2
4ms coarse update
125ms pos. loop
ControlLogix
MPL Motors
Devicenet
Axis Board(s)
Ethernet
L63 CPU
I/Os
Kinetix 6000
RS Logix 5000
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SW IEC1131-3 General Approach

• LADDER for process logics with boolean and
  continuous environment
• SFC when pending from motion commands to be
  terminated
• ST when heavy bunch of code need to be written in
  a linear form
• FBD for continuous algorithms such as design PID

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Motion Application Flow Chart
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Motion Application Flow ChartDETAILED
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Motion Application UML (high-level)
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SFC Application Main(example 1)
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A3-Flex Rockwell SW Architecture (example 1)
Periodic Task Very high priority
Periodic or Cont. Task Low priority
Periodic Task High priority
ST
ST
ST
Error Handler
PLC Logics
Motion Control
ST
SFC
Error Detection
SFC Main
SFC resets
SFC
SFC
Error Manager
Home Search., ON-OFF servos, run-stop prod.,
mainten.-service routines
JSRs
ST
SFC
Single Instructions
Group of move.s
Ladder
Single Instructions
SFC
Single move.s
ST
Single Instructions
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Flat Implementation example 2
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Structured Text Code Sample
ST (not IEC1131-3) Language
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IEC1131-3 Code Sample
video
IEC1131-3 Languages ST, SFC, Ladder, FBD
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• The approach has been