This thesis describes automation and control of a machine for magnetizing ferromagnetic rings.
The machine consists of six main components. The first one is used for picking up non-magnetized rings, and for dropping off magnetized or defective rings. The second component is made of optical control system for orientation control of rings and of a unit for changing the orientation of rings. The third component is a magnetizing unit. The fourth component is a unit for measuring magnetic flux of magnetized rings. The fifth component is an ABB robot which is used for manipulation with rings between different components. The sixth main component is a programmable logic controller (PLC) which is used for controlling the whole machine.
Siemens S7 PLC 315-2 PN/DP, Siemens touch panel TP177B, which is used for manipulating with the machine, and PC computer, which is used for running programs for optical control and for magnetic field measurement, are used for controlling the machine. PLC is used as the main control unit of the machine which coordinates all components of the machine. Sensors and actuators are wired to PLC’s input/output modules. Most actuators are pneumatic, connected and controlled trough valve manifold which communicates with PLC via Profibus communication. Profibus communication is also used for ABB robot and for Beckoff step motors, which are also used as actuators. Communication between PLC and control panel is established through industrial Ethernet protocol.
This thesis contains a short description of all main components of the machine. The main part of the thesis is programming and implementation of main control system which controls the entire machine. This was my main assignment on this project. During the production of the machine there were several subcontractors involved for different components of the machine. Demands and functionality of the machine were determined by the client. Programming and implementation of the main control system was a big challenge as there are several subsystems which have to be carefully coordinated. In addition to those challenges, the project involved issues I encountered for the first time in my career.