Thit k, ch to h thng gim st, o lng v iu khin cho my CNC qun dy trn c s vi iu khin cng ngh PSoC design

and manufacture supervision, measure and control system for CNC coil winding machine based on PSoC technology. ThS.V Xun Hng B mn Trang b in - in t, H GTVT Tm tt: Bi bo trnh by kt qu nghin cu thit k, ch to h thng st o lng v iu khin cho my CNC qun dy trn c s chip cng ngh PSoC. Bi bo gm cc ni dung chnh sau: tng quan v my CNC qun dy, thit k PSoC Card, cch kt ni iu khin bin tn v servo motor, v thit k giao din gim st, o lng v iu khin trn my tnh cho my CNC qun dy. Summary: This article presents the results of research, design and manufacture of supervision, measure and control system for CNC coil winding machine based on PSoC technology. This paper contains following main contents: overview about CNC coil winding machine, designing PSoC card, wiring diagram to control inverter and servo driver, and designing supervisory, measure and control interface for CNC coil winding machine. I. Ti sao phi nghin cu thit k, ch to h thng iu khin cho my CNC qun dy?

Hin nay my CNC qun dy c s dng nhiu trong cc nh my sn xut nh: Cng ty Cp in Trn ph, C in H ni, Cng ty Que hn Vit c, Nh my Ch to bin th ABB Vit nam .v.v. , gp phn nng cao nng sut lao ng, cht lng, tin cy v gim gi thnh ca sn phm. Cng vi s pht trin mnh m ca t nc, nhu cu s dng my CNC qun dy s tip tc tng trong nhiu nm ti. Cc my CNC qun dy u phi nhp ngoi vi gi thnh cao v trong cc nh my k trn cn nhiu my qun dy c ang c nhu cu ci tin, chuyn i thnh my CNC qun dy t ng. Thm vo , trong nc hon ton c th sn xut c phn c kh ca my CNC qun dy ny. Vit nam cha c c s no sn xut my CNC qun dy, mt s cng ty, vin nghin cu cng ang tin hnh nghin cu ch to my CNC nhng ch yu l my phay, my bo, my khoan cn my CNC qun dy c dng trong cc nh my ch to cp in, cp thng tin, nh my ch to dy qun my bin p, dy qun my in gn nh cha c nghin cu. Do vy vic nghin cu, thit k, ch to h thng iu khin cho my CNC qun dy s dng cng ngh tin tin, hin i nh h iu khin vect thng minh v Chip cng ngh PSoC, l hng i ng n y trin vng, c tnh thi s v ngha thc tin cao. Nhm ci to my qun dy c, nng cao chnh xc, tit kim nng lng, gim gi thnh cho my CNC qun dy, thay th cho thit b nhp ngoi gp phn vo tit kim ngoi t v tn dng tim nng tr tu ca t nc. y cng chnh l mc tiu ca ti nghin cu khoa hc v cng ngh cp B m s B2007-04-30 do chng ti thc hin. Trong bi bo ny chng ti s gii thiu kt qu nghin cu thit k, ch to Card gim st, o lng v iu khin trn c s chip cng ngh PSoC; y l mt phn quan trng trong h thng iu khin ni chung v h thng iu khin my CNC qun dy ni ring. II. Tng quan v my CNC qun dy

My CNC qun dy c nhiu chng loi khc nhau, nu phn loi theo theo chc nng qun dy ta c cc loi in hnh sau: My qun dy cp in, my qun dy hn (Nh dy truyn qun dy hn H8A-VD, W49-VD, Nh my Que hn Vit c), my qun dy my in quay, my qun dy my bin p.

Hnh1: My CNC qun dy my in [3]

Hnh 2: My CNC qun dy AM3175 [3]

Cu to my CNC qun dy: Mt my CNC qun dy c th chia lm cc phn chnh sau: Phn c kh, phn iu khin, ng c in v h thng cm bin sensor. + Phn c kh gm c cc c cu chnh: C cu nh dy, c cu qun dy, c cu ri dy.v.v. + ng c in: C ng c nh dy, ng c qun dy, v ng c ri dy. Xu th hin nay v trong tng lai l s dng ng c khng ng b ba pha rto lng sc v ng c ny c hiu sut cao, chc chn v lm vic tin cy. + H thng cm bin: Thng c cc loi cm bin sau: Encoder (o gc quay, tc quay), cm bin sc cng; cm bin cm bin quang, cm bin v tr bn tri, bn phi ca c cu ri dy.v.v. + Phn iu khin gm c: B bin tn iu khin cho ng c nh dy, qun dy v h iu khin v servo ri dy; h thng iu khin trung tm: Gm c PLC hoc Card vi iu khin c ci t chng trnh iu khin v giao din gim st, o lng trn my tnh hoc mn hnh hin th. H thng ny c chc nng t thng s, o lng v gim st qu trnh hot ng ca my CNC qun dy. Phi hp iu khin cc c cu trong my CNC qun dy v la chn phng php iu khin: qun dy u, p, khng b t th ta phi phi hp vic iu khin tc ng c servo ri dy vi ng c qun dy, v ng c nh dy vi ng c qun dy. Nu ng c qun dy qun vi tc nhanh th ng c servo cng phi ri dy nhanh, vic ri dy ny din ra lin tc trong mt vng qun dy, khi cun qun xoay c mt vng th c cu ri dy cng dch chuyn i mt di chnh bng ng knh qun dy. Cn dy qun khng b t nhng vn m bo cng cn thit th ta phi iu khin tc cun nh ng tc vi cun qun. Nh vy c ba ng c ny hot ng trong s rng buc ln nhau, di s gim st v iu khin ca b iu khin trung tm l Card gim st, o lng v iu khin.

 gii quyt bi ton ng tc qun v nh (cng tc di) th trc ht ta cn c h bin tn iu khin ng c qun v nh c chnh xc cao, tc ng nhanh, y chng ti dng bin tn 3G3MV ca hng Omron, iu khin vect vng kn, phn hi dng Encoder 360 xung/vng. Ta cng cn mt b iu khin trung tm c chnh xc cao, tc nhanh tnh ton, x l thng tin v a tn hiu t vo h bin tn iu khin vect, do phng n s dng Chip PSoC l kh thi. Ngoi ra h thng c th qun vi tc cao (nng cao nng sut lao ng) ta cng cn phi c c cu b v cm bin sc cng c chnh xc cao, lm vic tin cy. Da vo thng tin t cm bin sc cng b iu khin s a ra tn hiu iu khin iu chnh tc c cu nh dy sao cho ng tc vi c cu qun dy. III. Thit k, ch to h thng gim st, o lng v iu khin cho my CNC qun dy III.1. Gii thiu chung v h thng gim st, o lng v iu khin H thng gim st, o lng v iu khin l mt phn quan trng khng th thiu ca mt h thng sn sut t ng hin i ni chung v my CNC qun dy ni ring, n chim t l cao v gi thnh trong ton b h thng, y cng l mt trong cc phn phc tp nht v cha ng trong n mt hm lng tr tu cao (hiu theo ngha c v chiu su v rng). Vi mc tiu thit k h thng gim st v iu khin c gi thnh thp nhng vn m bo cc yu cu v k thut, gim gi thnh my CNC qun dy, thay th cho thit b iu khin c kh nng lp trnh PLC v h thng gim st nhp ngoi. Chng ti thit k mt Card chuyn dng gim st, iu khin my CNC qun dy, trn Card ny phn t c bn l Chip PSoC ca hng CyPress M, y l loi thit b lp trnh mi, c cu hnh mnh, ti nguyn phong ph, tc x l nhanh. H thng gim st, o lng v iu khin do chng ti xy dng c chc nng t cc thng s ban u cho my CNC qun dy (s vng cn qun, s lp cn qun, tc qun dy, ch qun dy .v.v. ); gim st cc thng s ang vn hnh ca my thng qua vic o cc tn hiu phn hi t cc cm bin; v iu khin hot ng ca h bin tn - ng c khng ng b qun dy, nh dy v ri dy thng qua vic x l tn hiu, tnh ton gi tr tn hiu t v a cc gi tr ny vo cc b bin tn, b iu khin servo motor. H thng ny gm c 3 phn chnh: Phn cng (hard ware), phn chng trnh trn Chip (firm ware), v phn mm SCADASWARE trn my tnh (software). Tm tt mt s chc nng v thng s chnh ca Card gim st, o lng v iu khin do chng ti thit k: + C 7 u ra s, dng iu khin hot ng ca 2 bin tn 3G3MV hng Omron (iu khin ng c nh dy v qun dy) v Servo motor (iu khin c cu ri dy), SmartStep A - Series R7D-AP08H ca hng Omron. + C 3 u o xung t Encoder tc , v tr ca c cu qun, nh v ri dy + C mn hnh hin th LCD 2x16 (hngxct): Hin th thng tin, thng s, trng thi ang hot ng ca my CNC qun dy. + Kh nng truyn thng vi my tnh qua cng RS232, h thng c gim st v iu khin qua giao din (phn mm SCADASWARE) trn my tnh + C u vo ADC (max 14 bits), u ra DAC ( max 9 bits ) + C 4 EEPROM ngoi, k hiu FM24C64, mi IC ny lu c 64 Kbit, thng tin c th lu tr n 40 nm, dng lu cc thng s hin hnh m bo h thng sau khi mt in vn vn hnh tt v tip tc qun dy m khng gy li. Gii php ny cho php pht trin nhiu ng dng hn, thun tin hn l dng b nh trong ca PSoC. EEPROM ny truyn thng tin vi PSoC theo chun I2C.

+ C kh nng np trc tip chng trnh t my tnh khng cn phi thay Chip. + Ngoi ra cn rt nhiu ti nguyn c sn trong PSoC nh: Timer, counter, PWM, khuch i .v.v. c th pht trin cho cc ng dng khc. III.2. Phn cp chc nng x l thng tin gia Card (phn cng+firm ware) v phn mm trn my tnh Cp trn cng: My tnh PC c ci t phn mm gim st, o lng v iu khin(SCADASWARE). Phn mm c dng t cc gi tr ban u, nhn thng tin t Card truyn ln, hin th cc thng s, v dng tnh ton v s l cc thng s bin i chm nh bn knh qun qun .v.v. Cp th 2: Card (phn cng) v chng trnh np cho chip PSoC (firm ware). Cp ny c chc nng: o lng tc , s vng quay, tnh ton tc t cho ng c nh, ng c qun, iu khin v tr ri dy, lu tr v cp nht cc thng s hin hnh ca my CNC vo EEPROM, hin th cc thng s trn mn hnh LCD, truyn d liu ln my tnh. con: Cp cui cng: C th chia lm hai cp + B iu khin: Bin tn, b iu khin servo. Bn thn cc thit b ny cng tch hp cc thit b tnh (vi x l tn hiu tc cao) tnh ton tn hiu iu khin. Trong cc b iu khin ny c b iu iu chnh t ng PID, b iu chnh v tr, b iu chnh m men .v.v. + C cu chp hnh v cm bin: gm c ng c khng ng b nh dy, qun dy, ri dy v cc cm bin thu thp d liu: cm bin bn tri, bn phi c cu ri dy, cm bin trong c cu b sc cng, encoder o tc ng c. Hnh 3: Phn cp iu khin III.3. Thit k giao din gim st, o lng v iu khin cho my qun dy CNC bng my tnh (Xy dng phn mm SCADASWARE Supervisory Control And Data Acquisition SoftWare ) Giao din c 3 phn chnh: Phn 1 (Select Mode): La chn cc ch qun cho my qun dy CNC: qun theo s vng t, qun theo s lp t, qun theo khi lng t (qun dy hn), qun dy my bin p. Phn 2 (Setting parameters): t cc thng s cho h qun dy nh tc qun, s lp, ng knh dy v vt liu dy qun. Phn 3 (Measuring parameters): Nhn cc gi tr o lng t Card (o c t cc sensor) truyn ln my tnh v hin th cc thng s ny.

Hnh 4: Hnh giao din chnh iu khin my CNC qun dy Tt c cc thng s t s c truyn xung Card PSoC, trn c s gi tr Chip PSoC s o cc thng s vn hnh, tnh ton, x l v a ra tn hiu iu khin thch hp, m bo s hot ng nhp nhng gia c cu qun dy, c cu nh dy v c cu ri dy. Ngoi ra cn c cc giao din con dng kim tra, vn hnh, iu khin ring bin tn hoc servo motor phc v cho vic sa cha v bo dng khi c s c hoc c th dng lm thit b th nghim phc v cho cng tc ging dy v nghin cu trong cc trng cao ng v i hc. III.4. Thit k phn cng cho Card gim st, o lng v iu khin S mch nguyn l ca Card hnh 5. Trn Card gm 2 chip PSoC: Vic dng 2 chip cho php ta pht trin nhiu ng dng khc m khng cn thay i phn cng. PSoC 1: ng vai tr l chip ch (Master) c nhim v nhn tn hiu t my tnh, thu thp cc tn hiu t cc cm bin tri -phi, cm bin sc cng, o tc , o v tr t Encoder v nhn tn hiu t PSoC 2 truyn sang, t x l iu khin ng c Servo ri dy v truyn thng tin ln my tnh v ng m cc van iu khin qu trnh hot ng 2 bin tn, cho chy v dng h thng. PSoC 1 s thng xuyn lu tr thng tin vo EEPROM, v s c gi tr trong EEPROM sau khi c in tr li. PSoC 2: ng vai tr l chip t (Slave) c nhim v l nhn tn hiu t my tnh v thu thp tn hiu t cc cm bin cng dy v trng dy t a ra tn hiu dng Analog iu chnh tc cho 2 ng c qun v nh sao cho dy qun khng b t, ng thi thu thp t cm bin s c t dy v truyn thng sang chip PSoC 1 cho dng h thng khi c s c.

A2 1 3 4 5 CAP 11 TXD 10 12 RXD 9 A3 CAP

uRS1 C1+ C1C2+ C2T1IN T2IN R1OUT R2OUT MAX232 Vs+ VsVC C GND T1OUT T2OUT R1IN R2IN

2 6 16 15 14 7 13 8

A4 CAP

A6 CAP

VC C VSS A63 CON1 A20 C8dcS V RES1 +12V A22 RES1 A25 RES1 CBduoi A23 RES1 CBtren A42 A31 HEADER 2 DIODE SCHOTTKY A44 DIODE SCHOTTKY 1 2 VSS A62 HEADER 3 1 2 3 1

chay 1K RES1 A7 RES1

A34 NPN D7 VSS LED D

VSS A19 RES1

xung analog1 analog2

A8 RES1 A9 D6 VSS LED

A35 NPN

A41 1 2 3 HEADER 3

VC C VSS A5 5 9 4 8 3 7 2 6 1 C DB 9 VC C VS S D11

A14 SW-SPS T D10 RES1

HT C8B /A VSS

p272 p012 p072

1K

SW-PB

A33 HEADER 2 chieu Vdd P0[6] P0[4] P0[2] P0[0] P2[6] P2[4] P2[2] P2[0] XR ES P1[6] P1[4] P1[2] XS DA C 28 VC 27 duoi CB CB 26 tren 25 24 23 RW2 22 E2 DB 62 21 20 DB 42 19 XR ES2 18 encoderQ RXD encoderN P002 A10 RES1 A11 RES1 LED C D5 A36 NPN

2 1

A47 DIODE SCHOTTKY CB T A26 RES1 +12V

A48 DIODE SCHOTTKY CB P A28 RES1

A32 2 1 HEADER 2

VS S

VS S

A27 RES1

A29 RES1

A54 A55 RES1 RES1

1 2 3 4 5 6 RS 7 LED4 LED2 8 9 10 SCL 11 SDA 12 C8B/A RX2 13 14 chay xung C8dcSV chieu HT

Psoc P0[7] P0[5] P0[3] P0[1] P2[7] P2[5] P2[3] P2[1] VS S P1[7]SC L P1[5]SDA P1[3] XS CL Vss Psoc Vdd P0[6] P0[4] P0[2] P0[0] P2[6] P2[4] P2[2] P2[0] XR ES P1[6] P1[4] P1[2] XSDA

28 27 26 25 24 23 22 21 20 19 18 17 16 15

VC C CB T CB P BT2 BT1

analog1 analog2

p072 p012 p272 DB 72 T2 R2 P012

RW E LED3 LED1 XR ES encoderQ TXD RXD TX2

DB 52

Psoc1 1 P0[7] 2 P0[5] 3 P0[3] 4 P0[1] 5 P2[7] 6 RS2 VSS P2[5] 7 P2[3] 8 P2[1] 9 VSS 10 P1[7]SC L 11 P1[5]SDA 12 P1[3] 13 XSCL 14 Vss Psoc1

17 16 15

BT2

A12 RES1 D4 A13 RES1 LED VSS

A37 NPN

VS S A52 1 2 3 4 4 HEADER

VC C TX2 RX2 XRES VS S VCC A49 2 1 HEADER 2 A1 B K A DB 7 DB 6 DB 5 DB 4 DB 3 DB 2 DB 1 DB 0 E R/W RS Vo Vdd Vss LED1 LED2 LED3 LED4 VCC VSS 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 A60 TX2 RX2 3 4 SW DIP-2 2 1 T2 R2 encoderN encoderQ

P002 P012 XRES2 VS S VCC

BT2

A21 RES1 100K RES2 D1 VSS LED

A40 NPN

5 4 3 2 1

VS S

A46 HEADER 5

1 2 3 4 VS S

A56 A0 A1 A3 GND 24c64 VC C RW SCL SDA

8 7 6 5

VC C SCL SDA

VC C

1 2 3 4 VSS

A58 A0 A1 A3 GND 24c64 VC C RW SCL SDA

8 VC C 7 6 SCL 5 SDA

A53 HEADER 5 BT1 A15 RES1 A16 RES1 LED D3 VSS

A38 NPN

A51 22 A39 NPN 22 1 2 3 4 4 HEADER VS S

VCC

VCC VS S

A24 RES1

A43 SW SPST

A61 SW SPST

VS S

LED

VS S

24c64

VSS

24c64

DB72 DB62 DB52 DB42 E2 RW 2 RS 2

24 V +12V -12V VCC

10 9 8 7 6 5 4 3 2 1

XRES

5 4 3 2 1

IV.

Cch kt ni gia Card PSoC vi bin tn 3G3MV v Servo motor ca hng Omron

Hnh 6: Cch u vi bin tn 3G3MV

V.

Kt lun

Bi bo trnh by kt qu nghin cu thit k, ch to h thng gim st, o lng v iu (Card PSoC, firm ware cho chip PSoC, phn mm SCADASWARE trn my tnh) v p dng vo iu khin m hnh my CNC qun dy. Kt qu vn hnh cho thy h thng gim st, o lng v iu khin do chng ti ch to lm vic tin cy v c chnh xc cao hon ton c th thay th cho thit b nhp ngoi.

RS RW E VSS VCC VS S XRES2 A45 HEADER 5 2

VC C

1 2 3 4

A57 A0 A1 A3 GND VC C RW SCL SDA

8 7 6 5

VC C SCL SDA

VC C

1 2 3 4

A59 A0 A1 A3 GND VC C RW SCL SDA

8 7 6 5

VC C SCL SDA A30 RES1

BT1

A17 RES1 A18 RES1 LED D2 VSS

A Title Size B Date: File: MACH DIEU KHIEN M QUAN DAY CNC AY Number Design: TRAN THE THINH Revision

A50 HEADER 10

4-Dec-2007 Sheet of D:\CUA THINH DE NHO\New Folder\mach thay HUNG\MyDesign.ddb Drawn B y: 6

Hnh 5: S mch nguyn l Card iu khin my qun dy CNC

Hnh 7: S ni dy vi Servo Driver

Hnh 8: Card gim st, o lng v iu khin

Hnh 9: M hnh my CNC qun dy Ti liu tham kho

[1]. Ti liu k thut v PSoC ca hng CyPress. [2]. Ti liu k thut v SmartStep A - Series R7D-AP08H v bin tn 3G3MV ca hng Omron. [3]. Cc website ca mt s hng: Omron, Cypress, Electromech, Siemen, ABB, Digmotor, GeorgeStevens, ReynoldsElectronics, http://www.alldatasheet.com