Revolutionizing Industrial Automation: A Case Study on the Adoption of PLC in Double Drilling Machines
In today’s fast-paced manufacturing landscape, efficiency, precision, and reliability are the keys to standing out in the competitive market. The integration of Programmable Logic Controllers (PLC) in industrial applications has transformed the way machines are controlled and optimized, enabling organizations to reduce production costs, improve product quality, and increase productivity. In this blog post, we will explore a real-world example of the application of PLC in double drilling machines, showcasing its capabilities and benefits.
Application Context
Our company has developed a double drilling machine with two stations, a key product in our portfolio. This machine is used to process dual parts simultaneously without interferences, significantly enhancing treatment efficiency and reducing investments. The basic principle of the machine’s operation is as follows: the power head of the cannon drill bit is placed flat on the base of the machine tool, with the treatment parts stored in the room pliers on the vertical sliding table. The sliding table moves up and down along the vertical line of the bit of the rotating gun drill, and during treatment, the forest runs at high speed and the sliding table causes the room to descend, piercing the product.
Traditionally, machine tools are driven by hydraulic cylinders, with the hydraulic valve switch controlling the action of the hydraulic solenoid valve to return the cylinder. However, this approach has limitations, as the precision of the machining hole depth is difficult to control, and the setting of the execution speed is not very practical.
The Advent of Servo Motors and PLC
To overcome these limitations, our company implemented the use of servo motors to control the high-end positioning of the screw slide platform. This upgrade allows for the easy adjustment of the machining speed and the control of the drilling depth with high precision. The PLC plays a crucial role in this implementation, providing unparalleled control and reliability.
PLC Control Solution
In this case, a simple CNC control system (CNC) is used, which is suitable for two axes with non-interference operation. The CNC system has a standard G-code programming and can easily perform servo positioning checks. However, when programming the G-code with two axes or multi-axes CNC, two independent positioning instructions cannot be executed simultaneously, which can lead to complicating the control process.
Why PLC is the Ideal Choice
Given the limitations of traditional hydraulic transmission and CNC control systems, we chose PLC as the ideal solution for this machine tool control requirement. The positioning actions of the tool-machine are not complex, and only two position control controls are necessary for the front processing and the inverted output positioning. Many types of PLC have high-speed pulse output functions, which have very practical relative positioning and absolute positioning instructions. Additional extension modules are not necessary, making it easy to implement movement control of the tool-tool.
Key Requirements
The machine tool needs an impulse output in two axes to control the operation of the screw bunker table respectively at the two stations. The positioning speed of the sliding table should not be less than 6 m/min. The precision of the positioning should be less than 0.01 mm.
The human-machine dialog machine users must be able to configure the touch screen to connect with the PLC, defining treatment speed and part processing parameters.
The PLC must be able to monitor certain internal key data in real-time, including part coordinates, power head engine current, and processing state, key data, or faulty signals, facilitating analysis of the machine condition and breakdown analysis.
The touch screen and PLC must communicate easily, with the PLC reading and writing data D and M.
- The treatment of barrel exercises should be easily adjusted according to different materials and sizes of parts and treatment holes. As a result, the machine tool must be able to control the speed of the power head by a frequency converter.
Conclusion
The implementation of PLC in our double drilling machine has revolutionized the way we control and optimize machine performance. With its flexible and reliable control platform, PLC has enabled us to improve productivity, reduce costs, and enhance product quality. By leveraging the advanced features of PLC, we are better equipped to face the challenges of the modern manufacturing landscape, providing superior value to our customers and staying ahead of the competition. In this blog post, we have showcased the benefits of PLC in industrial automation, highlighting its capabilities, advantages, and applications. By adopting PLC in your own production processes, you can unlock the full potential of your machines, achieving greater efficiency, precision, and reliability.
