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Electrical Drives and Control
Electrical Drives and Control
ASSIGNMENT
Module Code Module Name Course Department
MMD511 Electrical drives and controls M.Sc [Engg] in Machinery design Mechanical & Manufacturing Engineering.
Declaration Sheet Student Name Reg. No Course Batch Module Code Module Title Module Date Module Leader Prabhakar.P BAB0911001 M.Sc [Engg] in Machinery design FT11 MMD511 Electrical drives and controls 11/06/2012 to 07/07/2012 Batch Full-Time 2011.
Extension requests:
Extensions can only be granted by the Head of the Department in consultation with the module leader. Extensions granted by any other person will not be accepted and hence the assignment will incur a penalty. Extensions MUST be requested by using the Extension Request Form, which is available with the ARO. A copy of the extension approval must be attached to the assignment submitted.
All late assignments: must be submitted to Academic Records Office (ARO). It is your responsibility to ensure that the receipt of a late assignment is recorded in the ARO. If an extension was agreed, the authorization should be submitted to ARO during the submission of assignment. To ensure assignment reports are written concisely, the length should be restricted to a limit indicated in the assignment problem statement. Assignment reports greater than this length may incur a penalty of one grade (5 marks). assignment report. Each delegate is required to retain a copy of the
Declaration
The assignment submitted herewith is a result of my own investigations and that I have conformed to the guidelines against plagiarism as laid out in the PEMP Student Handbook. All sections of the text and results, which have been obtained from other sources, are fully referenced. I understand that cheating and plagiarism constitute a breach of University regulations and will be dealt with accordingly.
Date
<Assignment Title>
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Abstract
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In Part-A the debate is on the variable frequency drive and flux vector drive for controlling AC motors is presented by understand the various aspects involved such as
considering accuracy, complexity, response, manufacturability, reliability and cost etc. With proper justification and case study the debate is supported.
In Part-B assignment is based on the video provided by the module leader, were by understanding the cup filling automation processes video and the assignment is presented in which various electrical elements motors, drives, PLCs, mechanisms are implemented with proper justification. This part has four sub parts were first the sequence involved in cup filling processes is explained and by selecting the various elements of the automation machine the possible mathematical equations are derived. The various motors and used in the machine is compared in next part and suggestion for improvement in velocity and torque is explained. In the final part the five requirements of the control system is identified and system description diagram and control block diagrams are generated.
The Part-C is based on the understanding of the Part- B for the same cup filling automation processes the is extended in this part were this part has four sub parts in the first sub part the flow chart is shown with logic after identifying the five control task in the machine. In the next sub part a PLC ladder diagram is generated with proper assumption and is explained. And in the next sub part various modes of controlling the motors used in the automation processes is presented in the last sub part the servo valve and the servo motor is compared and their area of applications were presented.
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Contents
____________________________________________________________________________ Contents Declaration Sheet ......................................................................................................................... ii Abstract ....................................................................................................................................... iii Contents ........................................................................................................................................iv List of Tables ................................................................................................................................vi List of Figures ............................................................................................................................ vii List of Symbols ............................................................................................................................ix Nomenclature ............................................................................................................................ x 1.0 Introduction: ........................................................................................................................ 1 1.1 Stance taken for the debate:................................................................................................. 1 1.2 Variable frequency drive: .................................................................................................... 1 1.3 Flux vector control drives: .................................................................................................. 1 1.4Comparison of flux vector with VFD drives: ....................................................................... 2 1.4.1 Advantages of flex vector over VFD: .............................................................................. 2 1.4.2 Vibration and noise comparison:...................................................................................... 2 1.4.3 Efficiency comparison:..................................................................................................... 3 1.4.4 Efficiency at the full power/torque:.................................................................................. 3 1.5 Case study: .......................................................................................................................... 3 1.5.1 Results after installing flux vector: .................................................................................. 4 1.6 Conclusion:.......................................................................................................................... 4 2.0 Introduction: ........................................................................................................................ 5 2.1 Analyzing the requirement of cup filling automation: ........................................................ 5 2.2 The fundamental mathematical equations for the system: .................................................. 6 2.2.1 Mathematical equation for the conveyor for transferring cups: ....................................... 6 2.2.2 Mathematical equation for the gear box connected to AC motor: ................................... 9 2.2.3 Mathematical equation for the thermal heaters for sealing of cups: .............................. 11
<Assignment Title>
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2.3 Comparison of various motors drives used in automation processes:............................... 12 2.3.1 Velocity profile improvement suggestions: ................................................................... 14 2.4 The various control system used in cup filling automation: ............................................. 16 2.4.1Stepper motor control system: ......................................................................................... 16 2.4.2 Encoder control system: ................................................................................................. 17 2.4.3 Pneumatic solenoid valves control system: .................................................................... 17 2.4.4 Variable frequency drive control system: ...................................................................... 18 2.4.5 Sensor control system:.................................................................................................... 19 2.4 (B) System description diagram: ....................................................................................... 19 3.1 Introduction: ...................................................................................................................... 21 3.2 PLC ladder logic for cup filling automation: .................................................................... 23 3.2.1The assumptions made for cup filling automation: ......................................................... 24 3.2.2 Explanation of PLC circuit:............................................................................................ 25 3.3 Control of motors in the artifact: ....................................................................................... 29 3.3.1 The control system used for stepper motor is: ............................................................... 29 3.3.2Justification for using encoder with stepper motor: ........................................................ 30 3.3.3 The control system used for AC motor is: ..................................................................... 31 3.3.4 Justification for using VFD with AC motor: .................................................................. 32 3.4 Servo valve operated control and servo motor operated control: ...................................... 33 3.4.1 Servo valves: .................................................................................................................. 33 3.4.2 Servo motor: ................................................................................................................... 36 4.0 Learning outcome:............................................................................................................. 38 References ............................................................................................................................... 39
List of Tables
____________________________________________________________________________
Table No.
Pg.No.
Table 1. 1 Showing cost & energy savings ...................................................................................4 Table 2. 1 Various motors used in automation processes ...........................................................12
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List of Figures
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Figure No.
Pg.No
Fig 1. 1 Graph showing comparison of VFD and Flux drives ..................................................... 3 Fig 1. 2 Flux drives installed on motor......................................................................................... 4 Fig 2. 1Production processes flow chart....................................................................................... 5 Fig 2. 2 Conveyor ......................................................................................................................... 7 Fig 2. 3 Angular displacement...................................................................................................... 8 Fig 2. 4 Gear box connected to motor .......................................................................................... 9 Fig 2. 5 Electric band heaters ..................................................................................................... 11 Fig 2. 6 Unipolor drive ............................................................................................................... 13 Fig 2. 7 VFD drive ...................................................................................................................... 13 Fig 2. 8 Velocity profile ............................................................................................................. 14 Fig 2. 9 Velocity profile of the Stepper motor ........................................................................... 15 Fig 2. 10 modified velocity profile by RMS .............................................................................. 15 Fig 2. 11Suggested modified velocity profile of the Stepper motor .......................................... 16 Fig 2. 12 Stepper motor block diagram ...................................................................................... 16 Fig 2. 13 Encoder block diagram ............................................................................................... 17 Fig 2. 14 Pneumatic cylinder control block diagram ................................................................. 18 Fig 2. 15 VFD block diagram ..................................................................................................... 18 Fig 2. 16 Sensor block diagram .................................................................................................. 19 Fig 2. 17 System description block diagram .............................................................................. 20 Fig 3. 1 PLC ladder diagram ...................................................................................................... 23 Fig 3. 2 Assumed grouped operation in processes ..................................................................... 24 Fig 3. 3 Block-1 in PLC Ladder Circuit ..................................................................................... 25 Fig 3. 4 Block- in PLC Ladder Circuit ....................................................................................... 26 Fig 3. 5 Block-3 in PLC Ladder Circuit .................................................................................... 27 Fig 3. 6 Block-4 in PLC Ladder Circuit .................................................................................... 28 Fig 3. 7 Block-5 in PLC Ladder Circuit .................................................................................... 28 Fig 3. 8 Block-6 in PLC Ladder Circuit .................................................................................... 29 Fig 3. 9 Encoder ......................................................................................................................... 30
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Fig 3. 10 Cup unloading conveyor ............................................................................................. 31 Fig 3. 11 Block diagram of VFD ................................................................................................ 31 Fig 3. 12 VFD with AC motor.................................................................................................... 32 Fig 3. 13 Torque Vs Speed curve ............................................................................................... 33 Fig 3. 14 Servo valve .................................................................................................................. 34 Fig 3. 15 Cut section of servo valve ........................................................................................... 35 Fig 3. 16 Servo valve block diagram .......................................................................................... 35 Fig 3. 17 Servo motor ................................................................................................................. 36 Fig 3. 18 Pulse input to servo motor........................................................................................... 37 Fig 3. 19 Block diagram of servo motor..................................................................................... 37
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List of Symbols
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Description
Acceleration due to gravity - 9.81 Angular velocity Angle Force Torque Moment at the Load Moment at the cylinder Bulk modulus Mass Diameter Length Frequency Frictional co efficient
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Nomenclature Acronyms
AC DC VFD PID PLC PMC PWM CSI VSI Alternative current. Direct current. Variable frequency drive. Proportional integral derivative. Programmable logic control. Programmable motion control. Pulse width modulation. Current source inverter. Voltage source inverter.
PART-A CHAPTER 1
1.0 Introduction:
An AC electric motor is electromechanical device which is widely used in various applications to convert electrical energy into mechanical energy. At the initial stages the motors are designed to run at fixed speed and later on the drives are developed to run the motor by frequency of power grid. The drives are used to control the motors during the operation like VFD and flux vector drives etc, in order to effective use of the motor. As the VFD is the earlier invention which is widely used as a drive for AC motor and in this debate it should be analysed that the recent invention of flux vector drive can completely rule out the earlier VFD.
motor to the drive microprocessor. The motor rotor position and speed is monitored through the resolver or digital encoder to determine and control the motor actual speed, torque, and power.
and can also cause stray shaft currents that will still destroy motor bearings. But these problems are eliminated using the flux vector drive.
flow rate could be reduced by 50% (260 GPM) for 23hrs a day and then increased to full speed for the hour needed to complete the backwash cycle. The solution arrived was It was calculated that energy savings could also be realized by reducing the pump speed and eliminating the use of the throttle valve to reduce the flow by the affinity laws of centrifugal pump. To slow down the pumps flux vector drive is installed for both the pumps. After installing the overall energy saving, vibration and noise levels on the two motor and pump applications were notably reduced.
1.6 Conclusion:
From the above case study it can be identified that the level of energy savings by installing the flux vector drives the improvements and the advantages in the flux vector drives which will be eliminating the VFD may not be immediately but in future.
2.0 Introduction:
The Part-B assignment is based on the video provided by the module leader. The video is on the automation of Cup filling operation were the various different operation is performed in the various stages in sequence such as i) Cup loading ii) Cup rinsing iii) Cup filling iv) Al foil placing and cup sealing and v) Unloading of filled and packed cups. In this automation processes various mechanical and electrical drives and control systems are used with the available data in the video and by making the suitable assumption for the unknown data the assignment is to be presented. In general the production process flow is shown in Fig2.1 the cup filling automation processes comes under the special purpose machine (SPM) in which the below shown considerations are to be made.
the cycle time for each stage is assumed as 3 second which means for every 3 second the plate with the cup will be moved forward or indexed to one stage. In each stage 6 cups are loaded on the plate with holes fixed on the conveyor were the cups are held by the collet and when a pneumatic cylinder extends a plate from the cylinder extends from the cylinder expands the collet and the collet releases the cup into the holes drilled in the plate. Then the cup rinsing takes place were the cups are exposed to the atmosphere were the cups are allowed to pass through the chain conveyor by plates holding the cups for few stages ideally so as the cups are rinsed or cleaned by air supplied on the cups the conveyor is driven by the stepper motor. After rinsing the cup filling takes place at a time 6 cups loaded in a row is filled and using the capacitance sensor the level of filling is signaled, were the cycle time for the filling operation is assumed as 3 second. After filling Aluminum foil is picked and placed by pneumatic cylinder on all 6 cups. These foils are sealed to the cups by the heaters were a pneumatic cylinder is used to bring the heater in contact with the cups while extending and when the cylinder retracts the cups in the next row gets indexed and will be ready for sealing and the processes continues. In the next stage by using the pneumatic cylinders the cups are lifted by the grip arm of the cylinder when the cylinder extends and by the other horizontal cylinder the cups are placed on the unloading conveyor. The unloading conveyor unloads the filled cup continuously so that the new cups can be loaded on the unloading conveyor which is driven by AC induction motor with VFD. These are the various requirements and the steps involved in the automation of the cup filling processes.
chain and sprocket mechanism driven by the stepper motor is used and the cycle time for the each indexed cycle is assumed as 3 second the mathematical derivation for the conveyor is shown in the Fig 2.2 below.
Fig 2. 2 Conveyor Were, JM = stepper motor used to drive the conveyor. Ffr = Co-efficient of friction. Fp = Push or pull force. Fg = force due to gravity. Jp = Mass moment of inertia of pulley 1, 2 & 3. The circumference of the pulley (CP): The circumference of the pulley is the pulley length around the pulley which can be calculated by: C
:
= x D
Similarly: C C
: :
= x D = x D
: m :
Were, Dp = Pitch diameter of pulley 1, 2 & 3. Angular displacement (M) of the motor shaft can be defined as a point or line has been rotated in a specified sense about its axis. S shown in the Fig 2.3 below the point ti is the initial position when the shaft is rotated at the velocity the angular displacement tf can be expressed as = ti + t were t is the distance traveled.
Fig 2. 3 Angular displacement For the conveyor motor the angular displacement can be expressed as
=
:
Were, XL = distance travelled by the load. CP = Circumference of the motor. Angular velocity of the motor (M) The rate of change of angular displacement of the conveyor pulley is called angular velocity of motor as the motor is keyed to the same shaft of the pulley which can be expressed as linear velocity of load to circumference of pulley.
=
:
Were, VL = Linear velocity of the load. Angular acceleration of the motor (aM) The rate of change of angular velocity of the motor shaft is called angular acceleration of the motor which in the conveyor can be expressed as angular velocity of motor to the time taken. aM
=
Were, t = time Moment of inertia of the load (JL): The moment of inertia is related to the rotation of the motor shaft it is the measure of the motor resistance to any change in its state of rotation. JL = (WL +WB) /g x (DP /2)2 Were, WL = weight of the load. WB = width of the conveyor belt. DP = Pitch diameter of pulley. Therefore the total moment of inertia is
Electrical drives and control
JTotal=JM +JP1 + JP2(DP1 /DP2)2+JP3(DP1 /DP3)2 + JL /e To find the motor power to drive the conveyor: The power (P) is P = T X M Were, T = torque of the motor M = angular velocity of the motor In case of mathematical equation of the conveyor: Total torque = torque in acceleration + torque in running Torque due to Acceleration Ta = JTotal X aM Constant Torque during running TC = X
Fig 2. 4 Gear box connected to motor In the gear box the velocity ratio can be found by N D T = = N D T
N = Input RPM to gear box. N = Output RPM from gear box. D = PCD of driving gear. D = PCD of driven gear. T = Number of teeth in driving gear. T = Number of teeth in driven gear. In this case the velocity ratio (Nr) for the cup unloading gear box can be expressed as N = Input speed Output speed
Angular displacement of the motor (M) input to the gear box: M = Nr X L Were, Nr = velocity ratio of gear box and L = Distance travelled by the output shaft of the gear box. The Angular velocity of the motor (M) can be expressed as: M = Nr X L Were, L = angular velocity of output shaft from the motor. The total moment of inertia of the assembly can be calculated by adding the moment of inertia of motor + moment of inertia of the gearbox + moment of inertia of the load which can be expressed as: J = JM + Jr +
Were, JM = Moment of inertia of motor. Jr = Moment of inertia of the gearbox. JL = Moment of inertia of the load. e = efficiency of the mechanism.
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2.2.3 Mathematical equation for the thermal heaters for sealing of cups:
Fig 2. 5 Electric band heaters In the cup filling automation processes after filling of cups the aluminum foil is placed on the cups and sealing operation is carried out by the thermal heaters. To derive the mathematical equation for this operation considering a thermal heater with the temperature T kept in contact with the cups which has to be sealed which has the temperature TL and if the thermal resistance to heat flow from heater to the cups is R then Therefore net rate of heat flow (q) is: q = TT R The thermal capacitance C of the cups to be sealed can be expressed as: q1 q2 = C
As there are net flow of heat from the heater to the cups q1= q and q2 = 0 and therefore q=C dT dt
Substituting q in net rate of heat flow (q) equation: dT TT = dt R Rearranging the equation: C dT + T = T dt This equation a first order differential equation describes how temperature gradually raises in the RC cups from the heater with the temperature T.
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Step-accurate positioning without No control of position by the external linear encoder (open loop) motor Multiple pole motors are
Speed
The speed is proportional to the available for multiple speeds. It input frequency has two sets of windings one at low speed and one for high speed The high stiffness enables the rotor Low stiff cannot be held in a position requires a break It has no or little starting torque
Holding position
Torque
Acceleration
Moderate acceleration compared to stepper motor VFD and Flux vector drives
Drives
chopper drive
Table 2. 1 Various motors used in automation processes Unipolar drive for stepper motor: A unipolar drive is used in the automation processes for driving the stepper motor, the stepper motor moves one step when the direction of current flow in the field coil changes, reversing the magnetic field of the stator poles. In unipolar two Separate field Coils and are Charge over Switch are used. The unipolar circuit needs only one changeover switch which requires a double bifilar winding. This means that at a specific bulk factor the wire is thinner and the resistance is
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much higher the drive circuit appears to be simpler when implemented with discrete devices.a unipolar drive is shown in Fig 2.6.
Fig 2. 6 Unipolor drive VFD drives for Induction AC motor: The primary functions of a variable frequency AC drive are to convert electrical power to the usable form for controlling speed, torque and direction of rotation of AC motor. The AC electric motor used in a VFD system is usually a three-phase induction motor which has three main subsystems: AC motor, main drive controller assembly, and drive operator interface. Motors that are designed for fixed-speed operation are often used such as in cup filling automation processes. Elevated voltage stresses imposed on induction motors that are supplied by the VFD drive. The VFD drives are shown in the Fig 2.7.
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Fig 2. 8 Velocity profile As in the cup filling automation processes the cycle time is assumed to be 3 seconds as the conveyor is indexed by every 3 seconds. As above the velocity profile has 3 components accelerating velocity, constant velocity and decelerating velocity it is not possible for the stepper motor to take the trapezoidal velocity profile as shown above in Fig2.9. Instead it will take the velocity profile as shown below in Fig 2.10 for the maximum velocity Vmax, were there is no constant velocity only the accelerating and the decelerating velocity will be available as the cycle time is 3 second.
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Fig 2. 9 Velocity profile of the Stepper motor The improvement in the velocity profile can be done by finding the RMS (root mean square) which is calculated instead of normal average of velocity profile as the motor losses are mostly proportional to I2-R losses. The most important conclusion from this formula is the square root of the cycle time. Instead of triangular the profile can be modified as the equaling profile for the triangular profile which is trapezoidal profile which is just above the average line.
Fig 2. 10 modified velocity profile by RMS The most disadvantage of the trapezoidal profile is it will be resulting in the jerk as the velocity changer linearly in the during acceleration and the deceleration to avoid these jerk the trapezoidal profile can be modified into S- curve moves as shown in the Fig 2.11.
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In this the input command to the HMI is given through the HMI (Human/Machine interface). From HMI the command goes to the controller, were the controller is the combination of PLC, indexer and pulse generator which generates the signals as per the input command to the driver and the driver drives the Stepper motor.
Fig 2. 13 Encoder block diagram The control block diagram of encoder shows from the user interface the input command goes to PMC (Programmable motion controller) from there it goes to interface hardware then to motor controller/ amplifier to motor based on the motor position the encoder gives the position feedback to interface hardware which in turn generate pulse and send to motor controller and the motor controller corrects the position of the motor.
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Fig 2. 14 Pneumatic cylinder control block diagram In the solenoid control system the input is transferred from user interface to gripper script unit and goes to micro controller generate the electrical pulse and sends to the transistors from the transistors the required voltage is sent to the solenoid valves the operates the cylinder (gripper arm) the cylinder extends and when the operation is carried the cylinder gets contact with limit switches sends signals to the microcontroller and from there to transistors and transistor operate the solenoid and retract the cylinder.
Fig 2. 15 VFD block diagram The 3phase AC current is supplied to diode bridge rectifier were it is converted in to DC from there goes to DC filter and the inverter converts back to AC current and based on the speed reference by the user voltage and frequency control sends signal to the inverter and the inverter supplies AC current to the motor.
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Fig 2. 16 Sensor block diagram The sensor senses the source and sends the analog signals to the comparator unit the comparator unit does the logic and sends the binary data to microcontroller and the microcontroller signals the motor driver and driver drives the motor.
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3.1 Introduction:
In the cup filling automation PLC has to perform the following tasks as shown in the flow chart below in the Fig 3.1 were it has to control the automation by starting and stopping the operation in a proper sequence and has to allow the timings for the completion of the operations and has to take the logical decision which can also be called as artificial intelligence were the required actions to be carried if there is error in the process.
Note: in this cup filling automation processes cup rinsing takes place were the cups are loaded in the conveyor and filling doesnt takes place immediately after cup loading but it is allowed to pass through the air blower were the cups are cleaned and dried during which the cups are allowed to travel ideally many stages then the cups are filled and the further processes are carried out.
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Fig 3. 2 Assumed grouped operation in processes In the above shown figure the number indicated with 1 are grouped together and the number indicated with 2 are grouped together which means at the same cycle time the grouped operations are carried out at various stations simultaneously. The operations grouped at 1 are: i) Cup loading ii) Cup filling iii) Placing of AL foil. iv) Sealing v) Lifting of cups These operations are assumed to be carried out simultaneously but at different stages in the cup filling automation machine.
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i) Indexing ii) Picking of top cover iii) Placing of finished cups on unloading conveyor. These operations are assumed to be carried out simultaneously but at different stages in the cup filling automation machine. When the light Y0 glows it is assumed that cup loading process is carried out. When the light Y1 glows it is assumed that the nozzle opens and cup filling process is carried out. When the light Y2 glows it is assumed that indexing of cups by the conveyor is taking place. When the light Y3 glows it is assumed that the AL foil is picked by the pneumatic cylinders. When the light Y4 glows it is assumed that the AL foil is placed on the filled cups by pneumatic cylinders. When the light Y6 glows it is assumed that Al foils are sealed with the cups using thermal heaters. When the light Y7 glows it is assumed that sealed cups are lifted by the pneumatic cylinders. When the light Y8 glows it is assumed that the sealed cups are placed on the unloading conveyor. The process is assumed to be continues cycle and to stop the machine a push button X2 is pressed.
Fig 3. 3 Block-1 in PLC Ladder Circuit The push button X0 is pressed to start the internal relay M0 as push button is used the M0 is latched as shown above in circuit. Were the logic for the block is shown below:
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X0 0 1
M0 0 1
Were 0 indicates OFF and 1 indicates ON as X0 is push button until the X0 is pressed the internal relay M0 is on and when X0 is released M0 will be off, even after releasing of X0 to keep M0 in on condition the M0 is latched.
Fig 3. 4 Block- in PLC Ladder Circuit When the internal relay M0 is on and as well as the another internal relay M1 is on the assumed various grouped processes are performed at various station of the machine as the bulbs Y0,Y1,Y4,Y8&Y6 glows at this time for 3 seconds which indicates in the same 3 seconds of the cycle time the various operations like Cup loading, Cup filling, Placing of AL foil, Sealing, & Lifting of cups are carried out at the different stations of the machine the logic for the block shown above is: M0 0 0 1 1 M1 0 1 0 1 Y0 0 0 0 1 Y1 0 0 0 1 Y4 0 0 0 1 Y8 0 0 0 1 Y6 0 0 0 1
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Were 0 indicates OFF and 1 indicates ON from the table it can be noticed that when both the internal relayM0 & M1 is ON the all the operations will be carried out and if any one of the internal relay is in OFF condition all the operations will be stopped from this it can be noticed that since all the bulbs are branched if operation takes place all 5 process will be carried out and if not all 5 process will be stopped there is no possibilities of starting any 2 or 3 processes or stopping 2 or 3 process in this circuit.
Fig 3. 5 Block-3 in PLC Ladder Circuit When the internal relay M0 is ON and the various grouped processes are performed at various station of the machine as the bulbs Y2, Y3 &Y7 glows at this time for 3 seconds which indicates in the same 3 seconds of the cycle time the various operations like Indexing, Picking of top cover and Placing of finished cups on unloading conveyor are carried out at the different stations of the machine the logic for the block is shown above: M0 0 1 1 Y0 0 0 1 Y1 0 0 1 Y4 0 0 1 Y8 0 0 1 Y6 0 0 1 Y2 0 1 0 Y3 0 1 0 Y7 0 1 0
In the table 0 indicates OFF and 1 indicates ON from the table it can be noticed that the internal relay M0 is OFF and also the grouped operations Y0,Y1,Y4,Y8&Y6 is also OFF in this condition all the grouped operations of Y2, Y3 &Y7 will be also OFF and when the internal relay M0 is ON and the grouped operations Y0,Y1,Y4,Y8&Y6 is OFF in this condition the bulb Y2, Y3 &Y7 will glow which indicates the various operations like Indexing, Picking of top cover and Placing of finished cups on unloading conveyor are carried out at the different stations.
Electrical drives and control
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The other condition is the internal relay M0 is ON and Y0, Y1, Y4, Y8 &Y6 is also ON in this condition Y2, Y3 &Y7 bulbs will not glow which indicates these operations are not performed.
Fig 3. 6 Block-4 in PLC Ladder Circuit In the block the condition is the internal relay M0 is used to trigger the timer T1 in which the timer is set to 3 seconds (0.01s X 300). In which after 3 seconds the other internal relay M1 will be ON this internal relay M1 is used to control the other block shown below in the Fig() the logic for this block is: M0 0 1 (3 seconds) M1 0 1
When the internal relay M0 is OFF the internal relay M1 is also OFF and when the internal relay M0 is ON for 3 second the internal relay M1 will be ON.
Fig 3. 7 Block-5 in PLC Ladder Circuit In the next block the condition is the internal relay M1 is used to trigger the timer T2 in which the timer is set to 3 seconds (0.01s X 300). In which after 3 seconds the other internal relay M2 will be ON this internal relay M2 is used to control the other block shown in the Fig 3.4 the logic for this block is: M1 0 1 (3 seconds) M2 0 1
When the internal relay M1 is OFF the internal relay M2 is also OFF and when the internal relay M1 is ON for 3 second the internal relay M2 will be ON.
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Fig 3. 8 Block-6 in PLC Ladder Circuit In the next block of the ladder diagram the condition is the internal relay M2 is used to reset the timer T1 and also used to latch the circuit shown in the Fig 3.6 which in turn makes the process to be carried out continuously. The logic for this block is shown below: M2 0 1 T1 (Timer reset) 0 1
When the internal relay M2 is OFF the timer T1 will not reset and when the internal relay M2 is ON the timer T1 will get reset.
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Fig 3. 9 Encoder
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Fig 3. 10 Cup unloading conveyor The Ac motor is used for the conveyor which is used to unload the cups as shown in the Fig(). After A all the processes is been completed. To control this AC motor a Variable frequency drive is used the primary t functions of a variable speed AC drive, is to convert electrical power to the usable form for controlling speed, torque and direction of rotation of AC motor The purpose of VFD to control AC motor is: i. Energy savings- as the motor has to ramp up and ramp down continuously for unloading of cups cups. ii. Better process control and regulation helps in maintaining the cycle time in the processes. ss iii. Speeding up or slowing down a machine. machine iv. Inherent power-factor correction. factor correction v. Emergency bypass capability capability. vi. Protection from overload currents. currents vii. Safe Acceleration.
In VFD the following conversion takes place when the 3 phase power is supplied to the motor through the VFD. In the first converter stage the supplied power is converted to a higher adjustable DC voltage. In the inverter stage, the power transistors in the rectified DC are switched off and on. This produces a voltage waveform at the frequency which the motor requires. In the control system, the voltage waveform receives information from the motor-driven system and will adjust the output voltage to the selected value. The Fig 3.12. Shows the VFD connected to AC electric motor.
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direction. The Fig 3.13 shows the function of AC motor in various stages during unloading of cups stages in the automation processes.
Fig 3. 13 Torque Vs Speed curve Which in turn driving a load and a again taking power. In second quadrants and fourth quadrant the speed and torque are in mutually opposed directions that are the torque of the motor is opposing its rotation, giving a braking effect. As per the conservation of the energy mechanical and kinetic g energy of the load is being converted into electrical energy. The motor is behaving as a generator and the system as a whole is delivering power Thus a VFD is required to control the AC motor in power. order to better processes control and regulation of the cycle time.
3.4 Servo valve operated control and servo motor operated control: 3.4.1 Servo valves:
Servo valves are electro hydraulic valves or EHSV (Electro hydraulic servo valves) which can o transform analog or digital signal into a step less hydraulic output. Servo valves provide the accurate control of position, velocity, pressure and force in the hydraulic system. The term servo lic valve includes valve design with brushing spool assembly the movement of the spool in the valve is controlled by the servo which is attached to the valve and based on the movement of the spool the valve controls the direction of fluid flow to the cylinder. The servo valves have coils when the electric pulses are sent to the coils by the servo the valve changes its position so that the cylinder will be actuated.
The components of the servo valves are: Torque motor Two stages of hydraulic regulation.
were, the torque motor consist of coils, upper and lower pieces, armature and two magnets. The torque motor converts input signal from a valve driver or valve controller into a physical movement for the armature which inturn moves the spool.
Fig 3. 14 Servo valve Principle of operation of servo valve: The electromagnetic first stage produces a torque which may be assumed proportional to current and the flapper generates pressure that are applied to each end of the spool. The feedback wire which is coupled to the spool and the flapper creates the feedback. With a current applied the flapper rapidly returns to its central position within the spool displaced such that the wire feedback torque balances the electromagnetic torque as shown in the Fig 3.15. As the flapper in the valve tilts to an angle due the supply of current in the armature the spool displaces in the valve and allows the fluid to flow through the valve and when by the supply of current makes the armature to be vertical without any tilt of angle the flapper becomes vertical and does not allow the fluid to flow.
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Fig 3. 15 Cut section of servo valve The block diagram of the servo valve control system shown in the Fig 3.16.
When the current is supplied to the torque motor it sends to the torque summation unit which tilts the armature or flapper to the angle as per the supplied voltage of current which inturn moves the spool. From the spool the feedback wire is connected to the to the torque summation unit which in turn as per the flow requirement increases or decreases the angle of tilt of the flopper so as the spool will be displaced for the required flow. This is the closed loop system as it functions based on the feedback.
Fig 3. 17 Servo motor Working principle of servo motor: Servo motors are controlled by sending them a pulse of variable width. The control wire is used to send this pulse the various types of pulse send to the motor is minimum pulse, a maximum pulse, and a repetition rate. Given the rotation constraints of the servo, neutral is defined to be the position where the servo has exactly the same amount of potential rotation in the clockwise direction as it
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does in the counter clockwise direction. The pulse supplied to the servo motor is shown in the Fig3.18.
Fig 3. 18 Pulse input to servo motor The rotation of the motor shaft is determined by the duration of the pulse supplied to the motor. Three basic types of servo motors are used in modern servo systems: ac servo motors, based on induction motor designs; dc servo motors, based on dc motor designs; and ac brushless servo motors, based on synchronous motor designs. The block diagram of servo motor is shown in Fig3.19.
Fig 3. 19 Block diagram of servo motor In servo motor from digital controller the input goes to the amplifier which generate the pulses and run the servo motor the encoder or resolver connected to the motor gives back the feedback of the position to the digital controller and velocity feedback to servo amplifier based on the feedback the amplifier generates the pulses and runs the motor to correct the error.
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Whether assignment was able to assess module learning outcomes or not? Yes, the assignment was able to asses the module outcome which has covered all the topics covered in the module.
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References
________________________________________________________________________________ [1] Carrier Corporation Syracuse, New York variable frequency drive http://www.docs.hvacpartners.com/groups/public/documents/marketing/wp_varfreqdrive.pdf Retrieved on 16/03/2012. [2] Flux Drive Inc. Mel Korum Family YMCA CASE STUDY http://www.fluxdrive.com/docs/flux_drive_ymca_case_study.pdf Retrieved on 13/07/2012. [3] Ramin Monajemy, Control Strategies and Parameter Compensation for Permanent Magnet Synchronous Motor Drives http://vtechworks.lib.vt.edu/bitstream/handle/10919/11247/MASTER.pdf?sequence=1 Retrieved on 17/03 /2012. [4] Bobby Martinez, P.E, All Electric Motor Drives for LNG Plants http://lnglicensing.conocophillips.com/EN /documents/GastechElectricMotorPaper.pdf Retrieved on 19/03/2012. [5] Rockwell automation, Technical Application Notes http://http://www.rockwellautomation.com/solutions/get/RA-AP012A-EN-P_CLX.pdf Retrieved on 06/07/2012. [6] Moog servo valve, Moog servo valve repair and service http://www.blow-moulding-controls.com/_valverepairservicing.html Retrieved on 20/07/2012. [6] G. W. Younkin, (2007) Industrial Servo Control Systems - Fundamentals and Applications 2nd edition, Taylor and Francis, [7] W.Bolton, (2002) mechatronics 2nd edition pearson education publishing.
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