PLC in control system design and practice in ring spinning

An overview, system type FA506 spinning frame is the yarn quality is good, high degree of automation, simple operation, easy to manage the ring spinning frame, is suitable for pure and blend spinning of cotton or polyester spun yarn process, especially adopting PLC as controller, not only improve the control precision, and solved the defects of production management, reduce the operator labor intensity; And also improve the quality of the yarn spindle curve control, ensure the spindles forming, improved the output of the machine. System design characteristics: 1, using PLC to control the whole process of spinning, has a program to drive, automatic ring rail lifting, midway driving automatic tracking, automatic doffing after parking, automatic for the first class. 2, set spinning process parameters, according to the technological requirements automatically coordinated control; Achieve fixed-length doffing and spindle speed curve control. 3, display process of spinning spindle speed, drawing ratio, spinning class number, twist and cumulative production, etc. 4, using digital communication, improve the anti-interference of the system. Second, the system hardware control system include: digital quantity input and data detection, a programmable controller, actuator, man-machine interface. As shown in figure 1. 1, digital quantity input and data detecting part 1) All kinds of digital switch includes open parking switch, switch, used to open parking functions and implementation process requirement. 2) Part three automatic detection by the close of main motor, the steel plates, the brake sensor. Its role as when can automatically right after doffing began to stop, automatic leave first, create conditions for drive to reduce breakage. 3) Data detection part is composed of main shaft, front roller and back roller sensor. Its purpose is to automatically detect spinning spindle, roller before and after operation in the process of data, for calculating class production, multiple spindle speed, traction, yarn number, the process parameters such as twist, and provide data for the spindle speed curve control. 2, programmable controller ( PLC controller） Part of this part is mainly composed of FBs - 60 MC host and extension module, a programmable controller is designed for industrial environment and general automation device, it absorbed the microelectronics technology, computer technology and the latest achievements of automation technology, USES a programmable memory, realize the logic operation, sequence control, timing, counting and arithmetic operations, and through digital and analog input and output control each production process, FBs - 60 MC host has 16 points, 24 digital output, digital quantity input can take seven extension module, the system design of all digital quantity input all completed by the host, FBs - analog input by extension module 6 AD. 3, including the main actuator motor, suction machine, ring rail lifting motor, automatic lubrication device and automatic cleaning device, frequency converter, doffing power supply, etc. , to complete all spinning process technology. The inverter spindle speed control by frequency converter, spindle transmission parts, main motor. Its role is frequency converter based on PLC instructions ( Spindle speed control curve) Automatic adjustment of spindle running, improve the quality of yarn and production. 4, man-machine interface are TP27 touch screen man-machine interface, complete set parameters, display, can be directly set spindle running curve, control flexibility. And can modify the parameters according to the technical requirement. TP27 by PPI protocol communication with PLC. Second, the software design of electrical control software is divided into: control of the main program, like display subroutine, analysis of parameter set, digital communication subprogram and spindle running curve subroutine. 1, the control of the main program software part of the master control program, the program compiled according to the technological requirements, after power on automatically detecting the switch and sensor input data, and complete the entire spinning process automatic control and call subroutine. 2, the parameter setting display subroutine main basis TP27 configuration is complete, according to the parameters set including shifts setting, the error set, cumulative total output, class output display, spindle speed, the front roller speed, draw ratio, twist, yield, yarn number etc parameters display. The parameter setting menu program structure as shown in diagram 2. Like 3, calculation program based primarily on the main shaft, front roller and back roller detection sensor data sampling and complete system design parameters calculation result, in order to finish all kinds of display parameters calculation and fixed-length doffing, etc. Part 4, digital communications and spindle running curve subroutine mainly adopts free port communication protocol to complete data transmission with frequency converter. Communications set up free port communication control register is set to free port communication methods, procedure by receiving interrupt and the interrupt and send instruction XMT control communication operation of mouth, in the free port communication mode communication is controlled by program of ladder diagram. Communications Settings also defines the baud rate, parity and data length, etc. In order to make the spindle run curve smoothing. Between the set point and the point of using the mathematical method of build touch send parameter fitting, the part program block diagram as shown in figure 3. Three, the biggest characteristic is to design the control system applies digital communication way to complete the TP27 and the transfer of data between PLC and PLC and frequency converter. PLC controller Prt0 mouth and TP27 connection to PPI protocol communications to complete, according to the parameters set Port1 mouth connected with frequency converter, with free spindle operation curve control protocol communication is complete, in the past when we control the spindle speed curve can only choose analog to control frequency converter operation, hardware cost is high and the low control precision. After adopting digital communications, hardware is only a shielding line, enhance anti-jamming capability, provides conditions for the realization of the network transmission control parameters, which reduces the cost control; Digital communications and high precision, high reliability and low cost greatly improve the machine performance ratio and the market competition ability.
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