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1 南台科技大學南台科技大學 電子工程研究所電子工程研究所 碩士學位論文碩士學位論文 電腦化自動橫編織機電控系統之設計與 製作 電腦化自動橫編織機電控系統之設計與 製作 Design and Implementation of a Computerized Flat Knitting Machine 研研 究究 生：梁耀星生：梁耀星 指導教授：王明賢指導教授：王明賢 中華民國九十三年七月中華民國九十三年七月 2 南台科技大學南台科技大學 電子工程研究所電子工程研究所 碩士學位論文碩士學位論文 電腦化自動橫編織機電控系統之設計與電腦化自動橫編織機電控系統之設計與 製作製作 Design and Implementation of a Computerized Flat Knitting Machine 梁梁 耀耀 星星 指導教授：王明賢指導教授：王明賢 中華民國九十三年七月中華民國九十三年七月 3 博碩士論文授權書 本授權書所授權之論文為本人在南台科技大學 系(所) 組 學年度第 學期取得 士學位之論文。 論文名稱： 本人具有著作財產權之論文全文資料(含紙本及電子檔)，授予下列單位： 同意立即公開 同意一年後公開 單 位 本人畢業學校圖書館 (上述若勾選一年後公開者，請於繳交紙本論文給本校圖書館時特別聲明，否則一律以立即公開處理) 同意公開 不同意公開 單 位 國家圖書館（若同意公開，請於上傳登錄之後將所印出的 授權書送交所屬系所統一寄給國圖；紙本論文則一定要送 交教務處註冊組彙轉國圖，不論是否同意公開全文） 行政院國家科學委員會科學技術資料中心 （授權國科會科學技術資料中心者，請個別再寄論文一本 至台北市(106-36)和平東路二段 106 號 1702 室）。 為學術研究之目的以各種方法重製得不限地域、時間與次數以微縮、光碟或其他各 種數位化方式重製後散布發行或上載網站，藉由網路傳輸，提供讀者基於個人非營 利性質之線上檢索、閱覽、下載或列印，惟每人以一份為限。 上列論文為授權人向經濟部智慧財產局申請專利之附件或相關文件之一 (專利申請案號： )，請於_年_月_日後再將上列論文公 開或上載網路。 (勾選此項者，請於繳交紙本論文給本校圖書館時特別聲明，否則一律以立即公開處理) - 上述授權內容均無須訂立讓與及授權契約書。依本授權之發行權為非專屬性發行 權利。依本授權所為之收錄、重製、發行及學術研發利用均為無償。上述之欄位 若未鉤選，本人同意視同授權。 指導教授姓名： 研究生簽名： (親筆正楷) 學 號： (務必填寫) 電 話： E-mail： 地 址： 日 期：中華民國 年 月 日 圖書館 授權書版本:2003/05/01 4 南台科技大學南台科技大學 碩士論文碩士論文 電腦化自動橫編織機電控系統之設計與製造電腦化自動橫編織機電控系統之設計與製造 研究生：梁耀星 本論文業經審查及口試合格特此證明 論文考試委員 指導教授 所 長 中華民國九十三年七月六日 i 摘摘 要要 本論文大部分介紹電腦化自動橫編織機電控系統的設計與製作，系統架構為 一永磁同步馬達(PMSM) 搭配自行設計之馬達驅動器，帶動機頭之移動，驅動器 使用獨立功率 MOSFET 元件設計換流器以降低成本 ， 並採用 PI 控制速度理論以達 零穩態誤差。使用 8052 規劃七個步進馬達之驅動，完成前床及後床之三角、左度 目及右度目，與搖床之控制。規劃布片及領子等之花色及式樣的程式藉由人機介 面傳輸，人機介面可以為鍵盤輸入，PC 下載，或記憶卡讀取，程式、系統參數及 操作結果皆由 LCD 顯示。系統內之通訊協定有 RS232，RS422 及 RS485 等作為指 令與資料之傳輸。 本論文第四章則是運用了現代產品發展技術流程，期望在一定時間內完成產 品開發設計流程並在每一分派的工作中發揮最大功用。Gantt chart 為一方案規劃 工具，運用在本論文中用來表現完成方案過程中每一個分派工作與時間的的關係 表，藉此期盼能讓相關研究在容許的時間內完成，降低時間消耗。 鑒於科技日新月異，功能更甚以往的機器推陳出新，本論文第七章也引用價 值工程(Value Engineering)，價值工程為一高效率的方法學，其目的為價低成本， 增加生產量，促進創新，移除不需要的設計元件，改善品質。希望能對創新產品 提供一個新的思維。 ii Design and Implementation of a Computerized Flat Knitting Machine ABSTRACT In the paper, the control system of a computerized flat knitting machine is designed and implemented largely. A permanent magnet synchronous motor is used to operate the machine. We design the motor drive that discrete power MOSFETs are adapted in the inverter to reduce the cost. In order to get zero steady-state error, the PI control is considered in the velocity control loop. Microcontroller, 8052, programs the drives of seven step motors to manipulate the controls of cam, left stitch, and right stitch of front-end and back-end, and racking. The color and style of the accessories of clothing is programmed by using a keyboard, PC, or an external memory card. There are three communication protocols, RS232, RS422, and RS485, used in the system to transfer the instructions and data. Chapter 4 is used to apply the technology of the product development process to expect finishing the duty in each task and then accomplishing the product design and implementation in considerable time. Gantt chart used in this chapter is a project planning tool that can be used to represent the timing of tasks required to complete a project. Hope these kinds of research can be finished in shorter time to reduce the time wasting. Because of the technological change with each passing day, innovative machines are designed and implemented in a very short time. Thats the reason why value engineering will be applied as part of my gradation thesis. Value Engineering is an effective methodology for reducing costs, increasing productivity, fostering innovation, eliminating unnecessary design element, ensuring cost-effective project, and improving quality with required performance, reliability, quality and safety in a product, facility, design, system, service or process. Deeply hope this could supply a new thought to innovate new products. iii 致致 謝謝 在研究所求學的三年過程中，首先感謝恩師 王明賢教授除了傾囊相授專業 學門知識和獨立研究的態度、精神和方法以外並適時指導生命真諦，均給予我觀 念及方向的釐清有著非常大的助益，在此特別感謝王明賢老師孜孜不倦的教誨， 使得研究工作能順利進行，致使本論文得以順利完成。 論文口試時，承蒙孫育義老師、及陳遵立老師耐心審閱拙文，匡正疏漏，予 以細心指點及寶貴之意見，使本論文能更臻完備，並在觀念釐清上收穫良多，在 此由衷感謝。 本人就讀研究所期間，日久公司提供很多的協助，不論是技術交流或是硬體 設備上，對於本研究有相當的助益，尤其是該公司的許富順經理和廖鴻文工程師， 本人在此表達感謝之意。 其次，感謝實驗室成員（吳進全學長、陳鴻志學長、陳秉瑜同學、葉育杰同 學、王士豪學弟、及陳建豪學弟等）在論文研究的討論上給予諸多的幫助和指正。 另外，感謝 Dr. John E. Leland and other teaching staff in the Engineering Technology of Pittsburg State University 不吝指導，以及匹茲堡多位同學幫助，使得 本人在美國實習一年期間能順利進行。 最後，感謝多年來不斷給予我支持與關懷的家人，我的奶奶黃桃女士以及雙親 梁詠菘先生及詹月桂女士養育栽培之恩，在我遭遇挫折時給我加油打氣，皆是支 持我不斷向上的原動力。最後，再次感謝所有幫助過我的師長及親朋好友，大家 三年來不斷的關懷鼓勵與支持包容，使我能夠全心投入求學和研究中，希望您們 能與我共同分享這份喜悅與榮耀。 iv CONTENTS 摘要 i Abstract ii 誌謝 iii Contents iv List of Tables vi List of Figures vi Chapter 1. Introduction 1 1.1 Motive 1 1.2 Background and Purpose 1 1.3 Thesis Frame 2 Chapter 2. PMSM Model 3 2.1 Structure 3 2.2 PMSM Mathematic Model 3 2.3 DQ-Transformation 6 Chapter 3. PI Control 8 3.1 Brief Description 8 3.2 Constitution of PI Control 8 3.2.1 P Controller 9 3.2.2 PI Controller 10 3.3 Digital Implement of PI Controller 12 3.3.1 Trapezoidal Integration 12 3.3.2 Forward-rectangular Integration 13 3.3.3 Backward-rectangular Integration 14 3.4 System Design 14 Chapter 4. Process of a Computerized Flat Knitting Machine Development 17 4.1 Product Development Process 17 4.2 Gantt Chart 19 4.2.1 Introduction 19 4.2.2 Gantt Chart 20 v Chapter 5. System Architecture 23 5.1 Brief Description 23 5.2 Human-machine Interface 24 5.3 Main Drive 25 5.4 Step Motors and Their Drives 28 5.4.1 Operation of Step Motor 28 5.4.2 Step Motor Drive 29 5.5 Others 30 Chapter 6. Driving and Control 31 6.1 Systematic Flow Path 31 6.2 Step Motor 32 6.2.1 NJM3370A 32 6.3 AC Servo Motor 33 6.3.1 Speed Control 34 6.4 Experimental Results 35 Chapter 7. Value Engineering 39 7.1 VE History 39 7.2 Introduction 40 7.2.1 Scope Statement 40 7.2.2 FAST Diagram 41 7.3 Steps to Complete VE Plan 42 Chapter 8. Conclusions and Future Prospection 53 8.1 Conclusions 53 8.2 Future Prospection 53 References 54 vi List of Tables Table 1. Parameters of 6CC401 PMSM. 26 Table 2. Standards of a computerized flat knitting machine. 43 Table 3. The scope statement. 44 Table 4. The function worksheet. 46 List of Figures Figure 2.1 Rotary type of PMSM 3 Figure 2.2 PMSM phase module 5 Figure 3.1 Control system 10 Figure 3.2 Trapezoidal integration 13 Figure 3.3 Forward-rectangular integration 13 Figure 3.4 Backward-rectangular integration 14 Figure 3.5 Speed control block diagram 15 Figure 3.6 Simplified speed control block diagram 16 Figure 3.7 The Bode plot for PI control 16 Figure 4.1 The process chart of product design and manufacturing 17 Figure 4.2 The product development process 18 Figure 4.3 The project timelines 21 Figure 4.4 The Gantt chart 22 Figure 5.1 The block diagram of the control system of computerized flat knitting machine 23 Figure 5.2 The block diagram of the control system of the human-machine interface 24 Figure 5.3 The block diagram of the control system of main drive 25 Figure 5.4 Block diagram of a drive 27 Figure 5.5 Driving operations of step motor 28 Figure 5.6 The block diagram of the control system of front-end step motor drive 29 Figure 6.1 The timing of the operation of 3370A 32 vii Figure 6.2 The flow chart of 8052 and step motor 33 Figure 6.3(a) The 3000rpm step responses for kp=0.1875 and TLMT=TR 35 Figure 6.3(b) The 3000rpm step responses for kp=0.1875 and TLMT=TR 36 Figure 6.4(a) The 3000rpm step responses for kp=0.4375 and TLMT=TR 36 Figure 6.4(b) The 3000rpm step responses for kp=0.4375 and TLMT=TR 37 Figure 6.5(a) The speed loop load shock recovery tests for ig=2A and TLMT=TR 37 Figure 6.5(b) The speed loop load shock recovery tests for ig=2A and TLMT=TR 38 Figure 7.1 The FAST diagram 47 Figure 7.2 The generate ideas 48 Figure 7.3 The idea comparison chart 49 Figure 7.4 The evaluation matrix 50 Figure 7.5 The VE recommendation 51 Figure 7.6 The implementation plan 52 1 Chapter 1 INTRODUCTION 1.1 Motive In the application of automatic industry each component is used to be set together to combine a modern mechanical system. A mechatronic system designer must assemble digital and analog circuits, microprocessors and computers, mechanical devices, sensors and actuators, and controls so that the final design achieves a desired goal 1. In September 2002, there was an email from National Science Council to look for professors that are expert in programmable control of a flat knitting machine. It lets us see that this mechatronic system will be more interesting in the market. Also we expect that this machine will bring deep enhancement for relative industries and convenient for the customers who use it. 1.2 Background and Purpose In the beginning the hand flat knitting machine was developed but its low efficiency reduces its usage and life cycle. Later electrical flat knitting machine was born by using control theories of assembling several electrical components and DC motors. “Design and implementation of a computerized flat knitting machine” is the second project that we co-operate with Eternity Electronics Industry Co., Ltd. “Original design manufacture an AC servo motor drive” was the first project. First purpose is to reduce the cost. The technique and experience in the design of AC servo motor drive is transferred to the design in a computerized flat knitting machine such that the cost of the computerized control system has been reduced to be half of that made in Japan. Finally trying to use some methods about product development process, and value engineering to enhance flat knitting machine not only meets more customers satisfactions but also 2 earns lots of profits for the industrial manufactures. 1.3 Thesis Frame The paper is divided into four branches with further discussion as follows: Section 1, the introduction; section 2, the architecture of a computerized flat knitting machine; section 3, the driving and control of step motors and AC servo motors, and; section 4, conclusions and future prospection. Each section is divided into several chapters which will have some brief description as follows: Chapter 1 Introduction: Brief description about the motive, background and purpose, and thesis frame of this thesis. Chapter 2 PMSM Model: Introduction of PMSM mathematic model and its DQ-transformation. Chapter 3 PI Control: Talking about what PI controller affects the system then discussing the P and PI controller and its system design. Chapter 4 Process of the Computerized Flat Knitting Machine Development: Talking about the introduction of product development process and using the Gantt chart to tell about the process of flat knitting machine development. Chapter 5 System Architecture: Discuss each component used to combine together as our system architecture which is human-machine interface, main drive, step motors, power module and so on. Chapter 6 Drive and Control: Using step motor and AC servo motor to drive system and speed control then measure the results of our experiment. Chapter 7 Value Engineering: Talking about the history and introduction of value engineering and then using eight steps to Complete VE Plan of a computerized flat knitting machine. Chapter 8 Conclusions and Future Prospection 3 Chapter 2 PMSM MODEL 2.1 Structure PMSM is the synchronous motor which is the excitation using permanent magnet in order to use the brushless excited rotation to form the type of rotary magnetic field. Figure 2.1 shows its structure. The salient and cylinder are two types of PMSM structure. For salient type the gap reluctance in excitation and armature are different, but for cylinder type they are the same. Generally cylinder type is the most common one because of easy control. If necessary armature coil may be multi-phase but its always three phase in general. (a) Salient type (b) Cylinder type Figure 2.1 Rotary type of PMSM. 2.2 PMSM Mathematic Model Figure 2.2 is surface-mounted PMSM equivalent circuit. From this we can get the descriptive circuit equation 2.1 2-6. 4 + + + + = w v u w v u wwwvwu vwvvvu uwuvuu w v u e e e i i i pLRpLpL pLpLRpL pLpLpLR v v v 2 1 2 1 2 1 2 1 2 1 2 1 (2.1) In equation 2.1, dtdp = is differential operator, u v, v v, and w v are phase-voltages, u i, v i, and w i are phase-currents, u e, v e, and w e are back emf, and u, v, andw are inductive electromotive forces of three phase coils. Assume all the stator resistance, self-inductance, and mutual inductance in the coil are the same as follows: RRRR wvu = (2.2) wvu LLL= (2.3) MLLL wvvwuv = (2.4) Consider that armature coil also have leakage inductance l L ，then the phase inductance is as follows: MLL l 2 3 += (2.5) Then change the equation 2.1 as follows: + += w v u w v u u w v u e e e i i i pLR v v v )( ， (2.6) 5 u e、 v e、 w e in equation 2.1 are counter-electromotive forces. S N w u v u vw V vw uw L LR VV RL re R L u uv L Lvw re Figure 2.2 PMSM phase module. The excitation in u e 、 v e 、 w e was supplied by fu 、 fv 、 fw which are u、v、 w linked flux of three-phase armature coils, and the maximum is f , as equation 2.7 shows: reffu cos = ) 3 2 cos( = reffv (2.7) ) 3 2 cos( += reffw re in equation 2.7 uses u phase armature coil as its basis and takes the excited angle in clockwise direction. re is the angular speed of excitation showing as follows: =dt rere (2.8) Change u e 、 v e 、 w e as follows: 6 refrefuu pesin = ) 3 2 sin( = refrefvv pe (2.9) ) 3 2 sin( += refrefww pe 2.3 DQ-Transformation For acquirement of control characteristics or deduction of control methods, two -phase AC expressing equation of voltage or current is easier than three-phase AC expressing equation; however, two-axial DC expressing equation is the easiest. In order to enhance motor equations, its necessary to change the coordinate which is what we called coordinate transformation. As we do the coordinate transformation, the power is invariant. Consider the Park transform and voltage balance; later we use linear transformation to get d-q axis transfer relation in PMSM 2-6 as follows: + + = w v u re re re re re re q d v v v v v ) 32sin( ) 32cos( ) 32sin( ) 32cos( sin cos 3 2 (2.10) re is the electrical angle between the stator and rotor, then the anti-transformation will be: + = q d rere rere rere c b a v v v v v ) 32sin() 32cos( ) 32sin() 32cos( sincos 3 2 (2.11) Using equation 2.10, we can get equation 2.12 7 + + + = qq d re re q d ei i pLRL LpLR v v0 (2.12) R is the armature impedance, L is the armature inductance, and re is the angular speed. The torque of PMSM is: qtqafe ikiPT=3 (2.13) In the equation 2.13 P is number of magnetic poles, af is the flux which is the rotor magnet connecting stator, and t k is the torque constant. Comparing the model in equation 2.12 from equation 2.6, then PMSM will be easily controlled because we just need to use q i to control torque from motor output. If 0= d i, motor will have higher power efficiency and will cause magnetic decreasing for negative d i; however, its necessary to use linear transformation 2.10 and anti-transformation 2.11 in control loop. Though calculating equations 2.10 and 2.11 can be replaced by using lookup table, it will always take some time for a general chip. If we calculate the operations by using the DSP, we will decrease much time. 8 Chapter 3 PI CONTROL 3.1 Brief Description Control theory is important for nearly all engineering disciplines. In all these systems the system takes measurements of the current state and through software, hardware, or both the system moves to the desired state. In this chapter we will only be providing an introduction to control theory. Advanced control theory can be quite complex and rely on advanced mathematical techniques. In this chapter we will concentrate mostly on building the systems and implementing simple software control algorithms. The control method that we will discuss is referred to as PI control (Proportional; Integral). PI control uses a combination of three simple control methods to maintain a set point. This chapter will explain PI algorithms and we will discuss how the proportional and integral terms work independently and then how they work in combination. 3.2 Constitution of PI Control The use of PI control which includes proportional term and integral term always keeps until now. The proportional term is used to adjust the output of controller according to the error, and the integral term is used to eliminate the steady state error. These two functions are enough for most of the control systems. Because of easy structure, PI control is used widely by engineers until now. PI control can