2014 International Symposium on Computer, Consumer and Control

Control System Based on PLC for Winding

Machine
Wei Mo, Mei Wang, Jzau-Sheng Lin, Hongyang Zan1, Guangqing Sun1
1 College

of Electric and Control Engineering, Xian University of Science and Technology

*58

Yanta Road, Xian 710054, China

2 Department

of Electronic Engineering, National Chin-Yi University of Technology

57, Sec. 2, Zhongshan Rd., Taiping Dist., Taichung 41170, Taiwan
776418493@qq.com

provides the feedback information to the servo driver and to

the PLC, then to human-computer interface.

Abstract Aiming at the performance of winding machine

which implements the winding operation on special motor, a
control system is designed based on PLC and permanentmagnet AC servo motor. The hardware design of the control
system includes the serve drive design, photo electronic
coupler and A/D expanding circuit design, displayer selection.
The software design of the control system includes the main
interface, parameter setting interface, and operation display
interface, impulse computation for arbitrary winding turns,
and speed adjustment computation. Experiment proves that
the control system is stable and satisfies the requirement of
winding operation on special motor.
Keywords control system, winding machine, special motor,
PLC, servo system

Reducer
(reduction
ratio
1/i)
Humancomputer
interface

Servo driver

Servo motor

Winding
mechanism

Fig.1 Basic structure of control system of winding machine

B. Design of PLC

I. INTRODUCTION

The control system [7-8] has some requires for PLC as

the follows.
(1) The output pulses and direction signals can control
servo driver with the frequency more than 120kH.
(2) The output signals of PLC control the servo driver via
the photo coupler.
(3) A text displayer should be amounted in the control
system as the human-computer interface, and the parameter
settings and status display can be changed.
(4) The position feedback pulse can be read, and the
counting frequency is more than 120kH.
(5) The analog input port should be amounted, the range of
input voltage is 0~10V, and the resolution is above 1 212 .
Compared with Siemens S7 series, Mitsubishi FX
series, A-B Micrologix series, the PLC of micro-FBs series
of Taiwan is selected, because it not only meets the above
requirements, but also possesses the following features [9-11].
(1) The Average execution time of sequential instruction is
0.33 s.
(2) Power supply voltage is 100~240V AC or 24 V DC.
(3) The program memory reaches to 20K words.
(4) The program can be modified during running process
via Windows programming interface.
(5) There are 4 groups of high speed counter hardware with
32-bit, 8 kinds of mode of operation, counting frequency is
up to 920 KHz.

With the progresses of motor control technology and

the improvement of automatic winding levela large
market of winding machines have been developed for
manufacturing motor coil. The development of general
winding machines is oriented from manual winding to semi
automatic winding, and even to automatic and highprecision winding [1-4]. However, for some special
motorthere is not yet the suitable winding machine for
winding coil [5-6]. To satisfy the requirements of high
efficiency, high-stability and high-precision control, a kind
of new control system is designed, which is applied to the
winding machine to manufacturing the tower and copper
coils of special motors.
II. SYSTEM STRUCTURE AND HARDWARE
A. System structure
The basic structure of the control system of winding
machine is shown in Fig. 1. The control system is
composed of the units of PLC, human-computer interface,
servo driver, winding mechanism, encoder, and servo motor
and so on. The PLC is the control unit; Human-computer
interface has the function of input and output parameter
setting according to requirements; servo drive and servo
motor could be in the integrated structure; the encoder
978-1-4799-5277-9/14 $31.00 2014 IEEE
DOI 10.1109/IS3C.2014.31

PLC

Encoder

74

load torque Tf of motor are as below.

n M D
i
j 
J=
4
i , j =1

(6) There are 5 groups of 0.1ms high speed timers,

including 4 groups of 32 bits, and 1 group of 16 bits.
(7) It has the location function: 4-axis pulse output with
maximum frequency of 920 KHZ, and it has 3 operation
modes, and the location program can be uploaded and
download.
(8) The size is very small, and the price is lower.
(9) The communication speed reaches up to 921.6 kbps, and
the 5 communication units support the communications
with RS232, RS485, USB, Ethernet, etc.
(10) For the requirement (3), the expansion board of FBs
can be used with a relative lower price. The expansion
board unit FBs-B2A1D, 0~10V, 12 resolution, can meet the
application requirements.
The connection scheme of PLC is shown in Fig. 2.
FBs-20MC

i= j

Tf =

GD
i

(n 20) 

i , j =1
i= j

where M i is the quality of winding mould, D j stands for

the diameter of winding mould, Gi represents winding
mould gravity.
In order to match the torque and the inertia to avoid the
dithering problem of motor operation, a reducer of 3:1 is
needed because when the running speed is higher than the
rated speed, the rated torque goes beyond the range of the
used continuous torque.

Photocoupler

D. Selection of photo coupler and A/D expansion board

Text display
Servo motor

X0
X1

Servo driver
Pulse output A/B
Start

Encoder

In order to improve the winding efficiency, this

winding machine is mounted with the potentiometer to
regulate voltage. The range of voltage is 0.15V~10V. Then
the A/D module is needs. Moreover, the photo coupler is
used to reduce the electromagnetic interference and to
match the electric frequency. The design of photo coupler
circuit is shown in Fig. 3.

Motor

Y0
X2
Y1

Pause

X3
24V+

Reset

C0
C1

X4

Running

Y3
Manual/Auto

Fault

X7
Y4

24V+

A\D expansion

GND

Fig.2 Connection scheme of PLC

C. Servo driver design

The control system requires the drive motor [12-13] with 5
items below.
(1) Precise positioning based on the winding principle; the
accuracy is less than 0.1circle.
(2) Power is more than 500W; the constant torque can be
produced with the lower speed.
(3) Operation smoothly with smaller torque fluctuation.
(4) Small size, high efficiency, fast dynamic response.
(5) Operation with adjustable speed, and the speed range is
1~3000 rpm.
According to the above requirements, the highperformance permanent magnet AC servo system [14-16],
Yaskawa servo system SGDV-5R5A01A/SGMJV08AAA61, is adopted after the comparisons with Panasonic
A5, A-B, Kinetix, and the West series. The rated speed is
3000 rpm; the maximum speed is 6000 rpm; the power
output is 1KW; the frequency response is up to 1.6 KHz.
Servo motor [] is also required to meet the torque
requirement and simultaneously satisfy the inertia match.
The rotary inertia J of winding mould and the equivalent

Fig3. The design of photo coupler circuit

. SOFTWARE DESIGN
The control system software is composed of the
human-machine interface and PLC.
The operation interface includes three parts, main
interface, parameter setting, and display running condition.
The flow chart of PLC program is shown in Fig. 4.

In the software design, there are 2 parameters

should be calculated.
Firstly, the pulse number P should be calculated to
implement the winding after the coil number is given.

N p 100
P=
2

(3)

where N is the coil number, p is the output pulse number of

each rotation.

75

 
















!

*
$
#

%
$

"#!

!

+
&%
' !

*
+

&
' 
!

Fig. 5 One of interfaces of control system

()

Fig. 4 The flow chart of PLC program

Secondly, the speed n of the winding machine should

be calculated to realize the real-time adjustment.

n=

d nmax
472

(4)

where d is the output value of A/D D4072. nmax stands

for the highest speed which is set for the winding
machine.
Fig. 5 is partial software program of control system.
IV. EXPERIMENT
To evaluate the designed control system, the hardware
and software are integrated together. Experiment proves
that the control system is stable and satisfies the
requirement of winding operation on special motor. Fig. 6 is
the control system and winding machine.

Fig. 6 The control system and winding machine

V. CONCLUSION
In this paper, a control system is designed based on
PLC and permanent-magnet AC servo motor. The hardware
design of the control system includes the serve drive design,

76

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photo electronic coupler and A/D expanding circuit design,

displayer selection. The software design of the control
system includes the main interface, parameter setting
interface, and operation display interface, impulse
computation for arbitrary winding turns, and speed
adjustment computation. Experiment proves that the control
system is stable and satisfies the requirement of winding
operation on special motor.
ACKNOWLEDGMENT
This research is sponsored by Scientific Research
Foundation for Returned Scholars, Ministry of Education of
China ([2011]508) and Natural Science Foundation of
Shaanxi Province (2011JM8005), and sponsored by the
National Science Council of Taiwan under the Grant
NSC101-2221-E-167-040.
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