Design and modification of a longitudinal slicer using PLC and stepper motor
2026-04-06 04:46:44··#1
1. Introduction The MZQ-200 longitudinal slicing machine, as a major machine for producing decorative panels, operates on the following principle: the machine head presses down on the wood with a certain pressure via a special conveyor belt, slicing it forward into thin slices of a specific size. After each slice, the head returns and descends, repeating the cycle. Early slicing machines controlled the feed rate of a standard three-phase asynchronous motor after each slice using a time relay, stopping the feed with an electromagnetic brake. However, because the speed of the three-phase asynchronous motor varies with the load, the feed rate is inconsistent each time, resulting in uneven pressure, inconsistent slice thickness, and even failure to slice. Other methods control the feed motor's stop by adjusting the position of a microswitch, but this requires experience and is not conducive to adjustment. With the continuous development of industrial control technology, the performance-price ratio of programmable logic controllers (PLCs) is increasingly higher. Stepper motors are pulse-controlled, and their displacement depends on the number of pulses. PLCs also have pulse output and pulse control functions, making it easy to achieve position control between PLCs and stepper motors. This system replaces the head feed with PLC-controlled stepper motors to form an open-loop control system for precise feed. 2 System Composition The system uses a centralized PLC control system from LG (with built-in 2-axis position control, high-speed counting, etc., and ladder diagram programming software), and KINCO stepper motors and stepper motor controllers. An Easyview touchscreen is used to communicate with the PLC to display and set relevant parameters. The system flow is shown in Figure 1. Figure 1 System Flowchart (1) System Design Because this system has only one stepper motor, there is only 1-axis position control. P40 is the pulse output terminal of PLC position channel 1, and P42 is the direction control terminal. The wiring diagram of the PLC, stepper motor controller, and stepper motor is shown in Figure 2. [align=center]Figure 2 PLC and Stepper Motor Controller and Stepper Motor Wiring Diagram[/align] Figure 3 Parameter Setting Interface Quantitative control can be achieved using the absolute position start instruction POSDST S (channel specification), N1 (absolute/relative coordinate), SV1 (position address), and SV2 (position speed). Jogging control can be achieved using the POSJOG instruction. The jogging speed and direction can be set through the ladder diagram. In the position control interface, acceleration time (Accel), deceleration time (Decel), electronic gear backlash (Backlash comp), basic speed (Bias Speed), and upper limit speed (Speed limit) can be set. The upper limit speed (High speed) and lower limit speed (Low speed) (unit is PPS) of jogging can be set, as shown in Figure 3. (2) PLC communicates with the touch screen via RS232 port. The PLC communicates with the touch screen via RS232 port. The touch screen displays relevant data and help information and sets relevant data. For example, the distance of each feed of the machine head is actually converted into the number of pulses output by the PLC, which ultimately controls the number of feed steps of the stepper motor. For example, when the transmission ratio is 1:30, the lead screw pitch is 6mm, and the stepper motor rotates at 200 steps/revolution, the relationship between the set stepper motor step count (n) and the actual feed of the machine head is: n/200 × 1/30 × 6 = 0.1mm, meaning the machine head feeds 0.1mm for every 100 steps the stepper motor takes. Here, n is the PLC's position address, which can be set via the touchscreen. By appropriately setting the decimal point of the numerical input parameters on the touchscreen, the value can be changed by 10n or 101/n times. Setting 0.1mm on the touchscreen corresponds to a PLC input value of 100, and the PLC will output 100 pulses through a designated channel, thus controlling the stepper motor to run 100 steps. This setting is for easier and more intuitive parameter setting by the operator. If mechanical transmission backlash is ignored, it is easy to conclude that the automatic descent accuracy of the machine head is 1/200 × 1/30 × 0.6mm = 0.001mm. Please refer to Figure 4 for PLC position control parameter settings and ladder diagrams. Figure 4. PLC position control parameter settings and ladder diagram. Additionally, the PLC's down counter instruction can be used to pre-set the slicing quantity for convenient quantitative packaging. 3. Conclusion In summary, using a PLC to control a stepper motor for feeding simplifies circuit design, improves system stability and equipment feeding accuracy. Ladder diagrams and parameter settings can be easily created using programming software, and the touchscreen allows for accurate and intuitive display and setting of parameters, effectively improving product quality and equipment grade.