Speed Control of BLDCM for Industrial Sewing Machine Based on dSPACE
The Concentional algorithms applied in Industrial Sewing Machine (ISM) have some disadvantages such as less precision, lower speed response and more complicated due to the special requirement of the ISM. Taking the mechanical characteristics of ISM into consideration, a changing-dead-zone multi-segment-PID with digital filter algorithm is presented in this paper, which is applied in the speed control of the Brushless DC Motor (BLDCM) servo system. The improvement process of the arithmetic is specified in the paper. The mathematical model of the speed control of servo system is built by MATLAB/Simulink, and the online simulation is implemented on the software-hardware platform provided by Hardware-in-theLoop Simulation (HILS) tool dSPACE. https://vssewingmachine.in/juki-sewing-machine-price-in-chennai/ The simulation result is showed that the improved algorithm is more effective in the dynamic performance of the system compared with the increment-PI, and it also works well in the application of the practical product of ISM.
By the prompt development of textile industry, the design of the equipment of textile industry is developing towards high precision, multifunction and low cost. ISM is one of the key equipment in textile industry. It is composed of motor servo system and the traditional sewing machine, so it has some additional functions besides all of the functions provided by traditional sewing machine, for which the efficiency of product line can be improved greatly by its high automation, as well as the product quality. The precision of ISM is mainly determined by the control precision of the motor servo system. Therefore, it is essential of the research on the motor servo system to developing an ISM system. Presently, classic PID control theory is mainly adopted in the research on speed control of the motor servo system of ISM. Based on the classic PID control theory, increment-PI control algorithm or fuzzy PID control theory are also adopted in this research field [6,12,13]. Considering speediness, stabilization precision and overshoot of the ISM’s motor servo system which is a characterization of non-linear and strong coupled system, a comparison result among classic PID, increment-PI and fuzzyPID shows that the effect of control by Fuzzy PID control algorithm is the best, increment-PI algorithm takes second place and the classic PID control algorithm is the worst [6]. The precise mathematical model of the object will be not required if fuzzy PID control algorithm is adopted. Instead, the fuzzy control rules, which would be used to determine the control volume, are built mainly based on the experience of the developers and experts. However, if the developer is not enough familiar with ISM, the application of fuzzy control will cost huge time on making the fuzzy control rules for ISM’s motor servo system, and the fuzzy control rules may be half-baked or even incorrect. Consequently, the effect of fuzzy control will be much worse than classic PID control [9]. An algorithm is needed when the developers just have a few knowledge of the ISM, which will spend much less time to realize the motor control. The differentiator in classic PID control improves the system’s fast response characteristic, but it amplifies the external disturbance, which has a bad impact on the reliability of the system. Hence, the differentiator is deleted in the application of increment-PI control considering the complex industry environment for the ISM’s well working. This method is simple and practical, but the dynamic response, speed smooth and reliability of the system needs improving if this method is applied in ISM [6]. Combined various matured control theories with the author’s experiences in practical engineering, the control algorithm is improved based on the increment-PI control algorithm mentioned above. And a HILS with traditional sewing machine and motor is implemented by dSPACE. It is showed that the effect of the improved control algorithm is satisfied.
HARDWARE DESIGN OF THE ISM CONTROL SYSTEM
The schematic diagram of the hardware design of ISM’s servo system shows in Fig. 1. The driving motor of the ISM adopts BLDCM with four poles and three-phase whose power reaches 400W. According to the characteristics of the BLDCM and the function requirement of the ISM, PIC18F4431 microcontroller is adopted as the core control solutions of the hardware of this system. BLDCM is driven by square wave with full-bridge style
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