PROJECT TITLE
MILLING MACHINE CONTROL WITH AC DIGITAL SERVO DRIVE SYSTEM
Under the guidance of
Mr. C.SUBRAMANI M.E (Ph.d)
(Asst. Professor, School of Electrical Engineering)
Name MEGANATHAN. C
Reg No - 5050910057
MOHAMMED HUSSAIN .M - 5050910059 MURALI KRISHNAN. S MURUGANANDAM. D - 5050910061 - 5050910063
Overall View:
1. Project Objective 2. Introduction 3. Analysis of hydraulic & AC Digital Servo system 4. AC Digital Servo Drive System 5. Result 6. Conclusion 7. Reference
1.Project Objective
2. Introduction 3. Analysis of hydraulic & AC Digital Servo system 4. AC Digital Servo Drive System 5. Result 6. Conclusion 7. Reference
1. PROJECT OBJECTIVE:
To improve the following parameters of existing milling machine by changing the table movement control from Hydraulic to AC DIGITAL SERVO DRIVE SYSTEM, to
Increase the availability Reduce rejections Reduce power consumption
1. Project Objective
2.Introduction
3. Analysis of hydraulic & AC Digital Servo system 4. AC Digital Servo Drive System 5. Result 6. Conclusion 7. Reference
2.INTRODUCTION - About the company
Brakes India Ltd, a TVS Group company is a leading automobile brake manufacturer in India Customers include Multi national companies like Toyota, Nissan, Maruthi Suzuki, Volkswagen, Daimler and Indian giants like Tatas, Ashok Leyland, Mahindra & Mahindra
2.INTRODUCTION - About the project
The Milling machine has hydraulic system for controlling the table movement. Problems faced with hydraulics: - Less reliability and repeatability - More time taken for setting-up of machine - Components scrapped during setting - Needs skilled man power for setting and breakdown attending - High power consumption - Running of multiple parts not possible These problems are planned to be eliminated/ reduced by controlling the table movement with AC Digital Servo Drive system
2.INTRODUCTION - Working of a Brake System
Our Project is on Caliper Disc Brake
2.INTRODUCTION - Reason for Project Selection
Carrier
Housing
Brake Disc
The caliper brake has housing and carrier The carrier is mounted on the knuckle During braking, the entire vehicle inertia comes on the carrier The dimension of carrier is highly critical Hence, this project is selected
1. Project Objective 2. Introduction
3.Comparison of hydraulic & Electrical Servo systems
4. AC Digital Servo Drive System 5. Result 6. Conclusion 7. Reference
3. COMPARISON of HYDRAULIC and ELECTRICAL SERVO - What is a Servo?
3. COMPARISON of HYDRAULIC and ELECTRICAL SERVO - Example of a Servo
Motor Hydraulic/ Electric Position feedback
Position Input
Power source
3. COMPARISON of HYDRAULIC and ELECTRICAL SERVO - Merits and Demerits
No
HYDRAULIC SERVO
ELECTRIC SERVO
Positioning accuracy depends on hydraulic oil viscosity, temperature etc.
Needs skilled man power for setting and trouble shooting Suitable for manufacturing one part number in large volumes. High power consumption due to continuous running of Hydraulic motor Constraints in hydraulic pressure restricts the cutting parameters. Hence less output and low productivity. Low cost
Accuracy is independent of the environment. With closed loop control, micro millimeter accuracy is possible
Since control is through buttons and alarm messages, can be operated easily. With easy positioning, can be used for manufacturing multiple part nos. Servo motor gets power only when the table movement is required. Hence low power consumption. Suitable for very high cutting parameters. So productivity can be increased by many times. Cost is comparitively high
2 3 4 5
Changing the table position takes time Can be done by the touch of a button
1. Project Objective 2. Introduction 3. Comparison of hydraulic & Electrical Servo systems
4.AC Digital Servo Drive System
5. Result 6. Conclusion 7. Reference
4. AC DIGITAL SERVO DRIVE SYSTEM - AC Servo System Concept
AC Digital Servo Drive System
Servo Drive
Encoder
Servo Motor
Servo Motor, Servo Drive and Encoder are the important parts of an AC Servo System
4. AC DIGITAL SERVO DRIVE SYSTEM - Block Diagram
1
3 1. AC Servo Motor 2. AC Digital Servo Drive 3. Position Sensor
Servo Drive System
4. AC DIGITAL SERVO DRIVE SYSTEM - Drive types
4. AC DIGITAL SERVO DRIVE SYSTEM - Classification of Servo Motors
AC Servo motor is AC synchronous motor, with 3 phase winding in Stator and rare earth permanent magnets in Rotor. It is generally called as AC SERVO motor
4. AC DIGITAL SERVO DRIVE SYSTEM - Comparison of Servo Motors
S. no
Parameter Capacity
DC Servo Motor Less than 2 kW
AC Servo Motor 100W to 10 kW
Stepping motor Less than 100 W
Advantages
Disadvantages
Smaller outside High Speed dimensions. High Torque Large Torque Compact Good Operation Good Operation High output efficiency efficiency Cheap Good controllability No maintenance Low cost Out of step and magnet noise at low speed Out of step at low operations Costlier, compared to speeds Maintenance other models. Magnet noise at low speeds intensive due to
brushes
AC Servo motor is more suitable for High Speed, High response, faster acceleration and deceleration controls. Since no brushes, no maintenance is required.
4. AC DIGITAL SERVO DRIVE SYSTEM - Construction of AC Servo motor
Overall construction
Very simple design, life determined by bearing life, no brushes and winding in rotor. Working principle same as AC Synchronous motor.
4. AC DIGITAL SERVO DRIVE SYSTEM - Operation of AC Servo motor
Vector Diagram Vector Control or field oriented control Permanent magnetic field is shown as N-S Field oriented control generates three phase stator currents in such a way that the resultant current vector Ir is always perpendicular to the magnetic field vector B
4. AC DIGITAL SERVO DRIVE SYSTEM - Working of AC Servo Drive
Input AC DC Bus
PWM Inverter
Output Voltage from PWM Inverter
Control circuit
AC input is converted and inverted, and fed to the motor. The control Circuit monitors the Voltage, current etc and also has the Lock-out circuit to introduce delay in firing to compensate for the delay in OFF time of the IGBTs.
4. AC DIGITAL SERVO DRIVE SYSTEM - Types of Feedback devices
Resolver
Encoder
4. AC DIGITAL SERVO DRIVE SYSTEM - Comparison of feedback devices
S. no
Item
Photo Type Encoder Magnetic type encoder
Simple processing circuit Durable against noise, since Digital Signal High resolution Not suitable for high temperature application By Frequency to Voltage conversion Usable as Digital data
Resolver
Features
Complex processing Simple processing circuit circuit Durable against noise Rugged Strong against shock and Strong against noise and vibration vibration Not suitable for high Available for high temp. temperature application application By Frequency to Voltage conversion Usable as Digital data Uses phase variation of voltage as speed data Needs processing circuitry for getting incremental data
Speed Detection
Position Detection
Uses incremental pulse Uses incremental pulse Easy to apply Zero Easy to apply Zero position position pulse pulse
Photo type encoder is selected for our system, due to its High resolution
4. AC DIGITAL SERVO DRIVE SYSTEM - Working of Photo Encoder
Encoder Schematic
Pulses A,B and Marker Pulse - C
Fall and raise of A&B are counted for position, speed and direction Marker pulse C is used for arriving at initial position
4. AC DIGITAL SERVO DRIVE SYSTEM - System working
Position Input
3 AC Power flows from Drive to the motor Motor speed and position detected by Encoder and feedback first given to drive. Based on the error value, the amplitude of the power signal varies Position feedback given to other controls for checking the position and stopping the motor
4. AC DIGITAL SERVO DRIVE SYSTEM - Schematic
Before - Hydraulic system
After AC Servo Drive system
4. AC DIGITAL SERVO DRIVE SYSTEM - Steps in changing part no
BEFORE - HYDRAULIC SYSTEM AFTER AC SERVO DRIVE SYSTEM
Adjust hyd. cylinder position
Hydraulic Cylinder
Adjust cylinder travel speed
Hydraulic Valve
Check the dimension by trial & error Job checking If not ok repeat the above process
1. Project Objective 2. Introduction 3. Comparison of hydraulic & Electrical Servo systems 4. AC Digital Servo Drive System
5.Result
6. Conclusion 7. Reference
5. RESULT
- MTTR & MTBF
MTTR Mean Time To Repair : - It is the average time required to repair a failed device - It reduced from 7 hours to 0.5 hours MTBF Mean Time Between Failures: - It is the time elapsed between two failures - It increased from 100 hours to 350 hours Mean Time To Repair
Average Repair time in Hours
9 Average Repair time in Hours 8 7 6 5 4 3 2 1 0 MT
AC Servo System Replaced
400 350 300 250 200 150 100 50 0
Mean Time Between Failures
AC Servo System Replaced
Month
Month
5. RESULT
- Cycle time per component
Cycle time: - It is the total time from beginning to the end of the milling operation. - Lower cycle time will improve productivity and give more no of components for the same time frame.
Operation Time - In seconds
Before - with Hydraulic system
S No Operation 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 2 0 21 22 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36 37 38 39 4 0 41 42 43 44 45 46 47 48 49 5 0 51 52 53 54 55 56 57 58 59 6 0
1 2 3 4 5
Rapid forward Spindle start Feed start - Milling starts Rapid return Spindle stops
Cycle starts ---->
Cycle Ends ---->
1 2 3 4 5 6 7 8 9
After - AC Digital Servo Drive System
S No Operation
10 11 12 13 14 15 16 17 18 19 2 0 21 22 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36 37 38 39 4 0 41 42 43 44 45 46 47 48 49 5 0 51 52 53 54 55 56 57 58 59 6 0
1 2 3 4 5
Rapid forward Spindle start Feed start - Milling starts Rapid return Spindle stops
Cycle starts ---->
Cycle Ends ---->
-Cycle time reduced from 60 secs to 30 secs due to: * Faster speed of servo motor, Higher rigidity during milling
5. RESULT
- Average setting time
Average Setting time: - It is the time taken for changing from one product to another Average setting time
4.0
4.0 3.5 3.0 Time in Hours
2.5
2.0 1.5 1.0 0.5 0.0 With Hydraulics Setting Time With AC Servo
0.5
Setting time reduced from 4 hrs to 0.5 hrs by eliminating trial and error adjustment
5. RESULT
- Power Consumption
Before After
Hydraulic Power pack
Motor capacity in kW 5.0 Running time/day in Hrs 16 Power consumed/ day 60 Units
Servo Motor
Motor capacity in kW 2.5 Running time/day in Hrs 16 Power consumed/ day 16 Units
Power cost saving Rs 1 lakh per annum 44 Units/day, Rs 8/ unit for 300 days
5. RESULT
- Cost saving
Total cost saving working: Reduction of MTTR: Setting time reduction Rejections Power consumption Total Net Cost saving Productivity increase Total cost saving Cost of AC Digital Servo Drive System Return on investment Rs Rs Rs Rs Rs Rs Rs Rs Rs Before 21,000 12,000 1,500 144,000 178,500 137,100 200,000 337,100 600,000 2 years After 1,500 1,500 38,400 41,400
5. RESULT
No
Parameter
Unit of Required Measure Trend
Before Hydraulic system
After with AC DIGITAL SERVO DRIVE system
1 2 3 4 5
Reliability Mean Time To Time in Repair MTTR Hours Reliability Mean time Time in between failures MTBF Hours
7 .0 100 0.8 4.0 15
0.5 350 1.67 0.5 0
Repeatability Process Index no capability Index - CPk
Average Setting time Components Rejection Productivity per shift Power consumption Need for Skilled man power Cost Saving Hours Nos Nos kWh/ day No Rs in lakhs -
6
7 8 9
480
60
Required -
960
16
Not Required
3.37
1. Project Objective 2. Introduction 3. Comparison of hydraulic & Electrical Servo systems 4. AC Digital Servo Drive System 5. Result
6.Conclusion
7. Reference
6. CONCLUSION
All the project objectives are achieved: - Availability increased by decreasing MTTR and improving MTBF - Rejections reduced to Zero - Power consumption reduced by 44 units/ day
Cost saving of Rs 3 lakhs per annum achieved, with return on investment of 2 years
1. Project Objective 2. Introduction 3. Comparison of hydraulic & Electrical Servo systems 4. AC Digital Servo Drive System 5. Result 6. Conclusion
7.Reference
7. BIBLIOGRAPHY
1. Basics of Industrial Servo Drives -Marcel Dekker 2. Mechatronic Servo System Nakamura 3. Servo Motors and Industrial Control Theory Frederick F Ling 4. Electrical Technology BL Theraja & AK Theraja 5. Basic Electronics for scientists and Engineers Dennis Eggleston 6. A text book of Electrical Technology AC & DC Machines Theraja 7. Wikipedia 8. AC Servo Motors Mecapion 9. Servo System Basics - Omron
