The Real Time Control by the OPEN-CNC Complex Automation

THE ANNUAL SYMPOSIUM OF THE INSTITUTE OF SOLID MECHANICS

SISOM 2002 BUCHAREST May 16-17 -------------------------------------------------------------------------------------------------------------------------------------------------

The Real Time Control by the OPEN-CNC Complex Automation System of the Six Freedom Axes Mechanical Center Gunter Vogelsang*, Luigi Vladareanu**, Lucian Marius Velea*** Abstract. The paper presents results obtained by studies and research of technical solutions of complex automations for mechanical centers based on decentralized structures and distributed with programmable automates (PLC) and PC supervising with 3D graphic interface for generating contour on 6 degrees of freedom. Starting from a new OPEN-CPM automation concept of the mechanical centers, it was analyzed and implemented in the national RELANSIN 1999-2002 program by the date transmission flux, the task distribution in program structure, the control mod of position and the communication between PC and PLC.

The control and command of a mechanical center by applying top technology have been studied and research have been carried out on a decentralized and distributed structure with programmable automates and PC supervising, with graphic interface for generating contour of the programs on several axes. A new method has been applied for the control of the contour of movement of the mechanisms with six degrees of freedom through the numeric acquisition in real time based on multimicroprocessor systems. Also there have been made studies and research regarding the generating of references for the movement control on six degrees of freedom with a simultaneous touch of the target by processing in real time a movement low. The mechanical movements for the six degrees of freedom are made through several groups of positioning servomotors, with high performance, for generating in real time the new position taking into account the sizes of the piece, the diameter of the tool and the positioning on each axe. The base structure of the project suits to a new project concept of command systems for mechanical centers known as OPEN-CNC (fig.1), and its components are: PROGRAMMABLE AUTOMATE (PLC) for the control and command of the execution elements in function on AUTOMAT and MANUAL. When functioning on AUTOMAT the execution functions (from M00 to M99) are transmitted through a serial interface RS 232 from the PENTIUM PC. The communication is made through the EMAS functions block. It ensures the execution, in real time, of 4 functions. Also we have a serial transmission of the S functions on 5 digits (the change in the rotation speed of the tool with a 0.025% resolution), the F functions (the advance speed-with a 0.025% resolution) on 5 digits and the T functions (change in the tool number) on 2 digits. The tool’s real position is read through a specialized ICSF 08D1, ABB module and it is displayed on an intelligent multifunctional MT60-AABB terminal. The automate ensures a maximum number of 62 digital inputs, 16 digital outputs and another 80 configurable digital I/O. For the control of advance speed (F) and the rotation speed of the tool (S) analog outputs with 12 bytes resolution are used. The indexing M19 function is made through the analog measurement of a traducer existent in the machine, sampled by a proximity traducer at the indexing position. __________________________ *

ABB STOTZ KONTAKT GmbH, HEIDELBERG, GERMANY INSTITUTE OF SOLID MECHANICS, BUCHAREST, ROMANIAN ACADEMY SC INGINERIE SI TEHNOLOGIE INDUSRIALA VTC-SRL, BUCHAREST, ROMANIA

**

***

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SERVOMOTORS WITH A POSITIONING DRIVER – ensure the removal movement control on each freedom axe based on the reference points generated by the INTERPOLATOR module with PENTIUM PC soft. The servomotors are of type 9300 EPLENZE and ensure a positioning precision of 16 bytes by serial transmitting of the references on CAN bus or PROFIBUS, with communication speed of Byte/sec., respectively 12 bytes through analogic reference control (fig2).

LENZE CONTROLLER 9324-EP ∆S (11bits) INPUT X

STR

32

Σ / X

i

Σ

REG. POZ. PID

Σ

REG. VIT. PID

C-DA CONV

p

(0,2 2ms)

ENC

PE

THE INTERPOLATOR MODULE – ensures the generating of intermediary points between two position references. The programming is made in BORLAND C++ and allows calculating over 200 new references in an interval of 100µs. The arithmetical calculations are made in floating comma with a precision higher then 1µm for 1000 m. The interpolation can be made linearly and circularly. The communication with the main program is made through 2 resident RAM files, one for transmitting data and the other for position reception and commands. THE MAIN PROGRAM – ensures a graphic interface, specially created for this project, between the operator and the machine. By integrating the BIBEXE program for graphic interface specialized in programming tool machines with numerical command, the problems about the generating and execution of 3D surfaces and curves are solved. It allows graphic simulation of the execution technology adopted, which will lead to reducing the time for the process preparations. The simulating program for 3D linear interpolation and circular interpolation is an own conception and was made in Turbo-Pascal and also in Borland C++. The PLC program was made along with the operating panel. PC/PLC COMMUNICATION INTERFACE MODULE – allows communication on ISA bus INTERPOLATOR soft module and serial communication through USART with

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PROGRAM NATIONAL: RELANSIN 115 / 1999 - 2002 FINANTARE: A.N.S.T.I. MONITORIZARE: A.M.C.S.I.T. PARTENERI: ACADEMIA ROMANA - Inst. Mecanica Solidelor UNIVERSITATEA TEHNICA CLUJ NAPOCA

INGINERIE SI TEHNOLOGIE INDUSTRIALA

BIBEXE-OPEN-CNC

&

PC - OPEN - CNC AXA x1

∆XiR / 16

i

TP RELANSIN GENERATE FUNCT. TECHNOL. (FCT. AUX)

TP RELANSIN GENERATE PROG. TECHN.

XR / 32

INTERPOLATOR OPEN-CNC

∆XiAR 10V (12bits)

CNA 12bits

10V

/3 I/O I/O

-

27 /

/ 6

EN1

PLC

+

10V

-

+

PANOU SINOPTIC OPEN-CNC

/ 3 10V (12bits)

C O M 1

C O M

MT 60 SAE

AXA x5 LENZE

ΣAx RS 485 ICSFφ8 D1

1

iM R

CA/N 12bits

COM PARALEL

COM2

M ∆X Σ x

~3M

1 R

/ OUT EN1 6

/ BUS PC

COM2

LENZE

ΣAx

Σ

M

/ 6

~3M 5 R

5

xR

OUT

/ EN5 6

/ 6

EN5

KT94 -PLC. This allows higher speed of communication between PLC-INTERPOLATOR and BIBEXE. Thus, several commands executed only of PLC (manual removal on axes, setting on the zero position, homing, manual position to a certain target) was transferred to the INTERPOLATOR having more advantages: 1) increasing precision and the position time – b`ecause removals are made after a parabolic movement law for speeding through interpolation with real time control: 2) reducing the execution time of PLC program leading to higher speed of the position loop closing and respectively a better position control; 3) eliminating the problems introduce by the WINDOWS 98 operating system of PC, knowing that the interpolator is functioning with interrupter in real time. To these ends, it was necessary to conceive and to project, by applying some modern techniques, having on base AT90S4434 microcontroller, the PC/PLC communication module on ISA bus, the INTERPOLATOR and the PLC program to make a complex communication protocol on RS485 full-duplex serial bus and for making new programs: ”ASSEMBLER” program for microcontroller and FIRMWARE program for ISA communication. A main program named RELANSIN of interfacing for any type of mechanical center with 2 to 6 numeric axes commanded was realized. This ensures interfacing between PLC programmable automate and interpolator for movement control on axes and executing auxiliary functions. The program is in accord with international rules and standards in order to realize technological projects by including BIBEXE ,a specialized program of technological project, as a subprogram. The 11

simulation program of 3D linear interpolation and circular interpolation (fig.3.) was realized. The INTERPOLATOR is a RAM resident which ensures real time generating of position references, on the 6 numerical control axes, to the LENZE command and control drivers.

Fig.3. Graphic interface of simulation program for linear and circular interpolation in 3D The sequential movement control program of mechanical center by FBD programming of KT94 with CS31-ABB programmable automate as master role was realized. Also, FBD programming of SA93-ABB module is for reading the position and to realize homing function on X and Z axes, slave role in PLC net. Technological programs for a palette, a section palette and a closed curve formed of a segment line were made. Processed data by interpolator, which represents references for LENZE command and control drivers was generated. By the applying of high complex of interpolation methods and execution under BORLAND C++ program with high calculating capacity, there was obtained a generating precision of references more than 108 that correspond to an error less than 1µ to 100m. Results comparison was made both graphic and table for a palette, a section palette and a closed curve formed of a segment line. The program is projected to float interruptions from 100µs to 400µs, having the possibility to calculate in advance 200 reference points. That corresponds to an advance speed from 2400 mm/min. to 600 mm/min. Overwrite commands of advance speed and spindle speed are analogic reading on 12 bytes from PLC programmable automate through A/N conversion. This allows changes and real time control of advance speed and spindle speed. The last tests show that the interpolator calculated time necessary for arithmetical operations by changing the two speeds is under 10µs and doesn’t influence real time movement control. Speed curve closing through PLC using PLC PID instruction for numbered determination of speed error and N/A conversion on 12 bytes for making command analogic signal of LENEXA controller was realized. This brings a supplementary cost decrease, knowing there are 4 N/A converters included in the KT94 programmable automate. A serial communication between PC and PLACE with RS232 protocol through PLACE-ABB. specified telegrams transmission/reception through DRUCK and EMAS instructions was done. It obtains in this way the possibility to make 99 type M sequential operations, parallel execution of 4. Also the possibility to send the advance speed and the spindle speed from 0 to 99.999 mm/min and 21 tools number control. 12

Through serial communication between INTERPOLATOR and PLC, using DRUCK and EMAS telegrams with RS232 protocol there are sent, in real time, reference positions for PID soft position regulator implemented on PLC. The proportional band, amplification factor, derived and integrated time are chosen by the project in PLC program concordant with the mechanical system. The serial communication between PC and PLC with RS232 protocol is ensured through the PLC-ABB specific telegram transmitted/received through DRUCK and EMAS instructions. Communication principle consists of sending the telegrams from PC to PLC and if it is concordant to one of the auxiliary functions the PLC executes the PC function and transmits a recognition signal of the “ACK##” final sequence (where ## represents the number value of the realized auxiliary function), which allows the PC to continue the program. Those telegram types are: TELNET: #”M1##M2##M3##M4” – for execution of a 99 auxiliary functions quasi-simultaneously for any 4 of them; TELN2:#T##M##” –for changing 21 tools of any 99 auxiliary functions, TELN3:#”S#####F####-for changing advance speed and spindle speed with resolution on 5 digits, TELN4:#”X#Y#Z#A#B#C. For bringing in origin quasi -simultaneously or independent on any of those six axes. The 1 and 2 telegrams’ decodification is made through the indexing address (IDSB instruction for FBD programming) having M40,00 address base for first M1 auxiliary function respectively M70,00 for fourth auxiliary function from TELNET telegram. Also M80,00 for TELNET telegram which ensures 99 tools types (T=1-99) to any of 99 auxiliary functions (M=1-99). In this way it obtains the possibility to realized 99 type M secvential operations, with parallel execution of each 4. Also the possibility of advance speed and spindle speed transmitted from 0 to 99.999 mm/min and of 99 tools control. It was experimentated alarms control and generating for: outrunning inferior/superior limit on X,Y,Z axes, outrunning ware-house motor currents, outrunning spindle current motor; hydraulic force lack; air lack; outrunning driver current motor on 1-5 axes. When the damage appearance its intermittent overlapped after the existent display from MT91 terminal existing condition to reset alarm. It was realized homing functions on each movement axe, bringing to zero on MANUAL in the same time on X,Y,Z axes by pressing the BPOXYZ button independent on each axe by BPOX, BPOY, BPOZ buttons realized with interruption in damage situations. Also, positive or negative manual movement on each axe. For these movements control as for TRIP-SET, TRIP-RESET, SENSE +, SENSE commands necessary to the 3 LENZE controller were used 2 DC92ABB input/output configurable module of 32 input/output each. It was realized the reading and visualizing position on movement axes of mechanical center. For this it was used ICSF 08D-ABB specialized module for Y axe and tools store using 2500 rot/min incremental traducers. It is ensured a 2048000 impulses counting, that is enough instead of maximum 110000 impulses which can be generate on CPM axes.

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INIT = 1

INITIALIZATION DRUCK, EMAS INIT= 1

READING ENCODER POSITION AX1 - AX5

DISPLAYING POSITION AT SAE READ/DISPLAY AVANCE SPEED AND TOOLS SET FOR ADJUSTMENT DISPLAY AT SAE OF SPEED TOOL

CURRENT TOOL DISPLAY

AUT

MAN AUT / MAN MAN PC

MAN PC/ MAN PLC MAN PLC

SENDING TELEGRAM TO PC FOR CONTROLLE: DEP X, Y, Z, B.P.O., OVERWRITE F;S, STOP, START CICLU, RESET, READY, FAST S, STOP AVANCE, STOP TOOL.

READ TELEGRAM

GENERATING SEQUENZER:M00, M02, M03, M04, M05, M13, M14, M19, M6, M8, M9, M34, M35, Tnn, Snnnnn, Fnnnnn

GENERATING SEQUENZER: ROT BETA, CHANGE TOOL, ROT & DEP & REV MAG, ROT & STOP & DESC TOOL, COOLING LIQUID, CPM LIGHT, CARRY SPAN.

GENERATING OF ACK

Fig.4. For control in motor curve of store rotation was used a LENZE speed control equipment with 16 speeds game. Incremented traducers had ensured the introduction possibility of supplementary curve, position curve instead of current curve, specific flux and rotation for frequency converters. For control in position curve on Y axe was used an ACS300-ABB frequency converter.. For Z axe control was used a 9324EVLENZE-speed controller and on X axe 9324 EP position controller. Position error calculating was made by FBD programming of PLC-KT94 and position error generating to frequency converter through N/A conversion on 12 bytes.

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Owing to this command system and position control on axes was possible to be made the following specific sequential actions of mechanical centers known as M00-M02,M06,M8, M9 auxiliary functions. It was programmed PLC automate for control and command of following auxiliary functions:M03,M04,M05,M13,M14M34M35M40M41. Control and command system being an OPEN-CNC system allows adding until to 99 auxiliary functions, based on beneficiary request sequential. The OPEN-CNC command and control system realized during this phase ensures specific training functions of tools-machines programming with 3D functioning, respectively:G01-G09G43-G44G53-G59G80-G91.

000

13.07.00

15:45:00 RELANSIN 1999 CENTRU DE PRELUCRARI MECANICE → [J002] [h100]

002

13.07.00 → VITEZA REALA [J020] 15:45:23 → CURENTI MOTOARE [J030] → POZITIONARE PE AXE [J010] → HELP [J100] [h100]

[MD10,06]

[MD10,07]

ALARME

Fig. 5. Schema logica terminal inteligent MT91in mediul de programare SPS-PLUS. Contact RELANSIN 115/2001 realizat cu aportul Academiei Romane - Inst. Mecanica Solidelor si Univ. Teh.Cluj Napoca

The main program ensures a graphic interface, specially created for this project, between the operator and the machine. By integrating the BIBEXE program for graphic interface specialized in programming tool machines with numerical command, the problems about generating and making three-dimensional surfaces and curves are solved. It allows graphic simulation of the process technology, which will lead to reducing the time for the process preparations. Using the SPSPLUS development software, specific to these intelligent terminals, we have configured each display frame needed for visualizing the process parameter values and alarms status. (fig.5.). In the main menu there can be selected the display frames for visualizing the monitored parameters values, the frames for the setting of parameter limits, the Help for the limits programmed and storing in the PLC ‘s FLASH EPROM frame, as well as the alarm status exit frame. Finally, the bi-directional communication between the PLC and the MT60 terminal was realized. 15

The performances that we want to obtain by applying this project to CPM is available from our partner in industry SC UNIREA: - Range of axe movements: x- 450mm; y- 400mm; z-375mm β - 3600; AXA 5 (MAGAZIE) - 3600 - The positioning resolution on the axes: x,y,z ~ 440,000 increments for 2,500 imp/rot β ~ +/- 3 sec; AXA 5 ~ 0,10 - The max. speed for the work-advance-movement on the axes – F=7,000 mm/min - The max. speed for quick-advance-movement on the axes: 15,000 mm/min Acknowledgements. The authors wish to express their gratitude to the Romanian Academy, ANSTI (National Agency for Science, Technology and Innovation – ROMANIA), AMCESIT POLITEHNICA and ABB-STOTZ KONTAKT ( Heidelberg, Germany) for their support of the program of work reported herein. The work took place as part of the research project no. 115 /1999-2002 in the framework of the program for research and development RELANSIN’99. REFERENCES. 1.

VLADAREANU L., “Signal Processing with A/D recursive converters”, SISOM’91, The Annual Symposium of the Institute of Solid Mechanics - Romanian Academy, 28-29 Nov.'91, pg. 141-148. 2. VLADAREANU L., GH. PASCOVICI, “A New Selftraining Autocalibration Method for ADC's”, I.T.H.U.R.S'96, Symposium AMSE, International Conference on Intelligent Technologies in HumanRelated Sciences, LEON-Spania, July 5-7, 1996, pg. 439-443 3. VLADAREANU L., “A New Architecture for the High Speed Wilkinson-Recursive Subranging Converters with Improved Performances” International AMSE Conference,CCM’98,Lyon, France, July, 7-10, 1998. 4. ABB Schalt- und Steuerungstechnik - Advant Controller 31 - Three Times Higher Performance, 1998 5. ABB Schalt- und Steuerungstechnik - The descentralised, intelligent automation system ABB Procontic CS31- 1998 6. ABB Control S.A. - AC31 nouvelle ouverture pour l’automatisme,1997 7. ABB Schalt- und Steuerungstechnik - ABB Procontic CS31 - A simplist approach to decentralised automation, 1997 8. ABB Schalt- und Steuerungstechnik, CS31 - Intelligent decentralised automation system, 1996. 9. ABB Schalt- und Steuerungstechnik - Automation System ABB Procontic T200, Modular powerful, decentrally expandable, 1996. 10. ABB Schalt- und Steuerungstechnik -Low Voltage Control Gear - Automation Systems, ABB Procontic Types K200b, CS31, T200, T300,1996. 11. Gunter Vogelsang, Luige Vladareanu Lucian Marius Velea -ABB - PLC in Distributed Structures - a New Step Towards Top Technology,-The Anual Symposium of the Institute of Solid Mechanics – Romanian Academy SISOM'97, 15-16 Dec.'97, pg. 187-193. 12. Gunter Vogelsang, Lucian Marius Velea, Luige Vladareanu - ABB - PLC in Distributed Structures - a New Step Towards Top Technology – Power Source Automatic Switching by Means of ABB-PLC -The Anual Symposium of the Institute of Solid Mechanics – Romanian Academy SISOM'98, 15-16 Dec.'98, pg. 187193.

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