1 Introduction
Traditional cable cutters have relatively large following errors. To solve this problem, Delta's built-in flying shear function of the 20PM motion controller has excellently fulfilled various requirements, achieving synchronization of conveying and cutting line speeds, and adjusting the width of the synchronization zone by adjusting the width of the synchronization zone. To complete the cutting of different lengths of cable to ensure the accuracy of cutting.
2 Structure and working principle
2.1 Cable cutter
Cable cutting machine equipment structure shown in Figure 1, Figure 2. Cable cutting equipment This is a typical flying shear function application. Delta 20PM has built-in flying shear function. It can use DVP-20PM as the control center of Delta's electromechanical products to complete the control of the cutter and realize the equipment control. Claim.
2.2 DVP20PM Motion Controller
Delta DVP-20PM00D is a programmable controller with motion control dedicated functions. The biggest feature of the DVP-20PM00D is that the host directly provides the electronic cam CAM function, or that the DVP-20PM00D is a PLC with a built-in CAM function, so some locations directly call the DVP-20PM00D as a Delta 20PM motion controller.
The 20PM has two 500KHz inputs and outputs. In the CAM function, the X axis is defined as the slave axis, and the encoder input axis is the master axis. When the CAM Table is defined, the slave axis follows the defined spindle and follows the master axis motion. Using a high-speed dual-CPU structure and using an independent CPU to process motion control algorithms, various motion trajectory control, logic operation control, linear/circular interpolation control, etc. can be well implemented. The cable cutter utilizes the 20PM motion controller. The electronic cam function solves the problems of unequal length and the like that occur during the above high-speed cutting. 20PM's main features:
(1) 20PM is suitable for high-speed, high-precision, high-complex motion control applications;
(2) Multi-speed execution and interrupt location;
(3) 64K large capacity, built-in Flash memory bank;
(5) Two sets of differential pulse output with a maximum pulse output of 500KHz;
(6) Two sets of hand wheel control;
(7) Built-in electronic cam CAM function, easy to achieve winding, flying shear, chase and other applications;
(8) PLC sequential logic control and NC control (G code and M code) are supported.
3 cutting machine software design
3.1 I/O definition
3.2 Flying Shear Program Design Process
To write programs using the 20Pm flying shear function, follow these steps:
The DTO instruction is used to complete the given program of flying shear data. It needs to calculate the filling data D100-D112. Its parameters are defined as follows:
D101..D100 spindle length
D103..D102 slave axis length
D105..D104 synchronization length from axis
D107..D106 slave axis synchronization ratio (F2/F1)
D109..D108 slave axis maximum magnification limit
D110 acceleration curve:
0 const speed,
1 const Acc,
2 SingleHypot,
3 Cycloid)
D111CAM curve=0
0 leftCAM,
1 midCAMall,
2 midCAMbegin,
3 midCAMend)
The procedure for filling data D100-D112 in the program is as follows:
(1) D100 calculation:
D210 cutting length
D222 meter meter circumference
D212 meter wheel line
D224 actual meter meter total pulse number
D226 cutting length pulse number
D100=D226=D224=D210/D222*D212
(2) D102 calculation:
D416 cutter wheel pulse x D426 speed ratio = D200 cutter wheel pulse = (D102)
(3) D104 calculation:
D200 Cutter Wheel Pulse x D172 Synchronization Range = D204 Synchronization Pulse = (D104)
(4) D106 magnification calculation derivation process:
a. Spindle diameter D1 (mm)
Spindle pulse number R1 (Pulses/Rev)
Spindle speed F1(Hz)
Spindle speed V1(mm/sec)
b. Slave shaft diameter D2 (mm)
Pulse number R2 (Pulses/Rev)
Slave speed F2(Hz)
Slave speed V2(mm/sec)
c: According to the synchronization, the linear velocity is the same
V1=V2
(F1*3.14*D1/R1) = (F2*3.14*D2/R2)
F2/F1 = (D1*R2*K reduction ratio)/(D2*R1)
= (D250*D256*D258 reduction ratio)/( D252*D254)
=D274
=D106 pulse ratio synchronization ratio
(5) D108 magnification limit
(6) D110 acceleration curve selection:
0-3 curve selection progressive smoothing
(7) D111CAM curve selection:
Select 0 to ensure that the cutter returns to the upper zero after cutting
8: D112 result ok
The above part completes the process of calculating and populating data of D100-D112, that is, the design of the flying shear program is completed.
3.3 Flying Shear Program Operation Monitoring
D1799 Set X axis input terminal polarity terminal polarity PG0
D1800 input point status b5DOG origin signal to count point D50LDPm125 is invalid
D1816=530 Origin Return DOG falling edge detection origin return direction A/B phase pulse
D1828 X-axis zero return speed
D1830 X axis origin return deceleration speed
D1832 X axis zero signal number N
D1833 X-axis supplementary distance P k0 after return to origin
D1838X axis target position (I) P(I) (Low word)
D1848X axis current position CP (PLS) (Low word)
D1864=H305 X axis hand wheel input response speed setting A/B phase pulse 4 times frequency
D1846=100 X single speed positioning movement mode start
D1846=40 Origin Return Mode Start
D1846=2000 Insert single speed positioning motion mode to start
After the above analysis, the analysis process is written as a program to complete the main program design, and other various security protections and additional functions are not described together with the WPL program.
3.4 Electronic Camshaft CAM Curve
In the planning of CAM, 20PM programming software - PMsoft first generates the relationship of displacement and then generates the relationship between speed and acceleration, but here we plan with the relationship of speed, so we must first generate the speed relationship and then generate the displacement and acceleration, PMsof provides The convenience function can import the displacement data from the Export as speed data to complete the CAM diagram. The steps are as follows:
(1) Set the desired resolution, here we set 200 points:
(2) The speed relationship is established on the displacement map, where we assume that position 1 is at spindle position 100, position 3 is at spindle position 200, and position 4 is at spindle position 300:
(3) Export the displacement map and import it as speed data to get the speed diagram we want:
In the generated displacement diagram, the horizontal axis is the amount of the pulse returned from the spindle (feed axis), and the vertical axis is the amount of motion pulse from the axis (cutter axis). The displacement (pulse number) of the spindle is the cutting length. During the spindle movement, the slave axis (cutter axis) follows one cycle and cuts once. In the speed diagram, we can see that there is a synchronous cutting zone between the slave axis and the spindle, which ensures the speed synchronization between the two.
The above is the introduction of the flying shear function and how to create the CAM diagram. In the cable cutting machine, the spindle (feed) is not controlled by 20PM, but its movement is fed back to the 20PM by the meter-wheel encoder, so the feed spindle can also be established. The knife moves from axis to axis. Dynamic Adjustment of Cutting Curve Introduction CAM curve can be modified in real time in the program. The dynamic adjustment of cutting curve is done through FROM/TO instruction. It can be automatically changed in the next cycle as long as it is written before the cutting cycle is completed. Various smooth curves are provided for selection in the CAM curve parameters, satisfying the need for smooth acceleration and deceleration.
4 Conclusion
The cable fixed-length cutting equipment based on Delta's 20PM motion controller has been commissioned and is operating normally. The cutting repeatability is within ±1mm of the customer's process requirements. The 20PM flying shear function was successfully applied to cable cutters. This is another successful application case of the 20PM flying shear function, which can be widely used in material cutting and other occasions in all walks of life.
The DVP20PM is a motion controller in the Delta family of PLCs. It has powerful computing and processing capabilities and can easily perform various 2-axis and 3-axis motion control. It is especially suitable for high-speed positioning applications where position control and real-time response are required. And built-in high-speed winding, flying shear, chase and other high-level applications, widely used in food processing, packaging, woodworking, machine tools, cable cutting and other industries.
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