PLC Pneumatic Manipulator Control System
As common equipment in China's industrial field, the pneumatic manipulator has the advantages of simple structure, long service life, simple operation and quick action. The pneumatic manipulator has successfully expanded the application scope of the manipulator by virtue of the characteristics of the pneumatic transmission. With the industrial demand for higher standards, pneumatic manipulator is gradually developing toward intelligence. As the core technology of pneumatic manipulators, there are still some problems in the current development of PLC control technology. If these problems can be optimized, the intelligence of the pneumatic manipulator will achieve better development.
The pneumatic manipulator control structure
The importance of manipulators in the industrial field is self-evident. There are three types of manipulators, namely, manual manipulators, electric manipulators and pneumatic manipulators. Because pneumatic manipulators can expand the application range of manipulators, pneumatic manipulators have become a common choice in the industrial field.
With the development of science and technology and people's stricter requirements for machining technology, the requirements for the manipulator are not only up and down, left and right or telescopic functions, but also the pneumatic manipulator is now required to realize automatic work, that is, the automatic control of the pneumatic manipulator is carried out through PLC control system. The control structure of a pneumatic manipulator consists of two parts: a pneumatic device and a PLC control system, among which there are three control elements of the pneumatic device, namely a one-way valve, a one-way throttle valve and a pilot solenoid valve. The actuators of the pneumatic device are the air cylinder and pneumatic motor, which can convert the air pressure in the device into mechanical energy. There are several basic functional modules in the operation of the manipulator, namely, the manual operation module, semi-automatic operation module and fully automatic operation module. Among them, the most basic function of the pneumatic manipulator is manual control. The purpose of setting this function is to prevent mechanical failure and to manually control mechanical return when power is cut off. The semi-automatic operation module controls the start and stops of machinery manually, and this process also needs the participation of the PLC control system. The fully automatic operation module realizes the independent operation of the manipulator. If the corresponding program is set directly in the system, the manipulator will operate according to the established route.
Design of pneumatic manipulator control system based on PLC
Pneumatic manipulator is widely used in various industries because of their simple operation and strong anti-interference ability. Programming with PLC to control the operation of a pneumatic manipulator can make it run automatically, which can not only save manpower but also effectively protect the safety of operators. Therefore, it is very important to design this program to make the manipulator run reasonably. The design of the PLC control system of the manipulator is divided into four parts, namely the overall design of the manipulator and the hardware of the PLC control system.
1. Overall design
In the traditional control system of the pneumatic manipulator, there are some problems such as complicated internal wiring, poor flexibility and low reliability, and the application of PLC perfectly solves these problems. PLC is an electronic device operated by digital operation. Using PLC to control the manipulator is to use a specific algorithm to control the input and output of physical quantities. Through these physical quantities, relevant data can be obtained, so as to achieve the purpose of controlling the manipulator. In the overall design, there are three processes, namely input, execution and output. The input is the condition at the beginning of the task, and then the manipulator is controlled to perform the task through a certain program. Finally, the manipulator finishes the work after reaching a certain condition and stops running.
2. Hardware design of 2.PLC control system
PLC selection
Using PLC to control the pneumatic manipulator mainly depends on the cylinder action, and whether the cylinder action can accurately control the manipulator action is mainly judged by the magnetic limit switch. In the cylinder of the pneumatic manipulator, it is necessary to detect the two movements of extension and retraction. Therefore, in the design, limit switches should be installed for these two movements, together with the actions of starting and stopping, as well as the input and output points needed by the manipulator to perform the movements such as lifting or stretching. Different manipulators have certain differences in the requirements of input and output points due to different purposes. When selecting PLC, the number of input and output points and the quality of PLC should be considered, which is what should be paid attention to when selecting PLC.
Design of manipulator control panel
The control panel design of the manipulator is also carried out according to the specific requirements, and it is necessary to select the working mode before the specific operation. Figure 1 shows the design example of the manipulator control panel. Its different functions all share a switch. When selecting different functions, you can switch by twisting the switch.
Figure 1 Legend of the manipulator control panel
Design of PLC external electrical wiring
According to different uses, as well as the characteristics of the control system at work, combined with the control mode of the PLC system, the external electrical wiring diagram of PLC is designed.
Programming of PLC control system
In the programming of the PLC control system, some specific algorithms are needed, such as the recursive method and backtracking method. When programming, different designs will be made according to the working purpose of the manipulator, that is, programming will be made according to its function, and the control system will be divided into three categories by function, namely initialization program, return-to-original program and automatic program.
Initialization program design
In order to reset the electronic components such as the status relay and carry out the next program execution smoothly, the initialization program should be designed, and the PLC itself can provide an M8002 initial pulse for the pneumatic operation of the program.
Back-to-home programming
In the process of the manipulator's work, because the established procedure starts from the original position, if there are some unexpected situations in the middle, such as power failure, mechanical failure, etc., it is necessary to reset the manipulator. Otherwise, the manipulator cannot continue to run according to the established procedure, which will affect the manipulator's work. Therefore, it is necessary to design a procedure to return the manipulator to its original position. Whether the manipulator is in the original position is judged by its sucker and cylinder state. When the manipulator is in the original position, its sucker is in a vacuum state, and the cylinder is also in the original state. When the cylinder is in the original state, the lifting cylinder will be in the ascending limit state, the horizontal cylinder will be in the retracting limit state, and the manipulator as a whole will be in the left-turning limit state.
Automatic programming
Automatic program design determines the operation state of the manipulator, which is divided into two parts, namely the automatic mode sequential function diagram and the automatic program ladder diagram.
Automatic mode sequence function diagram
When the robot manipulators operate automatically, their different actions have sequences, so as to ensure the smooth operation of the robot manipulators. The sequence of automatic mode is related to the stability of the robot manipulators, so it is a particularly important link in the overall program design of robot manipulator automation. The specific design process is as follows: the automatic system first confirms whether the manipulator is in the initial position, and if it is in the initial position, it starts the automatic operation of the program. After receiving the instruction to start the operation, the automatic operation system of the manipulator starts the fixed operation according to the established program and repeats it periodically until the staff presses it. Stop button, then the manipulator will stop the ongoing work and automatically return to the initial position, which is convenient for the next work.
Automatic program ladder diagram
Although automatic production improves the efficiency of industrial production, it will also be plagued by the problem of product accumulation. The products produced by the pneumatic manipulator will be stacked in a fixed position, but if the products in this position are not cleaned up in time, the over-stacked products will eventually affect the operation of the pneumatic manipulator. It may even cause the pneumatic manipulator to be stuck and damaged, and bring losses to the enterprise. By designing the ladder diagram of the automatic program, the problem of product accumulation can be effectively solved. When the products are piled up to a certain amount, the pneumatic manipulator will automatically stop working, and the pneumatic manipulator will start the production of the products after the workers clean up the accumulated products. The ladder diagram of the automatic program of the pneumatic manipulator is designed according to the purpose of the pneumatic manipulator and the storage capacity of the product pool.
Communication design
The communication system is the core of the PLC control system, and it is the way for the pneumatic manipulator control system to perceive the external environment. When the pneumatic manipulator works, its position determines the next instruction of the control system, and the control system controls the pneumatic manipulator through the information fed back by the communication system. For example, when the pneumatic manipulator needs to be reset, the communication system will feed back the current position of the pneumatic manipulator to the control system, and the control system will "issue" a control command to control the pneumatic manipulator to complete the reset. The control system will also judge the operation state of the pneumatic manipulator according to the data information fed back by the communication, and can automatically stop the operation of the pneumatic manipulator once a fault is found. There are two ways of data communication, one is serial, which has the advantages of slow transmission speed, low cost and simple design, so it is widely used in PLC control systems. For parallel, compared with serial, the information transmission speed is obviously faster, but its cost is relatively high. Enterprises need to strictly control production costs in order to increase their operating profits. Although the speed of information dissemination in parallel mode is fast, compared with serial mode, its cost performance is relatively low, so enterprises generally don't choose this high-cost mode.
Control system test
After the programming of the pneumatic manipulator is completed, it needs to be tested to ensure the stability of the program. The general test process is as follows: firstly, make sure that the pneumatic manipulator is in the initial state; if the pneumatic manipulator is in other positions, it needs to be manually reset and adjusted. After the pneumatic manipulator is adjusted to the initial position, the test of the control system can be started, and the system can control the operation of the pneumatic manipulator to complete operation. Testers should observe every detail of the pneumatic manipulator operation and make records. The first test of the pneumatic manipulator control system is dangerous, so testers should pay attention to it.
To protect your personal safety, if you find any problems in the operation of the pneumatic manipulator, you should immediately stop the test, correct the problems in the control system of the pneumatic manipulator, and continue the test until all hidden dangers are eliminated, and ensure that the pneumatic manipulator can keep working normally in continuous operation for many times.
Conclusion
The pneumatic manipulator can provide a lot of productivity for enterprises, save labor costs, improve production efficiency and create more profits for enterprises. For industrial production, a pneumatic manipulator is very important. In today's society, people have increasing demand and dependence on highly automated equipment, and the full automation of pneumatic manipulators is more conducive to industrial production and can create greater value for enterprises. Based on the PLC system, the automatic operation of the pneumatic manipulator can be realized. According to different production requirements, different control systems need to be designed. Designers should strictly control all aspects of design, so as to avoid loopholes in program design, resulting in the failure of the pneumatic manipulators and even enterprise losses. After the completion of the design, the system test must be carried out strictly to avoid problems caused by program loopholes. In addition, enterprises can choose a PLC control system according to their own conditions, which not only meets the needs of business operations but also saves costs for enterprises as much as possible.
The pneumatic manipulator control structure
The importance of manipulators in the industrial field is self-evident. There are three types of manipulators, namely, manual manipulators, electric manipulators and pneumatic manipulators. Because pneumatic manipulators can expand the application range of manipulators, pneumatic manipulators have become a common choice in the industrial field.
With the development of science and technology and people's stricter requirements for machining technology, the requirements for the manipulator are not only up and down, left and right or telescopic functions, but also the pneumatic manipulator is now required to realize automatic work, that is, the automatic control of the pneumatic manipulator is carried out through PLC control system. The control structure of a pneumatic manipulator consists of two parts: a pneumatic device and a PLC control system, among which there are three control elements of the pneumatic device, namely a one-way valve, a one-way throttle valve and a pilot solenoid valve. The actuators of the pneumatic device are the air cylinder and pneumatic motor, which can convert the air pressure in the device into mechanical energy. There are several basic functional modules in the operation of the manipulator, namely, the manual operation module, semi-automatic operation module and fully automatic operation module. Among them, the most basic function of the pneumatic manipulator is manual control. The purpose of setting this function is to prevent mechanical failure and to manually control mechanical return when power is cut off. The semi-automatic operation module controls the start and stops of machinery manually, and this process also needs the participation of the PLC control system. The fully automatic operation module realizes the independent operation of the manipulator. If the corresponding program is set directly in the system, the manipulator will operate according to the established route.
Design of pneumatic manipulator control system based on PLC
Pneumatic manipulator is widely used in various industries because of their simple operation and strong anti-interference ability. Programming with PLC to control the operation of a pneumatic manipulator can make it run automatically, which can not only save manpower but also effectively protect the safety of operators. Therefore, it is very important to design this program to make the manipulator run reasonably. The design of the PLC control system of the manipulator is divided into four parts, namely the overall design of the manipulator and the hardware of the PLC control system.
1. Overall design
In the traditional control system of the pneumatic manipulator, there are some problems such as complicated internal wiring, poor flexibility and low reliability, and the application of PLC perfectly solves these problems. PLC is an electronic device operated by digital operation. Using PLC to control the manipulator is to use a specific algorithm to control the input and output of physical quantities. Through these physical quantities, relevant data can be obtained, so as to achieve the purpose of controlling the manipulator. In the overall design, there are three processes, namely input, execution and output. The input is the condition at the beginning of the task, and then the manipulator is controlled to perform the task through a certain program. Finally, the manipulator finishes the work after reaching a certain condition and stops running.
2. Hardware design of 2.PLC control system
PLC selection
Using PLC to control the pneumatic manipulator mainly depends on the cylinder action, and whether the cylinder action can accurately control the manipulator action is mainly judged by the magnetic limit switch. In the cylinder of the pneumatic manipulator, it is necessary to detect the two movements of extension and retraction. Therefore, in the design, limit switches should be installed for these two movements, together with the actions of starting and stopping, as well as the input and output points needed by the manipulator to perform the movements such as lifting or stretching. Different manipulators have certain differences in the requirements of input and output points due to different purposes. When selecting PLC, the number of input and output points and the quality of PLC should be considered, which is what should be paid attention to when selecting PLC.
Design of manipulator control panel
The control panel design of the manipulator is also carried out according to the specific requirements, and it is necessary to select the working mode before the specific operation. Figure 1 shows the design example of the manipulator control panel. Its different functions all share a switch. When selecting different functions, you can switch by twisting the switch.
Figure 1 Legend of the manipulator control panel
Design of PLC external electrical wiring
According to different uses, as well as the characteristics of the control system at work, combined with the control mode of the PLC system, the external electrical wiring diagram of PLC is designed.
Programming of PLC control system
In the programming of the PLC control system, some specific algorithms are needed, such as the recursive method and backtracking method. When programming, different designs will be made according to the working purpose of the manipulator, that is, programming will be made according to its function, and the control system will be divided into three categories by function, namely initialization program, return-to-original program and automatic program.
Initialization program design
In order to reset the electronic components such as the status relay and carry out the next program execution smoothly, the initialization program should be designed, and the PLC itself can provide an M8002 initial pulse for the pneumatic operation of the program.
Back-to-home programming
In the process of the manipulator's work, because the established procedure starts from the original position, if there are some unexpected situations in the middle, such as power failure, mechanical failure, etc., it is necessary to reset the manipulator. Otherwise, the manipulator cannot continue to run according to the established procedure, which will affect the manipulator's work. Therefore, it is necessary to design a procedure to return the manipulator to its original position. Whether the manipulator is in the original position is judged by its sucker and cylinder state. When the manipulator is in the original position, its sucker is in a vacuum state, and the cylinder is also in the original state. When the cylinder is in the original state, the lifting cylinder will be in the ascending limit state, the horizontal cylinder will be in the retracting limit state, and the manipulator as a whole will be in the left-turning limit state.
Automatic programming
Automatic program design determines the operation state of the manipulator, which is divided into two parts, namely the automatic mode sequential function diagram and the automatic program ladder diagram.
Automatic mode sequence function diagram
When the robot manipulators operate automatically, their different actions have sequences, so as to ensure the smooth operation of the robot manipulators. The sequence of automatic mode is related to the stability of the robot manipulators, so it is a particularly important link in the overall program design of robot manipulator automation. The specific design process is as follows: the automatic system first confirms whether the manipulator is in the initial position, and if it is in the initial position, it starts the automatic operation of the program. After receiving the instruction to start the operation, the automatic operation system of the manipulator starts the fixed operation according to the established program and repeats it periodically until the staff presses it. Stop button, then the manipulator will stop the ongoing work and automatically return to the initial position, which is convenient for the next work.
Automatic program ladder diagram
Although automatic production improves the efficiency of industrial production, it will also be plagued by the problem of product accumulation. The products produced by the pneumatic manipulator will be stacked in a fixed position, but if the products in this position are not cleaned up in time, the over-stacked products will eventually affect the operation of the pneumatic manipulator. It may even cause the pneumatic manipulator to be stuck and damaged, and bring losses to the enterprise. By designing the ladder diagram of the automatic program, the problem of product accumulation can be effectively solved. When the products are piled up to a certain amount, the pneumatic manipulator will automatically stop working, and the pneumatic manipulator will start the production of the products after the workers clean up the accumulated products. The ladder diagram of the automatic program of the pneumatic manipulator is designed according to the purpose of the pneumatic manipulator and the storage capacity of the product pool.
Communication design
The communication system is the core of the PLC control system, and it is the way for the pneumatic manipulator control system to perceive the external environment. When the pneumatic manipulator works, its position determines the next instruction of the control system, and the control system controls the pneumatic manipulator through the information fed back by the communication system. For example, when the pneumatic manipulator needs to be reset, the communication system will feed back the current position of the pneumatic manipulator to the control system, and the control system will "issue" a control command to control the pneumatic manipulator to complete the reset. The control system will also judge the operation state of the pneumatic manipulator according to the data information fed back by the communication, and can automatically stop the operation of the pneumatic manipulator once a fault is found. There are two ways of data communication, one is serial, which has the advantages of slow transmission speed, low cost and simple design, so it is widely used in PLC control systems. For parallel, compared with serial, the information transmission speed is obviously faster, but its cost is relatively high. Enterprises need to strictly control production costs in order to increase their operating profits. Although the speed of information dissemination in parallel mode is fast, compared with serial mode, its cost performance is relatively low, so enterprises generally don't choose this high-cost mode.
Control system test
After the programming of the pneumatic manipulator is completed, it needs to be tested to ensure the stability of the program. The general test process is as follows: firstly, make sure that the pneumatic manipulator is in the initial state; if the pneumatic manipulator is in other positions, it needs to be manually reset and adjusted. After the pneumatic manipulator is adjusted to the initial position, the test of the control system can be started, and the system can control the operation of the pneumatic manipulator to complete operation. Testers should observe every detail of the pneumatic manipulator operation and make records. The first test of the pneumatic manipulator control system is dangerous, so testers should pay attention to it.
To protect your personal safety, if you find any problems in the operation of the pneumatic manipulator, you should immediately stop the test, correct the problems in the control system of the pneumatic manipulator, and continue the test until all hidden dangers are eliminated, and ensure that the pneumatic manipulator can keep working normally in continuous operation for many times.
Conclusion
The pneumatic manipulator can provide a lot of productivity for enterprises, save labor costs, improve production efficiency and create more profits for enterprises. For industrial production, a pneumatic manipulator is very important. In today's society, people have increasing demand and dependence on highly automated equipment, and the full automation of pneumatic manipulators is more conducive to industrial production and can create greater value for enterprises. Based on the PLC system, the automatic operation of the pneumatic manipulator can be realized. According to different production requirements, different control systems need to be designed. Designers should strictly control all aspects of design, so as to avoid loopholes in program design, resulting in the failure of the pneumatic manipulators and even enterprise losses. After the completion of the design, the system test must be carried out strictly to avoid problems caused by program loopholes. In addition, enterprises can choose a PLC control system according to their own conditions, which not only meets the needs of business operations but also saves costs for enterprises as much as possible.