1. INTERNATIONAL JOURNAL OF ELECTRICALISSN 0976 – 6545(Print),
International Journal of Electrical Engineering and Technology (IJEET), ENGINEERING
ISSN 0976 – 6553(Online) Volume 3, Issue 3, October – December (2012), © IAEME
& TECHNOLOGY (IJEET)
ISSN 0976 – 6545(Print)
ISSN 0976 – 6553(Online)
IJEET
Volume 3, Issue 3, October - December (2012), pp. 130-136
© IAEME: www.iaeme.com/ijeet.asp ©IAEME
Journal Impact Factor (2012): 3.2031 (Calculated by GISI)
www.jifactor.com
EMBEDDED CONTROLLER USING MOTION CONTROL OF MOTOR
Ms. Mrudula A. Mulay Prof. J.G. Rana
J.N.E.C. Aurangabad J.N.E.C. Aurangabad
ashwinipade@yahoo.co.in jgr@gmail.com
ABSTRACT
This tutorial paper presents the results of solving speed and position control problems by using
embedded controllers. A feature of these controllers is that the sample time is not explicitly
included in the integral and derivative control equations. This feature was experimentally tested.
In the testing of the integral control with such feature, the controller was applied to a speed
regulation problem under the condition of rapidly changing load. In the testing of the derivative
control with the same feature, the controller was applied to a ringing removal problem.
These controllers performed as expected. All the embedded controllers were implemented in a
member of freescale Semiconductor's microcontroller family
Keywords: Limit Switch, Stepper Motor, microcontroller 89v51
INTRODUCTION
All recent industrial development in depend on the automation. For accuracy and other various
purposes automation is required in the industry. For doing automation accuracy is important
similarly cost required for the desired machine is also an important factor for them.
Embedded controller motion control of a machine can be an easy solution for it. If the embedded
controller will work for the controlling motion and speed of the motor then it may be very
beneficial. Because availability, cost , programming, replacement every thing can be easily
possible by using this type of controller.
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2. International Journal of Electrical Engineering and Technology (IJEET), ISSN 0976 – 6545(Print),
ISSN 0976 – 6553(Online) Volume 3, Issue 3, October – December (2012), © IAEME
We are concentrating on motion control of a motor. For using embedded controller for the
control action in this particular machine we are controlling the movement of the stepper motor,
as well as controlling switching of the AC motor.
Complex industry automation as well as complex computer nodes like high-end servers require
an infrastructure for maintenance and control. An off-the-shelf embedded controller is usually
the first choice for such purposes. This approach is challenged for complex applications by the
fact that a large amount of distributed industry standard interfaces has to be controlled and real
time responses have to be provided.
WORKING PRINCIPAL
Initially when we switched ON the system it will check for all drives are at home position. If it is
so, then cycle starts. The job is clamped at desired position on the disc. Then stepper motor
below the disc rotates in the 1200 angle. That is the stepper motor below the disc rotates from
Limit Switch LA to LB.
When the job comes in the position i.e. when stepper motor rotate up to the Limit Switch LB it
gives the signal to the controller at that time coil-20, coil-21,coil-40 and coil-41 becomes ON.
Coil-20, coil-21 is becomes on for the forward movement of the and stepper motor and coil-40
and coil-41 is used for the rapid movement of the stepper motor. The stepper motor starts
moving from Limit Switch LS3n to Limit Switch LS2n in a rapid movement.
As soon as stepper motor reaches at the Limit Switch LS2n position, the actual job of the AC
motor starts (Drilling, Cutting). This time we are not required the rapid speed. So the
microcontroller will give the instruction to switch OFF the coil 40 and coil 41. By switching
OFF the Coil 40 and coil 41 the stepper motor stops its rapid movement.
Motor will moves only in the forward direction for doing the required job. The distance required
to do the job for a motor is called feed travel. When the motion of the motor comes up to the
Limit Switch LS1 then AC motor stops, and coil 30 and coil 31 becomes ON which moves the
stepper motor in the reverse direction. As the stepper motor reaches to the Limit Switch LS3, the
coil 30 and coil 31 switched OFF.
CIRCUIT OPERATION
The basic controller device is a 89v51 microcontroller. This is an 8-bit microcontroller. It has
four input and output ports. This is sufficient for the operation of the system.
When the system turns on switching on signal is given to the microcontroller stepper motor starts
moving in the forward direction from limit switch 1 to limit switch 2 until the rotating induction
motor takes the required speed for the operation, from limit switch 2 to limit switch 3 required
operation is done as soon as stepper motor reaches up to limit switch 3 the required signal is
given to the controller input the direction of the stepper motor changes. It starts rotating in the
reverse direction.
To drive the stepper motor1,2 the driver IC ULN 2003 is used but, the current and voltage rating
of this stepper motor is very high to drive the motor, Darlington pair of transistors are used to
boost the voltage and current. According to the software installed in the microcontroller changes
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3. International Journal of Electrical Engineering and Technology (IJEET), ISSN 0976 – 6545(Print),
ISSN 0976 – 6553(Online) Volume 3, Issue 3, October – December (2012), © IAEME
forward and reverse direction of the motor. Here two driver circuits are required to drive the two
stepper motor.
To switch on the induction motor relay drives the ON/Off control for the motor. During the
reverse operation of stepper motor1,2 i. e. when the stepper motor reaches at limit switch 3
stepper motor starts moving in the reverse direction through the controller signals at the same
time the controller switch off the induction motor. Means during reverse direction of the stepper
motor induction motor is at rest.
As soon as stepper motor comes at the limit switch 1 the it gives the signal to the microprocessor
and it gives signal to drive the stepper motor3 which is situated under the revolving disk. The
stepper motor moves by the 1200 angle. As the motor moves in the desired angle it stops rotating
stop signal given to the microcontroller.
As stepper motor 3 stops rotating again stepper motor 1,2 starts moving in the forward direction
and the cycle gets repeated. During the process of the moving the stepper motor in the backward
and forward direction the declamping and clamping of the job is done.
STEEPER MOTOR
Specification of Stepper Motors
Type Torque Kg Voltage Current Weight in Kg. ø L
cm Volts Ampere/Phase (Appro.) mm mm
STM
60 6, 12 1.5, 2.5 7.3 108 165
1103
General Specifications for Machine
Sr. Feature Remark
No.
1 M/C Features
1) Mechanical structure - Heavy duty fabricated, stress relieved M/C base which
ensures vibration free performance
- LM Guide ways
2) Hydraulic power pack Std Assy
3) M/C Fixture stations Single station, separate for similar components if any
4) M/C Noise Minimum noise
5) Visual Indicators Tower lamp will be provided
6) Audio Indicators Optional : Buzzer will be provided after completion of
job.
7) M/C Overall dimensions L×W×H = @ 1500 × 1400 × 1700 (in mm)
8) M/C Visualization Acrylic sheets on M/C doors and control panel will be
provided
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4. International Journal of Electrical Engineering and Technology (IJEET), ISSN 0976 – 6545(Print),
ISSN 0976 – 6553(Online) Volume 3, Issue 3, October – December (2012), © IAEME
Sr. Feature Remark
No.
9) M/C Colour As per requirement
10) Counter for completed components Arrangement for counting of completed components
2 M/C Performance
1) Slide repeatability Within 20 µ (0.02 mm)
2) M/C Cycle time ----- (Tooling selection and Component geometry )
3) Spindle rpm As applicable
4) Spindle drive By V- belt & pulley
3 Electric Controls
1) Motor REMI make,
2) Control Voltage 24 V D.C.
3) Electrical controlling elements ---
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5. International Journal of Electrical Engineering and Technology (IJEET), ISSN 0976 – 6545(Print),
ISSN 0976 – 6553(Online) Volume 3, Issue 3, October – December (2012), © IAEME
Components Data
RAPID FEED
D1 D2 R1 R2 TOTAL TRAVEL TRAVEL TRAVEL
MODEL K ROTOR P 1102718 252 157 126 78.5 173 124 49
MODEL B ROTOR P 1102312 231 142 115.5 71 180.5 134.5 46
NMC ROTOR P 1100413 215 132 107.5 66 185.5 142.5 43
JEEP ROTOR - 1100819 290 199.5 145 99.75 151.75 105 46.75
YE2 ROTOR P 1101512 231 153 115.5 76.5 175 134.5 40.5
CULTUS ROTOR P 1101313 232 152 116 76 175.5 134 41.5
MODEL E ROTOR PD 1933 235 152.5 117.5 76.25 175.25 132.5 42.75
ISUZU AMB ROT P 1101918 256 163 128 81.5 170 122 48
HM ISUZU AMB ROT PD 2197 256 163 128 81.5 170 122 48
HM CONTESSA ROTOR 228 134 114 67 184.5 136 48.5
Settable parameters
Vc = Cutting Speed ----m/min
Vf.= Feed rate --- mm/rev
Component=
Tool home-Spindle dist.=
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6. International Journal of Electrical Engineering and Technology (IJEET), ISSN 0976 – 6545(Print),
ISSN 0976 – 6553(Online) Volume 3, Issue 3, October – December (2012), © IAEME
Slide Rapid rate.=
Stepper Full Step/Half Step.
Advantage
1. Availability :- Embedded controller is easily and widely available in the market.
Depending upon the requirement of the application one can select the required number of bit
processor
2. Simulation:- Can simulate easily.
By using C- programming, VB, Assembly language programming
3. Area required for the embedded controller card in the machine is very compact.
Requirement of area for the application is very compact as compared with other controllers.
4. On chip ADC is their so not needed to use external ADC. Analog signal is directly
converted in to the digital form
5. Flash Memory :- All microcontrollers are having the flash memory feature so that you
can easily change your program according to your requirement.
6. High speed for Low programming overhead
7. Simple interface
8. Low cost for low-resolutions
9. High speed for Low programming overhead
10. High throughput: Several bitsare transmitted on one clock transition
Disadvantages
1. Data and clock lines can be shared but each device requires a separate Chip Select
2. signal, limiting the number of devices in limited I/O systems
3. High cost for higher resolutions
4. Not all microcontrollers have analog inputs/outputs built-in
5. Complicates the circuit design when external ADC or DAC are needed.
6. Short distance, few feet maximum.
Applications
1. Mainly it is used for the dedicated system that is it is used for the motion control of the motor.
2. This system can be applicable for doing the cutting or drilling jobs by the requirement of the
user
Future Scope
1. Can provide Manual mode
2. As per the requirement of the use coolant will be provided
3. Can be interrupted by the operator as per requirement
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7. International Journal of Electrical Engineering and Technology (IJEET), ISSN 0976 – 6545(Print),
ISSN 0976 – 6553(Online) Volume 3, Issue 3, October – December (2012), © IAEME
REFERENCES
Web Site References
STEPPER with MC68HC11.htm
ieeexplore.ieee.org/stamp/stamp.jsp
defdeny.jsp.htm
www.bipom.com
www. Teknik.com
www.educypedia.com
Book References
Embedded System - Raj Kamal
Microprocessor and interfacing- Mazidi and mazidi
Microcontroller and Programming - A. H. Deshamukh
Klein, William, “Circuit Measures Small Currents
Referenced to High Voltage Rails”,
Electronic Design, January 7, 2002.
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