With the widespread use of products such as integrated circuits, printed circuit boards, color LCD screens, electronic components (such as relays and speakers), optical lenses, automotive parts, and medical supplies, dispensing robots, a key process equipment, are also being used more and more widely. This article mainly introduces the composition and characteristics of the dispensing robot control system based on the MPC05 independent motion controller, which was developed and produced by Lechuang Automation Technology Co., Ltd.
1 Introduction
With the widespread use of products such as integrated circuits, printed circuit boards, color LCD screens, electronic components (such as relays and speakers), optical lenses, automotive parts, and medical supplies, dispensing robots, a key process equipment in these products, are also being used more and more extensively.
To adapt to the trend of industrial dispensing equipment towards automation and speed, Lechuang Automation Technology Co., Ltd., based on years of research achievements in motion control technology, has developed and produced a dispensing robot control system based on the MPC05 independent motion controller. This system is a high-tech product integrating digital control, precision mechanics, and automatic dispensing, meeting the requirements of flexibility and speed in the dispensing process. It boasts high reliability and scalability while effectively reducing product costs.
Figure 1 Figure 22 System Composition and Process Flow
2.1 System Composition
The dispensing machine robot control system mainly consists of an MPC05 motion controller, stepper motors and drivers, a teach pendant, and other components, as shown in Figure 1. Serial port A connects to a computer for system debugging; serial port B connects to a professional teach pendant control box, allowing for teaching, modification, configuration, and processing of any graphic; the USB interface is used to download the firmware of the MPC05 motion controller and can also be used to download processing files.
2.2 Process Flow
The basic workflow of the dispensing robot system based on the MPC05 motion controller is shown in Figure 2. Customers can directly teach or convert CAD graphics according to their actual needs to design the dispensing graphics they need. The software system converts the dispensing graphics into motion commands and transmits them to the MPC05 motion controller. Then, by driving the actuator and controlling the dispensing head, the dispensing control is finally realized.
3. Design of MPC05 Motion Controller
The core unit of the dispensing robot control system, the MPC05 motion controller, adopts an "FPGA+DSP" solution. Figure 3 shows the controller's block diagram. FLASH memory is used to store the DSP program, and any extra space can be used to store configuration programs, machining programs, system process parameters, and field data. The NAND FLASH large-scale on-board memory is used to store configuration data, machining data, etc. The core of the controller is the DSP and FPGA; the DSP implements CPU functions, and the FPGA implements control and I/O functions.
The controller's processing files can be downloaded via RS232 or copied via USB flash drive. The output pulse direction signal is used to control stepper or servo drivers, and the I/O port is connected to stop or power signals, etc.
The MPC05 motion controller has two serial communication ports: Serial Port A is used to communicate with a PC, using a data transmission protocol similar to that of Panasonic servos; Serial Port B is a human-machine interface communication interface, using the standard Modbus protocol.
Figure 34. System Features and Functions
4.1 Complete Solution
The MPC05-based dispensing machine provides a complete solution from CAD software and control system to actuator, meeting any simplified or complex needs: Professional trajectory programmer (teach pendant control box): used for teaching and planning dispensing trajectory.
The Chinese user interface is simple and convenient to use, and you can quickly become proficient in its operation. It can teach, modify, configure, and process any graphic.
Teach pendant-free embedded adapter card: Provides processing capability without a teach pendant. In multiple devices, only one teach pendant is needed to meet the requirements, which can reduce costs.
Professional CAD control software: Supports converting AutoCAD format and G-code into machining files recognizable by the MPC05 motion controller;
MPC05 Motion Controller: High-performance 4-axis motion control, supporting stepper and servo motor control; stepper motors, servo motors and drivers.
4.2 Complex Graphics Processing Capability
With a professional motion controller at its core and a user-friendly interface, the dispensing robot control system can handle very complex graphic processing.
Supports two processing types: direct teaching or CAD drawing conversion;
Supports teaching editing of points, line segments, circular arcs, and elliptical arcs, and allows switching between any plane selection;
Supports arbitrary delay, supports speed change during motion, and automatic continuous interpolation control;
Supports process control such as glue release delay and early glue shut-off;
Supports array processing and analog output;
Supports direct reading of CAD files and G-code files, and supports chamfering and fillet processing;
It comes with built-in CAD drawing capabilities and supports automatic path selection and custom processing order.
4.3 CAD Software Functions
It comes with built-in CAD processing capabilities, making it easy to control the manufacturing process using CAD drawings.
Supports reading AutoCAD DXF files, and supports multiple file formats from DXF2000 to DXF2006;
It supports G-code editing and allows for arbitrary conversion between G-code, graphics, and DXF files;
Directly output graphics, DXF files, or G-code as dispensing machine processing files;
It has built-in graphic editing capabilities for points, lines, polylines, rectangles, polygons, circles, arcs, ellipses, elliptical arcs, runways, and more;
The origin, processing order, and arbitrary graphic orientation can be customized;
Automatic trajectory optimization and loop detection. Supports rounded corners and chamfering.
4.4 Adaptability and Expansion Capability
No restrictions are placed on the mechanical system; the transmission mechanism, actuator, and platform structure can be freely selected.
The MPC05 motion controller has a pulse output frequency of 7.5MHz, which can meet the requirements of high-speed machining.
It has 16 inputs and 16 outputs, and its control capabilities can be expanded arbitrarily.
Optional origin and positive/negative limit signals provide precise control capabilities;
Parameters such as pulse equivalent, platform size, speed limit, and impact can be customized;
Optional controller size and user interface customization;
Optional file copying, design once, use unlimited times; supports USB file download, etc.
4.5 Other Functions
First, it is simple and convenient to operate. The system is designed with ease of use in mind. Without affecting the functionality, the number of buttons is reduced to a minimum, simplifying the operation process. Worker training is simple, saving training time and costs.
Secondly, it has a trajectory storage function. In the dispensing machine control system, it can store 99 working trajectory graphics in the teach pendant at the same time, and 32 in the MPC05 motion controller. With just a simple selection operation, it can quickly adapt to different workpieces; after one download, it can be removed from the teach pendant.
Furthermore, the glue spraying needle is adjustable, which can adapt to the requirements of workpieces of different heights within a certain range, and ensures that the motion trajectory does not need to be recalibrated when changing the glue dispensing machine needle.
Finally, key components are carefully selected to ensure high speed and precision while meeting the high reliability requirements under automated production conditions.
5. Summary
The dispensing robot control system based on the MPC05 independent motion controller features ease of use, simple operation, and a user-friendly human-machine interface. It boasts smooth motion trajectory, uniform glue application, powerful functions, high reliability and stability, and effectively reduces product costs. It is currently widely used in various dispensing robot equipment.
