Application Of Mitsubishi Motion Controller In Small Roll Forging Conveyor System

A Summary
      Roll forging transmission system is widely used in forging industry.Mitsubishi The system consists of a roll forging machine and a manipulator conveying mechanism, replacing the traditional free forging and manual feeding system.Mitsubishi The roll forging conveyor system improves the automation level, improves the product quality precision, reduces the labor intensity of workers and saves the cost. The roll forging conveyor system introduced in this paper is applied to the motion controller of a hardware factory.

Structure of Two-roll Forging Conveyor System
    The roll forging conveying system is composed of a roll forging machine and a manipulator conveying mechanism. The roll forging machine consists of two upper and lower pressure wheels and a die. The die is fixed on the upper and lower two pressure wheels, and is driven by the roller to realize forging of the product. Roller is rotated by two 15K servo motors at the same time to realize simultaneous roll forging transfer of the die. The transmission mechanism of the manipulator is composed of the rotating shaft of the gripper, the feeding shaft in X direction, the displacement moving shaft in Y direction, the rotating shaft of the chassis and part of the positioning sensor.

Three Control Processes

      The roll forging machine is driven by two MR-J2S-15KB4 and HA-LFS15K14 roll forging conveyors, which start at the same time and keep synchronization. The transmission structure of the manipulator is mainly driven by four MR-J2S-700B and HC-SFS702. The starting of upper and lower pressure rollers is detected by X-axis feeding in place, the clamping signal of mechanical melon and the zero position signal of pressure rollers are started. Each station rotates one circle, returns to the origin, X-axis servo OFF is in a free sliding state during the rolling process. After the free sliding position is connected with a detection signal (feeding position signal is disconnected), X-axis servo ON and Y-axis are started, moving from the first station to the second station, two-position detection signal is connected, and the gripper rotation axis is rotated. After a certain angle, the X-axis starts to move quickly to the second position, the in-place detection signal is connected, the X-axis servo OFF is in a free state, and the upper and lower pressure rollers start. In this way, roll forming is carried out in three and four positions. At the end of the four workstations, the Y-axis returns to one workstation, the mechanical melon rotation axis returns to the original angle; the chassis rotation axis rotates at a certain angle, the rotation is in place to detect a connection, the mechanical claws are loosened, and the formed products are sent to the conveyor belt. After the mechanical claw is loosened, the chassis rotating shaft continues to rotate at a certain angle, the rotation is in place to detect the second connection, the automatic feeding system starts feeding, after the material detection is connected, the mechanical claw grasps; the clamping signal is connected, the chassis rotating shaft rotates to the original position, and the periodic work begins.

Four Control Systems

      整个控制系统由6轴组成，压辊轴功率较大；从性能稳定性考虑，我们选用两台MR-J2S-15KB4及HA-LFS15K14驱动上下压辊；四台MR-J2S-700B及HC-SFS702驱动机械手传送结构。控制系统选用多CPU系统：Q02CPU+Q172CPUN，Q172CPUN最多可以控制8轴，编程方便简单。用SSCNET总线与伺服放大器进行连接，方便可靠。具体参见下图：

Five main input and output signal lists

 Six-motion SFC program

      Motion SFC program (including the setting of system parameters, etc.) is written by MT Developer. The whole program is divided into three parts: main program, automatic operation and manual operation. SFC program uses automatic operation mode and uses external input signal as trigger to start the servo program. When setting up a multi-CPU system, two CPUs are selected, and the refresh address is automatically refreshed, without setting the address. The servo unit system uses the pulse unit. The procedure flow chart is as follows:

     References for multi-CPU system settings are as follows:

     Q02CPU settings:

       Q172 CPUN settings:

Concluding remarks

      This control system adopts Mitsubishi motion CPU system with excellent performance. By using high-speed serial communication, the motion controller and servo amplifier can be connected quickly and the wiring can be simplified. The software avoids the tedious parameter setting and control program, and adopts the motion SFC program to realize the complex servo control.