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March 29, 2012

PID APPROACH & ISSUES IN SERIES CONTROL SYSTEMS FOR MACHINE AUTOMATION. Ing. Adriano Chinello Technical Director Automation Division Gefran S.p.A. March 29, 2012. 1. IFAC Conference on Advances in PID Control. General Targets for Series Control Systems.

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March 29, 2012

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  1. PID APPROACH & ISSUES IN SERIES CONTROL SYSTEMS FOR MACHINE AUTOMATION Ing. Adriano Chinello Technical Director Automation Division Gefran S.p.A. March 29, 2012 1 IFAC Conference on Advances in PID Control

  2. General Targets for Series Control Systems • Standard PLC application development (IEC 61131-3, PLCopen) • High-value PLC software libraries: easy, complete, time-saving, … • Cost – optimized hardware architecture • Respect of target control specifications among many different machines and over a wide range of operating conditions Reference applications: • full-electric injection moulding machine (FE IMM) • Hydraulic injection moulding machine (HY IMM) March 29, 2012 2 IFAC Conference on Advances in PID Control

  3. Specific Targets for IMM Control Systems • Precise, repeatable and smooth changes between different control loops on single motion axes (position – speed – torque – mould pressure) • Electronic Noise Filtering / Tolerance (high power and inductive loads, poor cabling and shielding, …) • Compresence of very different processes: - Electric Motion control (cyclic + events) 0.1 ÷ 1 ms - Hydraulic Motion control (cyclic + events) 1 ÷ 5 ms - I/O (cyclic) 5 ÷ 20 ms - Thermoregulation (cyclic) 50 ÷ 100 ms - HMI (events) > 100 ms - Supervisoring, Statistics, etc… (cyclic + events) low priority March 29, 2012 3 IFAC Conference on Advances in PID Control

  4. PID Distribution in a FE IMM Architecture HMItask Remote I/O Panel PC I/O real-time controlloops Monitoring / data collection GDnet / CANopen Opticalinternal link Servo rack Modbus / CANopen Motionhigh-levelcontrol Position / AI Loop Speed / TorqueRef CurrentTorqueSpeedLoop Powerhigh-levelcontrol PLC / SPC / auxtasks Analog Input Power / ThermoLoop Power Controller PressureSensor March 29, 2012 4 IFAC Conference on Advances in PID Control

  5. Panel PC - Fieldbus Performance and Cost PID decentralisation allows Panel PC and fieldbus downsizing www.cpubenchmark.net cost March 29, 2012 5 IFAC Conference on Advances in PID Control

  6. PLC Motion Application Library • Standard PLCopen • Only one software application for the whole machine • High-level programming, fieldbus and hardware independent • Standard Function Blocks with add-on (more flexibility) • Special Function Blocks with interfaces in line with the standard March 29, 2012 6 IFAC Conference on Advances in PID Control

  7. Example: Injection Axis Control • Easy to develop, with a series of Function Blocks in blending • Switchover on position, pressure, … • Control phases preloaded into the drive March 29, 2012 7 IFAC Conference on Advances in PID Control

  8. PID Open Issues • Smooth control switch vs time reactivity • Noise rejection vs time reactivity • Robust tuning procedures for reliability in series production: possibly one single tuning (or tuning procedure) for many machines and many different moulds for each machine • PID modularization and packaging into PLC software libraries, with both “simple entry level” and “complex advanced” user interface March 29, 2012 8 IFAC Conference on Advances in PID Control

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