Application of PLC in the hydraulic disc brake assembly testing system

Detection system, the application of PLC in the hydraulic disc brake assembly newmaker welcome to e exhibition hall 3 showrooms gearbox transmission/steering/brake system, clutch and brake system. 。 。 1 introduction brake is one of the important parts, ensure the safety of the motorcycle driving modern high-speed motorcycle adopt disc brake. The stand or fall of disc brake performance of motorcycle brake safety plays an important role, therefore, the performance of the motorcycle disc brake testing, is an important part of motorcycle brake system detection system. In order to ensure the quality of production of motorcycle brake disc, improve safety performance of motorcycle brake disc brake, must be conducted on the performance of the motorcycle disc brake accurate detection. By PLC and PC combined detection system, high precision and easy and reliable. 2 structure and working principle of the brake disc brake friction pair of rotating components is end to work on the surface of the metal disk, brake disc, and is fixed on the wheel. The fixed element is made up of two to four working area is not large friction piece with metal backboard of brake block. All these brake blocks and astatic devices across the brake disc on both sides of the clamp type pliers stents, always called brake pliers [ 1] 。 Hydraulic brake is to use lever principle and PASCAL's law, passed in and increase the operating force on the wheel braking torque and friction between the friction element and the friction driving motorcycle in the kinetic energy into heat energy, absorb and release heat to rely on the friction element, achieve the goal of slow down or stop. Impose external force on the brake handle, make the handle brake fluid pressure in the cylinder and the cylinder at the end of the tubing to brake caliper pistons, piston driven friction clamping brake disc and produce the wheel braking [ 1] 。 Thus, brake pliers jaw force determines the brake and braking ability and jaw force and displacement and joystick force. So must be from three aspects to test the performance of hydraulic disc brake, the jaw force, displacement and joystick force. Hydraulic disc brake principle diagram is shown in figure 1. Figure 1 hydraulic disc brake principle diagram 3 inspection system of the test system is mainly composed of machine body, PLC controller, PC of three parts, the system composition is shown in figure 2. Figure 2 test system of test machine body is mainly composed of test bench, clamp, force and jaw force sensor, joystick, displacement sensors, limit switches, motors, cylinders, etc [ 3] , is the basis of the detection system. PC is the core of the whole control system, the main use of good graphic user interface, display the size of the handle and jaw forces and handle displacement and other parameters and the corresponding curve, and sent the PLC control instructions. PLC is the system of the machine, is responsible for the high speed data acquisition ( The location of the control handle) , implementation logic, timing, counting, and other functions, through serial communication port up machine send PLC controller working state and relevant data, at the same time accept the work instruction from superior machine, send commands to alarm, printer, etc, to realize the upper machine control system management, increase the ability of the PLC controller control and control, make the whole system and distributing control system. When press the start button after the whole test process is controlled by PLC automatically, simulated brake actuator driven brake handle, the force and jaw force sensor, joystick displacement sensor for detecting analog signal transmitted to the PLC simulation module, PLC through the rs485/232 communication interface and the upper machine, PLC, sensor analog signals into digital signals transmitted to the PC, monitor, show the strength of the handle and jaw strength and handle the size of the displacement and the corresponding parameters, such as curve, set when the motor running time at the end of the stop and reverse to reset the pneumatic actuators, limit switch up limit protection, when the pneumatic actuators, push the handle and the limit switch contact motor automatically stop, if you have any test results qualified exceeds the value, alarm will promptly report to the police. Four main controller system design adopts Siemens PLC, s7 - 300 series PLC powerful functions, USES the modular design, with the central processing unit ( cpu) , all kinds of signal module ( sm) , communication module ( cp) , function module ( fm) , power supply module ( ps) , interface module ( im) And so on, there are a variety of specifications of the CPU to choose from. 西门子s7 - 300, it is a modular structure, system composition and extensions are very convenient [ 2] 。 3. S7-1 the system hardware configuration 300 main configuration is as follows: power module choose ps3075a; The central processing module ( cpu) Choose cpu313c - 2 dp; Digital quantity input module ( di) Choose sm321 di16xdc24v; Digital output module ( do) Choose sm322 do16xdc24v / 0. 5个; Analog input/output module ( ai/ao) : choose sm334. 3. 2 I/o definition and programming design of PLC input and output terminal distribution as shown in table. Testing process after starting test done automatically according to the program design, according to the measured value of the set of set limit to, the system automatically detect unqualified products and alarm, its flow chart is shown in figure 3. Figure 3 main program diagram 5 last word the whole testing system based on PLC and the upper machine design, the realization of digital display of the analog signal, detection more accurate quickly, reduce the operation complexity. PC to provide the support software, can achieve perfect monitoring function, manage and provide friendly man-machine interface. All alarm system parameters of fault information and so on can be through the PC monitor. To further improve the integration degree of system reliability, reduce its complexity, the PC and PLC real-time communication in control, improve the automation level of the enterprise information and test equipment.
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