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Retrofitting of PLC,CNC and VVVF Drives in a Double Column Planning Machine in Order to Improve Efficiency

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Retrofitting of PLC,CNC and VVVF Drives in a Double Column Planning Machine in Order to Improve Efficiency Retrofitting of PLC,CNC and VVVF Drives in a Double Column Planning Machine in Order to Improve Efficiency Rathina kumari.T1,Sathya.K2,Siva sankari.K3,Suganya.P4 1,2,3&4BE-Student of EEE,Kalasalingam Institute of Technology,Virudhunagar. E-mail:[email protected], [email protected], [email protected], & [email protected] Abstract – The project deals with the preparation So it is proposed to control the table movement by process of boiler drum shells before welding. The using an AC induction motor. And the speed of the AC operation process (planing) involved in double motor is controlled by using variable voltage variable column planing machine is based on thyristor frequency drives(VVVF drives). control system. When the tool or job for It is advisable to retrofit the system with themachining has to be set, table in the planing PLC and CNC to make the system more reliable and machine has to be moved..Motion control of the table semi automatic. By this accuracy of greatest site is is provided with the help of a Variable Voltage achieved. Variable Frequency (VVVF) drives. The primary purpose of a Variable Frequency drive is to provide The CNC is used for position control and the CNC speed control for an AC motor with reduced losses is used for logical control. CNC operates the machine and also to provide current limit and automatic tools by sending a series of coded instruction, The PLC speed regulation for the motor. The whole manual lists the coded instructions or commands in a logical process of operation is made semi-automatic with the sequence. The introduction of PLC controllers totally help of Computer Numeric Control (CNC) and eliminates huge volumes of contactors or relays. Hence Programmable Logic Control (PLC). the machine maintainability, productivity and the speed control of the table motion can be improved due to Key wards: Drives,PLC,CNC technology up gradation. I. INTRODUCTION II. EXPLANATION FOR THE SCHEMATIC DIAGRAM: Double column planning machine or double column Plano miller as the name indicates that is used mainly for planning purposes. Double column planning machine has the structure supported by two columns support a cross beam. In between the two column longitudinally there is a bed fixed to the ground. The bed consists of V shaped groves at the two sides which continuous along the bed in the longitudinal direction. Above the bed there is a rigid table which is half the length of bed, which moves to & fro along the bed in the longitudinal length of two v shaped grooves. It has inflow of oil through lubrication system for providing frictionless path of table on the bed. The speed control of the DC motor is done by ward leonard system. Difficulties of this method are a) it is not energy efficient. b) produces heavy noise c) results in wastage of power that accounts 30%. Fig1:Schematic diagram of planing machine ISSN (PRINT) : 2320 – 8945, Volume -1, Issue -4, 2013 33 ITSI Transactions on Electrical and Electronics Engineering (ITSI-TEEE) The above figure shows the structure of double column planning machine.In the double column planing machine, the planing operation is performed after mounting the job on the top of the table. This planning operation has to be done in a sequential manner as per the requirements, in order to minimize energy losses and to increase the job accuracy. Hence for the purpose the manual system has been converted as semi-automatic with the help of PLC and CNC. Before the table movement, the motor and its corresponding drive receives enable signal from the heart of the machine which is nothing but the CNC. The purpose of the CNC is to control the various types of motion employed in the machine along with the help of PLC. The PLC is a Fig 2: Ward leonard system programmable controller which is mainly employed for The ward-leonard control system has two groups of the logical sequential control of these various types of arrangements. One is generator group and the other is motion. Here the PLC works only when there is an motor group. Here we use three generators named as enable signal from the drives, CNC and machine G1,G2, G3 and two A.C. motors M1 and M2.The motor elements input. The ESA operator panel is the interface M1 is used to drive generators G1 and G2 with same panel unit which interfaces the CNC along with the PLC speed, and the motor M2 is used to drive G3. G3 is the through the serial communication ports. The input to the main generator because it gives the input supply to the CNC is in the form of built in machine codes which has armature of motor M3, which is used to drive the been provided by the manufacturer. But the input to the machine in an industry such as planning and milling PLC is through programming. The encoder is employed machine.The generator G1 has resistance switch which in order to sense the motor output and provide current is used to regulate the G2 which is fed to the field feedback to the motion. Here the drives employed are of winding of G3. Sowe regulate the G3 output supply by variable voltage variable frequency drives, where the varying the resistance switch. Similarly the output of G1 V/F ratio is maintained constant in order to acquire is directly connected to the field of motor M3. The smooth variation of motor speeds without any increase speed of motor M3 is varied by varying the generator in the torque as well as the current. Here the motion set. The ward-leonard system works on the principle that table is such that accelerates, then runs at constant speed speed is varied by varying both armature and field. It is and it terminates after the deceleration. Here the drives also said as the voltage control method. The speed of the operate in the closed vector mode. Hence losses are motor can be controlled or varied by varying the reduced as they are provided as feedback to the system switching resistance connected in generator G1. It varies itself. For each and every motor a separate drive has both field and the armature of the motor. It directly been provided based on the type of requirement, mode varies the field of the motor but armature is varied by of operation and its application. Depending upon the varying the field of G3. A reversing switch is also mode of operation both the drives namely motoring provided to reverse the motor direction. The main drive and the regenerating drive is provided for the disadvantage of using ward-leonard system is less same motor. Motoring drive is operated when the motor efficiency because it requires an external supply for the drives normally in the forward direction. In cases such a two A.C. motors and the reliability of motor-generator breakdown or during the g failure of supply, the set is also less. So the overall efficiency of the machine regenerating drives redirects the previously retained is also poor. voltage back to the source , thereby preventing the motor from damage due to over current. IV. VVVF DRIVES (Variable Voltage Variable Frequency drives): III. EXISTING SYSTEM: Motion control is required in large number of Ward-Leonard Control System industrial and domestic application like transportation Ward-Leonard system is the precision control systems, rolling mills, textiles mills, fans, pumps etc. method to control method to control the speed of D.C. Systems employed for motion control are called drives motor. This method is most popularly used in many and may employ any of the prime movers such as diesel industrial applications. or petrol engines, gas or steam turbine, steam engines, hydraulic motor, electric motor for supplying ISSN (PRINT) : 2320 – 8945, Volume -1, Issue -4, 2013 34 ITSI Transactions on Electrical and Electronics Engineering (ITSI-TEEE) mechanical energy for motion control. VVVF drives are Computer Numeric Control (CNC) nothing but variable voltage variable frequency drives. Numeric control can be defined as a form of programmable automation, in which the process is controlled by the numbers, Letters and symbols. In NC, the numbers form a program of instructions designed for a particular work part or job. When the job changes instruction of program is changed. This ability to change the program for each new job is what gives NC its flexibility. It is much easier to write new program then to make production equipment.NC technology is applied to variety of operations including drafting, assembly Inspection, sheet metal press working and welding. However NC finds its principle application in metal machining process.CNC is an NC system that utilizes the dedicated, stored program Computer to perform Fig 3: Block diagram of VVVF drives some or all of the basic numeric control functions. Because the trend towards downsizing in computers, The above figure shows the internal components of most of the CNC system sold today used a a vvvf drive. The source may be an AC source or a DC microcomputer based controller unit. Over the year’s source. The power modulator modulates flow of power microcomputer have also been used in CNC controls. from the source to motor such that motor is imparted The external appearance of the CNC machine is very speed-torque characteristics regarding by the load. The similar to that of conventional NC machine. Part modulator also coverts electrical energy of the source in programs are initially entered in a similar manner. the form suitable to the motor. The controls of power Punched tapes are still the common device to input the modulator are built in the control unit, which usually programming to the system.
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