PROGETTO del CONTROLLO di MACCHINE AUTOMATICHE per l’IMPACCHETTAMENTO (MOTION CONTROL for PACKAGING MACHINES)

1. MECHATRONICS PROGETTO del CONTROLLO di MACCHINE AUTOMATICHE per l’IMPACCHETTAMENTO(MOTION CONTROL for PACKAGING MACHINES) Davide Borghi

2. The Course • Course characteristics: multi-discipline contents • Course Goal: “speak the same language” and be able to design the machine “as a whole” (not mechanics and motors separately). • Course Limitations: no time to go deeply in each subject, so I will try to give you the tools and hints to investigate further; not everybody is interested to deepen every subject, so don’t worry if sometimes you miss some parts…

3. (1/2) Index PID Control PID Theory Serial (Rockwell Kinetix) and Parallel (Danaher SAM) PID Digital PID & Feed Forward Vibrations Analysis Control-Motor-Load relationships Bandwidth PID – bandwidth relationships Vibration measurements Sizing Planetary gearboxes versus direct-drive Servo-System Design EMC hints Trouble Shooting of a rig solution (in fase di prima verifica) Packaging Machines Motion Architecture Mechatronics in the Packaging World Mechatronics on packaging machines …bits of history Where is the Performance Limit? (motor => electronics => mechanics) Multiaxes systems (e.g.: A3-Flex, DIMC, PT) Programming Interface: RS-Logix5000 IEC1131-3 Application Program Example Brushless Motors Electric Motor’s Choice (kinematic chain, torque characteristics, field weakening - deflussaggio) Stator Re-Winding (riavvolgim. motore) Brushless motors technology Resolvers and Encoders Linear Motors Torque Motors

4. (2/2) Index • Drives AC brushless drive DC brushless drive Resolver to Digital Converter Regenerative breaking (Recupero in rete) Control Strategies Clark&Park Transforms IPxx Protection Servo System TroubleShootingon the field THE END

5. Bibliography • 1.Luciano Bonometti: “Convertitori di Potenza e Servomotori Brushless”, • Editoriale Delfino, Milano, 1996 • 2.Hughes: "Electric Motors and Drives", 1993, Heinemann, 348pp., codice RS: 912076 • 3.CYMEX: Cyber Motion Explorer, CD-ROM, Alpha getriebebau GmbH info@alphagetriebe.de • 4.“THE MOTION BOOK” version 4.0, Rockwell Automation/Allen-Bradley – 2004 www.ab.com/motion • 5.“DSP Solution for Permanent Magnet Synchronous Motor”,Texas Instruments • 6.Ashish Tewari, “Modern Control Design With MATLAB and SIMULINK” • 7.Dean C. Karnopp, Donald L. Margolis, Ronald C. Rosenberg • “System Dynamics : Modeling and Simulation of Mechatronic Systems” • 8.D.M. Auslander, J.R. Ridgely, J.D. Ringgenberg, David M. Auslander • “Control Software for Mechanical Systems: Object Oreiented Design in a Real Time World” • 9.Gabriele Canini, Cesare Fantuzzi“Controllo del moto per macchine automatiche”, Pitagora Editrice, Bologna 2003 • 10.Claudio Melchiorri“Traiettorie per azionamenti elettrici”, Progetto Leonardo, Bologna 2000 • 11.“Tecniche di misura digitale lineare e angolare”,Heidenhain • “Intelligent Control Systems Using Soft-Computing Methodologies”, • Ali Zilouchian,Mo Jamshidi, CRC Press

6. Bibliography: internet links • Bosch internet site: http://app10.bosch.de//en/default.htm • Danaher Motion internet site: http://www.danaher.com/ • Elau internet site: http://www.elau.de/english/framesets/frhomenic.htm • HDD internet site: http://www.hdd.se/ • Kollmorgen internet site: http://www.kollmorgen.de/, http://www.kollmorgen.com/ • Mektron – Pacific Scientific internet site: http://www.mektroninc.com/pacsci.html • Pacific Scientific internet site: http://www.industry.net/c/mn/017k3 • Parker internet site: http://www.parker-emd.com/uk/ • Rexroth – Indramat internet site: http://www.indramat.com/ • Texas Instruments internet sites: http://www.ti.com/, http://www.ti.com/sc/momentum/dm2sa2x6t4, • B&R internet site: http://www.br-automation.com/welcome.htm • Baldor internet site: http://www.baldor.com/ • Festo internet sites: http://www.festo.com/, http://www.festo.com/food/eng/index.htm • GE-Fanuc internet site: http://www.gefanuc.com/index.asp • HydraForce Hydraulic Cartridge Valves internet site: http://www.hydraforce.com/ • Rockwell Automation internet site: http://www.automation.rockwell.com/ • SERCOS related links: http://www.sercos.com/links.htm • Siemens Machine Control Systems – Packaging internet site: http://www.aut.sea.siemens.com/machine/systems/packaging.html • Stegmann encoders: http://www.stegmann.de/english/html/produkte/index.html

7. Why Automation? • The machinemakes FAULTS that can be: • Detected • Measured • Corrected • Predicted • Manmakes ERRORS that, not always, can be: • Detected • Measured • Corrected • Predicted

8. Mechatronics: what’s in a name… • Mechanical system control is undergoing a revolution in which the primary determinant is becoming the control software. This is enabled by developments in electronics and computer technology. • Mechatronics (Yaskawa Electric, 1970): “new kind of mechanical system where the electronics take the decision-making function formerly performed by mechanical components…” • Mechatronics (now, 2004): …there has been a shift from electronics to software as primary decision-making software, the definition thus becoming: • “The application of complex automatic decision-making to the operation of physical systems”. • Real time software differs from conventional software in that its results must not only be numerically and logically correct: they must also be delivered at the correct time; it must embody the concept of duration.

9. Other Components Operator Interface e.g. communication i.e. human factors Computation i.e. SW + HW Actuation Feedback i.e. energy conversion, power modulation i.e. energy conversion, signal processing Target System Mixture of: mech., fluid., therm., chem., electrical Parts of a mechatronic system

10. set point controller actuator PLANT sensor General Control System

11. D I - - + + S - + - P + Analog Controller

12. clock host DSP DAC Load PA M PID ANALOG WORLD DIGITAL WORLD ADC sensor Digital Controller

13. ANALOG vs. DIGITAL Controllers DIGITAL Diagnostics Programmable (SW) Not depending on environment (temp., pressure, humidity, …) Deterministic behaviour Advanced Algorithms * Memory HMI Quantization (discr. represent.) Truncation (16x16=32bit) Limit Cycles Register Overflow Sampling Rate • ANALOG • Huge bandwidth (no sampling) • Resolution • Easy design • Time-dep. Performances • Temperature drift • HW design: no easy change • Trimmers Pros Cons

14. *Examples of Advanced Algorithms that can be implemented on Digital Controllers: • Kalman Filters (optimal observer) • LQR – Linear Quadratic Regulator (optimal controller) • Adaptive Control • Possibility to handle non-linear systems • Fuzzy Logics • Neural Networks • DNA Computing • Time Sharing Multitasking • FFT – Fast Fourier Transform (time => frequency) • Debugging Functions • HMI – Human Machine Interface • Data Logging • Data Communications (Field Bus) • Sensorless Algorithms

15. “Il Mondo del Packaging” • Solid • Food • others… • Pharmaceutical • Semi-Solid • Food • Toys • Pastorized • Liquid Food • Cigarettes • Tissues • Aseptic • Liquid Food • Personal • Care • Beve- • rages • Chocolate • Beauty Care

16. Raw Material Supply (e.g.: trees) The Packaging Material (e.g.: carton layers) Converting T h e P a c k a g e Card Board Packing Fill Cap Palletize Label Food Treatment (e.g.: UHT, Past.) The Product Food Supply (e.g.: cows)

18. Openings

19. Filling Machine animation

20. Filling Machine (cont’d)

21. Packaging Line

22. Esempio di Packaging Line

23. ...at the customer site

24. Distribution Equipment Macchine automatiche situate dopo la macchina riempitrice (filling machine) • Accumulators • Cap Applicators • Card-Board Packers • Film Wrappers • Handle Applicators • Straw Applicators • etc..

25. Mechatronics on Packaging Machines

26. Packaging Line Monitoring System modem Automatic data logging Data transfer - modem/diskette Data analysis - off line software An excellent tool to analyse and improve performance & quality

27. 3 Generations of Motion Control • I Generation: Fully ANALOG • II Generation : ANALOG and DIGITAL • III Generation : Fully DIGITAL and INTEGRATED with STANDARD IEC1131-3 programming languages

28. Bits of history… The TypewriterServo : Packaging Machines = Electronics : Typewriter • Mechanical • Electromechanical • Electric • Electronic • Word Processor • PC with impact Printer • PC with laser printer • PC with ink jet printer • Email chronology

29. Where is the performance limit? • First the limit was in the Motordue to the backlash in the key slot and/or other backlashes or static/starting friction (that is the same thing since with applied current there’s no motion). • Then the limit became the Electronics • due to the low band-width. • Now the limit is the system Resonance Frequencydue to elasticity and inertias. • 1) limit the gains (bw =G/J) • 2) Notch or Low Pass Filter • 3) high stiffness (direct drive solution) • In 2) and 3) I can have high gains high resolutionsincos encoder (0.01” or 1nm accuracy)

30. Drive Drive Drive Drive Drive Drive M M M M M M Multiaxes Systems Industry-wide Interface Industry Guideline Compliant Machine Interface Sensor Network Machine Controller Motion Network OEM Core Competency

31. Machine Machine supervisor Machine controller Module Module Module Module Module supervisior Module supervisior Module supervisior Module supervisior Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Sub Module Modular Software & Software modeling

32. Packaging Line Line Supervisor Line Controller Modular Software & Software modeling (cont’d)

33. Multiaxes Systems (cont’d) animazione • Packaging Machine: 3-50 axes: toward 100 axes machines on the long run (Human Body:150 axes, i.e. 300 muscles with 2 muscles to give one complete degree of freedom) • Each motor has a: • winding (power) cable • feedback cable (encoder or resolver) • PTC temperature sensor wirings and, if present, brake wirings • Each power cable is attached to a drive (one drive generally drives one motor).

34. Position, Speed, Current Loop Field bus Controller, Profile Generator Position, Speed, Current Loop M Position, Speed, Current Loop M Position, Speed, Current Loop M Position, Speed, Current Loop M M M DC-bus Multiaxes Systems(cont’d) • The ideal partition line has to be found: • …for having the field bus • band-width as low as possible. • Solution: close every loop in the drive or integrate the electronics in the motor (but I would have the DC bus running through the whole machine for having breaking/acceleration actions balanced among all axes, as a mechanical shaft would do).

35. Programming Interface With a field bus, the axis becomes only an object of the bus: I can connect the PC to any bus point for monitoring/accessing any bus device

36. HW Architecture: example 1 4ms coarse update rate (7 axes) 125ms pos. loop

37. HW Architecture: example 2 4ms coarse update 125ms pos. loop ControlLogix MPL Motors Devicenet Axis Board(s) Ethernet L63 CPU I/Os Kinetix 6000 RS Logix 5000

38. SW: IEC1131-3 General Approach • LADDERfor process logics with boolean and continuous environment • SFCwhen pending from motion commands to be terminated • STwhen heavy bunch of code need to be written in a “linear” form • FBDfor continuous algorithms such as design PID

40. Motion Application Flow Chart

41. Motion Application Flow ChartDETAILED

42. Motion Application UML (high-level)

43. SFC Application Main(example 1)

44. A3-Flex RockwellSW Architecture (example 1) Periodic Task Very high priority Periodic or Cont. Task Low priority Periodic Task High priority ST ST ST Error Handler PLC Logics Motion Control ST SFC Error Detection SFC Main SFC resets SFC SFC Error Manager Home Search., ON-OFF servos, run-stop prod., mainten.-service routines JSRs ST SFC Single Instructions Group of move.s Ladder Single Instructions SFC Single move.s ST Single Instructions

45. “Flat” Implementation:example 2

46. Structured Text Code Sample ST (not IEC1131-3) Language

47. video IEC1131-3 Code Sample IEC1131-3 Languages: ST, SFC, Ladder, FBD

48. Profiles calculation SFC+ST implementation for motion UML design Debugging LADDER Implementation for PLC Mech. Design Manufacturing Assembly • The approach has been: