The Designed Operation of the Machine Control System on HL-2A Tokamak

The Ethernet and field-bus communications are used in the machine control system （MCS） of HL-2A. The control net, with a programmable logic controller （PLC） as its logic control master, an engineering control management station as its net server, and a timing control PC connected to a number of terminals, flexibly and freely transfers information among the nodes on it with the Ethernet transmission techniques. The PLC masters the field bus, which carries small pieces of information between PLC and the field sites reliably and quickly. The control net is connected into the data net, where Internet access and sharing of more experimental data are enabled. The communication in the MCS guarantees the digitalization, automation and centralization. Also provided are a satisfactory degree of safety, reliability, stability, expandability and flexibility for maintenance.

NUMERICAL MODELING OF MULTI-CYLINDER ELECTRO-HYDRAULIC SYSTEM AND CONTROLLER DESIGN FOR SHOCK TEST MACHINE

A high fidelity dynamic model of a high-energy hydraulically-actuated shock test machine for heavy weight devices is presented to satisfy the newly-built shock resistance standard and simulate the actual underwater explosion environments in laboratory as well as increase the testing capability of shock test machine. In order to produce the required negative shock pulse in the given time duration, four hydraulic actuators are utilized. The model is then used to formulate an advanced feedforward controller for the system to produce the required negative waveform and to address the motion synchronization of the four cylinders. The model provides a safe and easily controllable way to perform a ＂virtual testing＂ before starting potentially destructive tests on specimen and to predict performance of the system. Simulation results have demonstrated the effectiveness of the controller.

Development of PLC-based Tension Control System

Fiber winding tension is an important factor in the molding techniques of composite material which influences the quality of winding product directly, and the tension control is a key technique in fiber winding techniques. This paper introduces a closed-loop tension control system with the programmable logic controller （PLC） with function modules as its control kernel, the alternating current （AC） servo motor as execute element and the radius-following device to accomplish the real-time radius compensation. The mechanism of the tension control system is analyzed and the numerical model is set up. The compensation technique of the radius of the scroll is analyzed. Experimental results show that the system is well qualified with high control precision and high reaction speed.

Review on grid-forming converter control methods in high-proportion renewable energy power systems

Grid-forming(GFM)converters can provide inertia support for power grids through control technology,stabilize voltage and frequency,and improve system stability,unlike traditional grid-following(GFL)converters.Therefore,in future“double high”power systems,research on the control technology of GFM converters will become an urgent demand.In this paper,we first introduce the basic principle of GFM control and then present five currently used control strategies for GFM converters:droop control,power synchronization control(PSC),virtual synchronous machine control(VSM),direct power control(DPC),and virtual oscillator control(VOC).These five strategies can independently establish voltage phasors to provide inertia to the system.Among these,droop control is the most widely used strategy.PSC and VSM are strategies that simulate the mechanical characteristics of synchronous generators;thus,they are more accurate than droop control.DPC regulates the active power and reactive power directly,with no inner current controller,and VOC is a novel method under study using an oscillator circuit to realize synchronization.Finally,we highlight key technologies and research directions to be addressed in the future.

Pressure Regulation for Earth Pressure Balance Control on Shield Tunneling Machine by Using Adaptive Robust Control

Most current studies about shield tunneling machine focus on the construction safety and tunnel structure stability during the excavation. Behaviors of the machine itself are also studied, like some tracking control of the machine. Yet, few works concern about the hydraulic components, especially the pressure and flow rate regulation components. This research focuses on pressure control strategies by using proportional pressure relief valve, which is widely applied on typical shield tunneling machines. Modeling of a commercial pressure relief valve is done. The modeling centers on the main valve, because the dynamic performance is determined by the main valve. To validate such modeling, a frequency-experiment result of the pressure relief valve, whose bandwidth is about 3 Hz, is presented as comparison. The modeling and the frequency experimental result show that it is reasonable to regard the pressure relief valve as a second-order system with two low corner frequencies. PID control, dead band compensation control and adaptive robust control（ARC） are proposed and simulation results are presented. For the ARC, implements by using first order approximation and second order approximation are presented. The simulation results show that the second order approximation implement with ARC can track 4 Hz sine signal very well, and the two ARC simulation errors are within 0.2 MPa. Finally, experiment results of dead band compensation control and adaptive robust control are given. The results show that dead band compensation had about 30° phase lag and about 20% off of the amplitude attenuation. ARC is tracking with little phase lag and almost no amplitude attenuation. In this research, ARC has been tested on a pressure relief valve. It is able to improve the valve＇s dynamic performances greatly, and it is capable of the pressure control of shield machine excavation.

Bayesian zero-failure reliability modeling and assessment method for multiple numerical control(NC) machine tools

A new problem that classical statistical methods are incapable of solving is reliability modeling and assessment when multiple numerical control machine tools(NCMTs) reveal zero failures after a reliability test. Thus, the zero-failure data form and corresponding Bayesian model are developed to solve the zero-failure problem of NCMTs, for which no previous suitable statistical model has been developed. An expert-judgment process that incorporates prior information is presented to solve the difficulty in obtaining reliable prior distributions of Weibull parameters. The equations for the posterior distribution of the parameter vector and the Markov chain Monte Carlo(MCMC) algorithm are derived to solve the difficulty of calculating high-dimensional integration and to obtain parameter estimators. The proposed method is applied to a real case; a corresponding programming code and trick are developed to implement an MCMC simulation in Win BUGS, and a mean time between failures(MTBF) of 1057.9 h is obtained. Given its ability to combine expert judgment, prior information, and data, the proposed reliability modeling and assessment method under the zero failure of NCMTs is validated.

IMPROVE THE KINETIC PERFORMANCE OF THE PUMP CONTROLLED CLAMPING UNIT IN PLASTIC INJECTION MOLDING MACHINE WITH ADAPTIVE CONTROL STRATEGY

The kinetic characteristics of the clamping unit of plastic injection molding machine that is controlled by close loop with newly developed double speed variable pump unit are investigated. Considering the wide variation of the cylinder equivalent mass caused by the transmission ratio of clamping unit and the severe instantaneous impact force acted on the cylinder during the mold closing and opening process, an adaptive control principle of parameter and structure is proposed to improve its kinetic performance. The adaptive correlation between the acceleration feedback gain and the variable mass is derived. The pressure differential feedback is introduced to improve the dynamic performance in the case of small inertia and heavy impact load. The adaptation of sum pressure to load is used to reduce the energy loss of the system. The research results are verified by the simulation and experiment, The investigation method and the conclusions are also suitable for the differential cylinder system controlled by the traditional servo pump unit.

The Innovation of CNC Machine Interface Based on DNC System

This paper describes the innovation schemes of the interface of a CNC machine which cannot communicate with a computer by a Direct Numerical Control(DNC)interface and the functions of a DNC interface system.One architecture of hardware and software of a practi- cal single-chip computer based on DNC interface system developed by the authors is given. Without any change of the original hardware and software,this DNC interface system has been used to innovate the CNC machine's interface to implement the direct communication between a computer and a CNC machine and to achieve no tape transmission of a part program and ma- chine parameters.It has been demonstrated that this DNC interface system has certain practical values in improving the reliability,efficiency and production management of CNC/NC machine.

Carbon Emission Modeling and Analysis in Manufacturing Process for Numerical Control Machine Tools

Reducing carbon emissions( CEs) is the urgent demand all over the world. In order to realize the low-carbon numerical control( NC) machining, the evaluation model of a part's manufacturing carbon emission with NC machine tools was built by considering the influences of the cutting tool geometrical parameters.The manufacturing CEs were produced by electric power,cutting tools,and cutting fluid consumed in manufacturing process. The parameters of cutting tools affected not only the CEs,but also the machining quality. Then the actual constraint models of the machine performance,machining quality were given in order to optimize the cutting parameters and achieve the low-CEs. Finally,a case was given to analyze the influences of the cutting tool angles on the manufacturing CEs. The results show that the CEs decrease as the rake angle and edge angle increase under the constraints of the machine specifications and machining quality.

Specialized Numerical Control Plasma Cutting Machine

The large thermal cutting equipment——The DHG. CNC numerical control plasma cutting machine is produced by The Ha’erbin Welding & Cutting Equipment Co. It specializes in the precise formation and baiting of nonferrous boards and thin carbon steel plates at a high speed. It avoids the disadvantage of flame cutting, which cannot cut nonferrous and thin steel plates.

An Investigation into the Life Cycle Cost of a Typical Computer Numerical Control Machine

This paper relates to a typical computer numerical control (CNC) machine, model FDXNC 128, and analyzes the payoff period quantitatively and forecasts the future maintenance cost and the evaluation of the economic benefit by using Life Cycle Cost (LCC) method and grey theory. The discussion shows conclusions that are beneficial to the production, management, and decision making of the enterprise.

Development Trend of NC Machining Accuracy Control Technology for Aeronautical Structural Parts

High-performance five-axis computer numerical control machine tools are widely used in the processing of Aeronautical Structural parts. With the increase of service life, the precision of CNC machine tools equipped by aeronautical manufacturing enterprises is declining day by day, while the new generation of aircraft structural parts are developing towards integration, large-scale, complexity, thin-walled and lightweight. It is very easy to produce dimension overshoot and surface quality defects due to unstable processing technology. The machining accuracy of aircraft structural parts is also affected by complex factors such as cutting load, cutting stability, tool error, workpiece deformation, fixture deformation, etc. Because of the complexity of structure and characteristics of Aeronautical Structural parts, the consistency and stability of cutting process are poor. It is easy to cause machining accuracy problems due to tool wear, breakage and cutting chatter. Relevant scholars have carried out a lot of basic research on NC machining accuracy control and achieved fruitful results, but the research on NC machining accuracy control of Aeronautical structural parts is still less. This paper elaborates from three aspects: error modeling method of NC machine tools, error compensation method, prediction and control of machining accuracy, and combines the characteristics of Aeronautical Structural parts, the development trend and demand of NC machining accuracy control technology are put forward.

STUDY ON THE FEEDFORWARD COMPENSATION OF THE MOTIONERRORS OF NC MACHINE TOOLS

A feedforward compensation naethod of the motion errors of NC machine tools imple- mented with software is proposed , with which the motion errors can be compensated whithout changing the original computer control systems of the NC machine tools. The experimental results show that the circular interpolation profile machining errors decrease by a factor of 2/3 after com- pensated.

Reliability Analysis of Electrical System of Computer Numerical Control Machine Tool Based on Bayesian Networks

The core of computer numerical control(CNC) machine tool is the electrical system which controls and coordinates every part of CNC machine tool to complete processing tasks, so it is of great significance to strengthen the reliability of the electrical system. However, the electrical system is very complex due to many uncertain factors and dynamic stochastic characteristics when failure occurs. Therefore, the traditional fault tree analysis(FTA) method is not applicable. Bayesian network(BN) not only has a unique advantage to analyze nodes with multiply states in reliability analysis for complex systems, but also can solve the state explosion problem properly caused by Markov model when dealing with dynamic fault tree(DFT). In addition, the forward causal reasoning of BN can get the conditional probability distribution of the system under considering the uncertainty;the backward diagnosis reasoning of BN can recognize the weak links in system, so it is valuable for improving the system reliability.

Production Control of a Manufacturing System with Random Machine Breakdowns

We consider a serial production system with machine breakdowns, where the machine at each station alternates between up and down states with exponential up and down time distributions. To obtain insight about the optimal production strategy, we focus on one production station. Its production process (output) and that of the previous station (input) are modeled by point processes with stochastic intensities. Our objectives is to control both input and output intensities such that expected discounted profit is maximized. We show that the optimal control policy is of a threshold type which is characterized by two threshold values.When each station in the serial system has reliable machines, the well known Kanban production strategy, which was first developed in Toyota Motor Co. of Japan, is usually used to control the production process at each station. Our result in this paper implies that, among other things, the traditional Kanban control rule has to be modified if the production environment is random.

MOTION VELOCITY SMOOTH LINK IN HIGH SPEED MACHINING

To deal with over-shooting and gouging in high speed machining, a novel approach for velocity smooth link is proposed. Considering discrete tool path, cubic spline curve fitting is used to find dangerous points, and according to spatial geometric properties of tool path and the kinematics theory, maximum optimal velocities at dangerous points are obtained. Based on method of velocity control characteristics stored in control system, a fast algorithm for velocity smooth link is analyzed and formulated. On-line implementation results show that the proposed approach makes velocity changing more smoothly compared with traditional velocity control methods and improves productivity greatly.

The Electrical Control System PLC Transformation of The XA6132 Milling

For the electrical control system of XA6132 milling machine circuit complexity, reliability and flexibility, high failure rate. Mitsubishi FX2N-40MR programmable controller is used to improve the performance and efficiency of the entire electrical control system by technological transformation. Mitsubishi FX2N-d0MRPLC on electrical control system transformation can expand link to the technological transformation of the similar equipments.

The Electrical Control System PLC Transformation of The T68 Boring

T68 boring machine electric control system circuit is complex, its reliability and flexibility is poor with high failure rate. The mitsubishi FX2N-40MR Programmable controller for the technical innovation of electric control system improves the work performance of the whole electric control system and the work efficiency. This paper introduces the mitsubishi FX2N-40MR PLC in T68 boring machine electric control system, the application of the elaborated system＇s hardware and PLC program design can provide work for technical reform of similar equipment.

Determinate mathematical model of couple bearing force of magnetic-liquid suspension guide-way with complicate constraint

Magnetic-liquid suspension guide-way system( MLSGS) is coupled supported by permanent magnetic suspension and hydrostatic bearing. The structure and bearing mechanism of MLSGS of heavy computer numerical control( CNC) machine tools are introduced and the mathematical expression of bearing force of bearing unit is derived and it can be broken apart into six parts which sustains directly the coordinate components of broad external load,where the air gap of permanent magnet and hydrostatic oil film can be simplified as elastic supports,the compatibility equations of deformations for oil films and air gap are presented,and then the bearing capacity calculation of the bearing unit is transformed into a determinate problem. Considering the guide-way as a rigid body,the mathematics expression between the bearing unit's bearing force and the oil film variation is linearized,and the oil pocket's bearing capacity which bears different components of the external load is calculated separately. The six components of the bearing unit are added up,and the final general mathematics expression is derived. The proposed research offers a general simple method for calculating the bearing capacity of MLSGS with complicate constraint,which can be mastered simply by engineering designer and can improve design efficiency and accuracy.

Intelligent Forecasting of Sintered Ore’s Chemical Components Based on SVM

Using object mathematical model of traditional control theory can not solve the forecasting problem of the chemical components of sintered ore.In order to control complicated chemical components in the manufacturing process of sintered ore,some key techniques for intelligent forecasting of the chemical components of sintered ore are studied in this paper.A new intelligent forecasting system based on SVM is proposed and realized.The results show that the accuracy of predictive value of every component is more than 90%.The application of our system in related companies is for more than one year and has shown satisfactory results.