vii
TABLE OF CONTENTS
Declaration i
Approval ii
Abstract iii
Dedication v
Acknowledgement vi
Table of Contents vii
List of Figures xii
List of Tables xv
List of Abbreviations, Symbols, Sign xvi
1.0 INTRODUCTION
1 1.1
Objective 2
1.2 Statement of Problems
2 1.3
Scope 3
1.4 Organization
3
2.0 LITERATURE REVIEW
4 2.1
Programmable Logic Controller PLC 5
2.1.1 PC Hardware Structure
6 2.1.2
Input Output System 7
2.1.3 Memory Units
8 2.1.4
External Data Communications 9
2.1.5 PLC Programming
10
2.2 Servo Motor
12 2.2.1
Introduction to the Servo Motor 12
2.2.2 Servo Motor Control
16
viii 2.3
Wire 17
2.3.1 Standard Wiring Colours
17 2.3.2
Gate Rating 19
2.3.2.1
Detailed Instructions for using the Wire Size Calculator 20
2.3.2.2 Full-Load Currents in Amperes, Single-Phase
Alternating-Current Motors From 1999 NEC 21
2.3.2.3 Full-Load Current Three-Phase Alternating-Current
Motors From 1999 NEC 22
2.4 Application Formula
26 2.4.1
Angular Distance 26
2.4.2 Angular Velocity
26 2.4.3
Torque 27
2.4.4 Mass Moment of Inertia
28 2.4.5
Torque Motor 31
2.5 Control System
31 2.5.1
Response Characteristics and System Configuration 32
2.5.1.1 Input and Output
32 2.5.1.2
Open-Loop Systems 33
2.5.1.3 Closed-Loop Feedback Control Systems
34 2.5.2
Control Engineering: Analyze and Design 36
2.5.2.1 Transient Response
37 2.5.2.2
Steady-State Response 37
2.5.2.3 Stability
38
3.0 METHODOLOGY
40 3.1
Methodology Flow Process Chart 41
3.2 Detail Description of Methodology Flow Chart
42 3.3
The Design Process 44
3.3.1 Ball Screw
44 3.3.2
Ball bearing 46
ix 3.4
The design process 47
3.5 Simulation Calculation
52
4.0 RESULT
54
4.1 Mechanical part
56 4.1.1
Solid Work 56
4.2 Control box
58 4.2.1
Solid Work 58
4.2.2 Electrical Wiring
59 4.3
Programmable Logic Controller PLC 60
4.3.1 Ladder Diagram
60 4.3.2
Circuit Diagram 63
4.4 Bill of Material BOM
65
5.0 DISCUSSION
67
5.1 Mechanical Part
68 5.1.1
Lead Screw mechanism 68
5.1.2 Bracket for Servomotor
69 5.1.3
Selection of Coupling 71
5.2 Control box for Servo driver
72 5.2.1
Electrical Circuit IEC Standard for Control Box
72 5.2.2
The Function of electrical Diagram 73
5.2.3 Testing circuit for Control Box
74 5.3
Programmable Logic Controller 77
5.3.1 Ladder Diagram CX-Programmer
77 5.3.2
Electrical circuit between PLC and Servo Driver 80
5.3.3 Testing the PLC Training Kit
81 5.4
Components Analysis 82
5.4.1 Permissible Buckle Load and Tensile Compressive Load
82 5.4.2
Driving Torque 85
5.4.3 Servomotor Position
86 5.5
Control Engineering Analysis 88
x 5.5.1
Servomotor Feedback Controller 88
5.5.2 Transfer Function for Servomotor
90
6.0 SUMMARY AND CONCLUSION
