The position control system is composed of a PLC and its expansion modules, a PPI pulse comparison and output amplifier, an AAI signal conversion unit, a hydraulic servo valve controller, a hydraulic cylinder displacement sensor (magnetic scale), an amplifier and phase detector, and a human-machine interface touch screen. It operates as a closed-loop feedback system. Due to the failure of the original OMRON C200H computer, the system has been upgraded using a Siemens S7-CPU226 along with digital input/output expansion modules EM223 and EM222, and an analog input/output module EM235. The touch screen has also been replaced, and the control software has been reprogrammed to improve functionality.
Previously, the load sorting was divided into two categories: qualified and unqualified. Now, it has been expanded to four qualified grades plus one unqualified grade, allowing for more precise classification. The CPU 226 is a DC input and DC output type, featuring 24 input points and 16 output points. The EM223 and EM222 are 16-channel DC input and 16-channel relay output modules, while the EM222 is an 8-channel relay output module. The EM235 is used for processing analog signals from the load cell.
All parameter inputs and system displays are managed through the touch screen, which is configured using dedicated editing software. The PPI board serves as a pulse comparison and amplification output module. It receives pulse width modulation (PWM) signals and direction signals from the PLC outputs Q0.10 and Q0.11, compares them with the position signal from the displacement sensor, and then generates an analog output to drive the hydraulic servo valve. This allows the hydraulic cylinder to move precisely to the desired position.
In terms of motion control, the process begins with the hydraulic piston rod returning to the origin (O). Once the origin position is detected, the system moves to the operating point (W), controlled by a PWM signal from Q0.10, and verified by a hardware position sensor. From there, the piston moves to detection point 1 (X1), using a pulse train (PTO) signal from Q0.10. Software calculates whether the movement is complete based on the number of pulses set. The same process is repeated when moving from X1 to X2. The piston remains at both X1 and X2 for a set period to capture stable load readings.
After completing the detection at X2, the piston returns to the operating point (W). The first half of this movement uses a PTO signal, while the second half uses a PWM signal, again verified by the position sensor at W. The next spring is then tested in the same way, completing the entire spring load detection cycle.
The control program is written in ladder logic and has been successfully implemented on a spring testing table. It has been applied to detect the springs of intake and exhaust valves in real motorcycle engines, achieving excellent results.
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