1MicrocomponentThicknessComprehensiveDetectingPlainTestControlSystemDesigningZhenweiDuanYanhuaLiDenrenKongChanganDiDepartmentofprecisioninstrumentofSchoolofMechanicalEngineeringinNUST,Nanjing,210094Phone(086-Mail:Abstract:Thisarticleintroducestheoverallplanofthetesting&controllingsystemoftheplatformfortestingthethicknessofthemicrocomponent,theworkingprincipleandthedesignmethod.Itintroducesthedrivingsystem,controlledbythePLCprogrammedcontrollingstep-motor,toaccomplishthetestingofmicrocomponentintheformofproductionchain.Itintroducesthecommunicationandcontrolmethodbetweenthethickness-testingsensorandPC.ItdiscusseshowcanthePLCcontrollingmicrocomponentmaterialdistributionmachineaccomplishesdistributiontask,whengettingsortsignalsformPC.Itdiscussestherealizationmethod,inwhichallkindofstatusinoperatingprocesscanbetestedandthefaultcanbetolerated.Thissystemwasdebuggedinindustriallocationanditsfeasibilitywasprovedwell.keywords:microcomponent，detecting，classificationautomatization，ManipulateMicrocomponentisacriticalunitinairconditionandaircompressor,whosegeometrydimension,surfaceroughness,margintoleranceetcdeeplyeffectstherefrigerationandcalefactionofthem.Actuallyasthedemandofairconditionandaircompressoraremoreandmorevast,thedemandofmicrocomponentismoreandmorevasttooandthedegreeofaccuracyofmicrocomponentismoreandmorehigher.Nowafterthemicrocomponentwasmachiningedandproducted,whichwasmainlydetectedmanually,theverificationbecamewheretheshoepinches.Thetraditionalverificationmethodhastheproblemofslowvelocity,lowefficiencyandmaninducedfactoreffect.SowedevelopedthisMicrocomponentThicknessComprehensiveDetectingPlain.TheProgrammableLogicControllerofS7-200catena,whichismadebytheSiemensandtheindustrialcontrolcomputerarethenucleusofthistopic.Wecombinationthedeeplyactivationcapability,thehighreliability,thesuperiorproportionalinyamongtheperformanceandthecost,theexpedientapplicationofTheProgrammableLogicControllerwiththedeeplydata-processingcapability,theamicablerelationamongmanandcomputer,thehighadministrationhorizontaloftheindustrialcontrolcomputer,thenwedevelopthisMicrocomponentThicknessComprehensiveDetectingPlainTestControlSystem.Weachievetheautomatizationoftheexaminationofthemicrocomponentthicknessandtheexclusiveclassificationprocess,andenhancethelevelofautomatization,gettogetheronbettereconomiceffect.IThedesignofthemicrocomponentthicknesscomprehensivedetectingplainTheMicrocomponentThicknessComprehensiveDetectingPlainismadeupofthedrivingandmeasurementmechanics,theclassificationmechanicsandthecontrolsection.Inageneralway,theconcentratedanddecentralizedsystemcanbefallenintothreetiers:thetopismanagementwhomanagesthewholesystem；themiddleisconcentratedsupervisorywhomonitor,controlanddeploythewholesystem；thebottomisdecentralized-implementation,whosetaskiscontrolthelocalsystem.Inthesystem,theindustrialcontrolcomputerundertakesthetaskbelongingtothetopandmiddleassupervisorymanagement；PLCundertakesthebottomtaskascontrolimplementationtier2.Theindustrialcontrolcomputertransfersthemanagementdecision,controltask,controlparameteranddeploydictationtothecontroltierPLCbycommunicationcable,PLCtransferstheparameter,processcontrolanddatatothemanagementtierbycommunicationcable.Thefunctionflowchartofwholesystemisasfig1.2Fig1TheoverallstructureofthesystemATheautomateddetectingplainTheautomateddetectingplainismadeupofmeasurementplainandthedrivingmechanism.Measurementplainisthebasicreferenceofthemicrocomponentsgeometricalparameter,whosedegreeofaccuracyishigherthanthatofthemicrocomponent.Duringthemeasurementprocess,themicrocomponentslideswithsurfaceoftheoperatingboard.Inordertoguaranteethestationarityduringthedrivingprocess,andeschewtoleadintheadditivelapsetoengenderthedeformationbecauseoftheshockofthedrivingmechanics,thedrivingmechanicsexploitsthedesigningoffissionconstitutionalformulatodisbranchthemeasurementplainandthedrivingmechanics,thendescendtheinfluenceofthedrivingmechanicsbyalongway.Weneedtomeasurefivedotsonthediagonalofeverysurface(itcanbetakenintoonedotinthecrossover).Inthisway,themicrocomponentnotonlyrotates90degree,butalsorollsover180degreeonthepipleline.Byprotractingfavourablebandyonthemeasurementplain,wecanmakethemicrocomponentrotatefavourableangulardegreeaccordingtotheprimarylocus,andtorealizetheturningofthemicrocomponentbydesigningthespatialtextureoftheindustrychain.BclassificationorganThemicrocomponentistransferredtotheclassificationorgandowntheslipway.TheclassificationorganclassifiesthemicrocomponentbyvirtueofcontrollingsteppermotortorotatehomologousangulardegreewhenthePLCacceptingclassificationinformation.ThePLCcontrolsthesteppmotorinthewayofPTO.PTOmodecanexportmuchimpulsetrain,andenableimpulsetraintoqueuetoestablishconduitline.Itcanbeclassifiedtwoenominationsincludingsingleconduitlineandmultipleconduitline1.Thissystemadoptsthemultipleconduitline,andestablishsthelistinvariablememoryblocktocontrolperiodictimeofoutputimpulseandpulsenumber,thenachievestocontrolthesteppermotorrateandangulardegreeexactly.ThePLCreckonsheterogeneousconditionsbyinductiveswitchintheclassificationprocess.Forinstance,thearrivalsignal,thealignsignal,theclassificationcompletionsignal.IfThePLCdiscoversfalsecondition,itwilldeliverhomologousalarmsignaltotheindustrialcontrolcomputer,thentheoperatingforcecaneliminatethebug.CThecontrolsectionThePLCisthenucleusofthecontrolsection,whichcarriedoutthecommandoftheindustrycontrolcomputerbythecommunicationofthem.WhentheindustrialcontrolcomputerinterfaceswithPLC,becausePLCexploitsstandardRS-485,whichisnotcompatiblewiththeindustrialcontrolcomputerRS-232,wemustswitchoverbyPC/PPIcommunicationcable2.Theindustrialcontrolcomputeristheadministratorofallthesystem,.Itcontrolsthesensortomeasuresthegeometricalparameterofthemicrocomponentontheindustrychain,andcalculatestogettheclassificationinformationofthemicrocomponent.ThePLCisthemanipulativenucleusofallthesystem,itcompletesthefacilitywhichincludestheactivationgoverning,theconditionsense,theimplementationofthedictationandsoon.ThePLCcontrolstheperformanceoftheclassificationmechanicsandthedrivingmechanicsbyacceptingtheinformationoftheindustrialcontrolcomputer.IIThedesignofthecontrolsystemAThecontroldemandofthesystemInordertoaccomplishthedetecting,transmissionandclassificationofthemicrocomponent,thesystemwasdemandedtoaccomplishthefunctionsasfollow:1)Canaccomplishthesteadytransmissionofthemicrocomponentinindustrychainandensurethequeueofthemicrocomponent,whichwasformedbyentryorderofthechain,wasorderlinessandSortcontrolsignalSensorsignalPTOoutputDrivecontrolControlsignalMeasurementplainPLCRS-485IndustrycontrolcomputerRS-232SortcontrolsystemPC/PPIMotor1Mtor2StatussignalStatussignal3integrality.2)Thespeedofformerdrivingorganmustbenotfasterthanthelaterclassificationorgan,andattheleastensurewhentheclassificationorgandidntaccomplishedtheclassification,thereisnomicrocomponententrytheclassificationorgan.3)Ensuretheclassificationorgancanautoresetwhenthestepmotorwasoutofstep.4)Whennotonlyonemicrocomponententrytheclassificationorgan,theworkerwillbetoldthesystemwasintrouble.Inthemeantimethemotorcanbeestimatedwhetheritworkswellandtheangulardisplacementoutputiscorrect.5)Thesystemmusthavecertainfault-tolerantcapacity,whenitoccurscommonerrors,thesystemcanrehabilitatebyitself.Butwhenthefatalerrorwasoccurred,thesystemcanclewthepossiblesortorapproximatelyorientation.BTheworkprincipleofcontrolsystemThecontrolsystemismainlymadeupofmotordrivingsection,communicationsection,statusdetectingsectionandalarmsection.EverysectiondefinedintheoutputandinputofPLCasfig2:Fig2Thecontrolsystem1)StepmotoranddrivingsectionThestepmotorisexecutecomponentwhichconvertstheelectricpulseoutputofPLCtoangulardisplacementorrectilinealdisplacementwhichisindirectproportiontotheelectricpulse.Theformerdrivingsectionstepmotormainlyaccomplishesthespeedcontroloftheindustrychain,andthelaterclassificationsectionmustaccuratelycontroltheoutputangulardisplacementanddirectionofthestepmotor.Whenthestepmotoroutofstepintheprocess,thephotoelectricencipherormustbeusedtocontrolthephaseoutputofthestepmotorandensuretheoutputaccordwiththepracticality.Thelaterclassificationsectionadoptsthemodeofautoresettoeliminatetheaccumulatederrorofthemotorandensurethatthemotoroutputcertainangulardegreefromzeropositioneverytime.2)StatusdetectingandalarmdesignTheprocessstatusofthesystemcouldbeestimatedbyinductiveswitchwhichwerefixedinthecertainpositionofthesystem.Whenthestatusdidntaccordwiththegivenstatus,thesystemshouldalarm.Themodeofthealarmisdesignedinacousto-opticmode,accordingastheponderanceoftheerrors.3)ThecommunicationofthePLCandthecomputer.Theprogramofthecommunicationport,includingtheparitybit,thelengthofthedataframes,realizedthecommunicationofthePLCandthecomputer.IIIThesoftwaredesignofthesystemThesoftwareoftheindustrycontrolcomputer,whichwasadoptedobject-orientedwindowsapplicationandprogrammedinBlandC+compiler,hadluxurioushuman-computerinteraction,multilevelmenudesignandwasoperatedeasily.UsingSTEP7-Micro/WIN32programmedthecontrolsoftwareofPLC,whichbasedonWindowsapplicationanddesignedspeciallyforS7-200seriesPLCofSiemens.Ithasthepowerfulfunction,wasmainlyusedtodevelopprogram,atthesametimealsousedtosupervisethestatusofprogramimplementationrealtime2.AThesoftwaredesignofPLCThesoftwareofPLCcanbeseparatedintomainprogramMain(),normalsortprogramMicro_Sort(),autoresetprogramAuto_Reset(),interruptserviceroutine(ISR)Interrupt(),initializationroutineIni_Install()anderrorhandlingprogrametcinstructural.Allthesubroutineswaredecidedwhichcouldbecalledbymainprogramaccordingtoindustrycontrolcomputerorexternalcommand.Themaincontrolflowchartgraphmanifestasfig3.Whenthesystemwaspowerup,theinitializationroutinewascalledtoaccomplishtheinitializationofwholesystemandthescanningofalltheinductiveswitch,whichwasaccordingaswhetherthesystemDirectioncontrolI0.2I1.7I0.0I0.1InputPLC226CommunicationportOutputQ0.5Q0.2Q0.1Q0.0AlarmdisplayManualcontrolinputStatusdetectingsensorMotor2MotordriverMotor1MotordriverPC/PPI4wasingear.ifnot,thePLCwillsendinitializationfailsignaltoindustrycontrolcomputerandwaitfortheworkertotreatwith.Iftheinitializationwasaccomplishedwell,thePLCwillsendreadysignaltotheindustrycontrolcomputer.Diagram2whentheindustrycontrolcomputerreceivedthesignal,thesystemwillbestartedtowork.Fig3ThecontrolflowchartofthePLCIntheworkingprocess,thePLCwasscaningalltheinductiveswitchtosupervisetheworkstateofwholesystem.Whenthesortorganreceivedthearrivesignalofmicrocomponent,thePLCwillcontrolthesortorgantosortthemicrocomponentaccordingtothesortsignal,whichreceivedfromindustrycontrolcomputer.Duetoithasnotonlyonesort；itmayresultinsortmistakebecauseofbreakingstepofthemotor.Soafterejectingthemicrocomponent,thePLCjudgedwhetherthesortsignalwasaccordwiththecompletesignal.ifnot,thealarmwillbestartedandthesystemwillbehanged,thesorterrorwillbesendtoindustrycontrolcomputeraswell.B.Softwarefault-tolerantdesignInthefaceofcomplicatedindustrycircumstance,softwarefault-tolerantwastheindispensabilitypartofthesystemrobustness.Theerrorsweresortedintofatalerrorandcommonerroraftercomprehensivelyconsideringallthepossibility.Inthesoftware,anerror-handlingprogramwasespeciallydesigned.Whenanerrorappeared,PLCprogramjudgedthesortoftheerror,byreadingthecodeoftheerrorandthestateinformationofthesystem,andtreatedwithitaccordingtotheponderanceoftheerror.Thesystemalarmwasdesignedinsound-lightmodeanddifferencedaccordingtotheponderanceoftheerror.Inordertoavoidtheprogramwasoutofcontrol,thesoftwaretropwassettingintheblankmemoryofthePLC.Thetransferinstructionwasalsousedtomaketheprogram,whichwasoutofcontrol,jumpingtotheerror-handlingprogram,andthesystemwouldsetright.Inthedetectingprocessof