SPEED SYNCHRONIZATION OF
MULTIPLE BLDCMOTORS IN TEXTILE & PAPER MILLS USING MICRO CONTROLLER
ABSTRACT
Multiple
motor setups have vast application in industries. The application can be in
textile mills, paper mills and robotics. In these all application the
synchronization is must between the motors to perform certain task. Speed
synchronization is very essential in these all operation to avoid damage to the
product. The synchronization is done by using microcontroller chip which
controls the master slave whose speed is followed by the other motors which all
have to be synchronized.
Key
words: Speed synchronization, textile mills, paper
mills, microcontroller chip, and master slave.
INTRODUCTION
In
this project motors are wirelessly synchronized to make the differential speed
error among multiple motors to zero. One motor acts here as transmitter and
rest of all as receivers. So, if a particular speed is set in the transmitter
then automatically rest of the motors speed would be matched to the same speed
of the master slave. A display unit connected with the module will display the
full speed in rpm and the observer can enter the required percentage with help
of a keypad to obtain the required speed for rest of the motors. The pulse
width output from the microcontroller would be automatically adjusted by the
microcontroller to maintain the DC power to the motor such that the entered speed
percentage matches the running RPM. The above operation is taken care by using
OPTO isolator and a MOSFET connected to motor. The aim of this project is synchronization
of multiple motor system by making use of wireless technology. This project
uses radio frequency to synchronize different motors speeds. This system is
used in many industries like textile mills, steel plants, and paper plants
where large numbers of the motors used on conveyor are desired to be synchronized
for performing certain task. In paper mills & textile mills where multiple
motors work together on a conveyor belt to draw clothes, it is desirable that
all the motors should run at same speed, so that balanced tension can be
achieved to avoid damage to the clothes. Manpower and time is also saved in
this arrangement. User can set the desired rpm for the motors. As this system
is Wireless, it is easy to operate and control the system which eases the whole
process. The speed synchronization of multiple motor arrangements is very
important task which is here carried out wirelessly by using microcontroller
chip. Due to wireless connection between the motors the motors can be kept in
any position it is not necessary as earlier old concept of conveyor belt that
the motors should be kept only on parallel series or mixed with each other. Multiple
motors used in textile industries & paper mills or any other for cloth
drawing or to pull the paper as in paper mill need to be synchronized for same
speed. Traditionally we use conveyor belts in order to synchronize multiple
motor for such works. But that has many draw backs. This can be come over by
using the wireless synchronization of multiple motors.
Drawbacks of using conveyor belt for speed synchronization. [Earlier
Method]
•
The master slave [main motor] will be the hardest to start, stop and maintain
smooth motion on the whole process.
•
All the motors should be connected in Parallel.
• As
there are moving elements like belts between the motors, we need to change then
if it is not serviceable and regular service in also required when they will
get damage.
•
The design of master slave or follower motors in the system may be series,
branch, or mixed.
•
Again the system and its product will determine what piece of equipment is
directly synched or digitally rationed to each other piece of equipment.
Maintenance
is bit difficult as there are more mechanical parts in the system.
Solution
for old Concept of Conveyor Belt:
There
are so many other different techniques for the solution this problem. But those
are not that reliable. In order to reduce man intervention and save the labor cost and time both we can
use microcontroller to control, operate and synchronize this task. As compared
to conveyor belt method is compatible as it involves hardware as well as
software in this module. We can program microcontroller to control its speed
and also can set the required speed through keypad to get our work done.
Synchronization can done either wired or wirelessly. In this project we are
using RF communication technology for wireless communication.
HARDWARE REQUIREMENTS:
8051 series Microcontroller, Crystal, RF MODULE, LEDs,
Resistors, Capacitors, Diodes, Transformer, Voltage Regulator, IR sensor,
MOSFET, Keypad, Transistor, OPTO-isolator, BLDC fan.
SOFTWARE REQUIREMENTS:
MPLAB & CCS C compiler. Language: Embedded C or Assembly.
BLOCK DIAGRAM FOR TRANSMITTING UNIT:
BLOCK DIAGRAM FOR RECEIVER UNIT:
BLOCK DIAGRAM FOR RECEIVER UNIT:
HARDWARE COMPONENT:
WORKING OF PROJECT:
· The speed of the
motor is sensed by an IR pair and is displayed on LCD and is also fed to the
MC.
· The required
speed is entered using a keypad which is interfaced with MC.
· The motor is
interfaced to the MC through aopto-coupler & a MOSFET which drives the
motor.
· PWM pulses are
generated from MC according to the entered speed and the motor is adjusted to
that speed and maintained at that speed.
FLOW CHART:
SOFTWARE REQUIRED:
· Keil an ARM
Company makes C compilers, macro assemblers, real-time kernels, debuggers,
simulators, integrated environments, evaluation boards, and emulators for
ARM7/ARM9/Cortex-M3, XC16x/C16x/ST10, 251, and 8051 MCU families.
·Compilers are
programs used to convert a High Level Language to object code. Desktop
compilers produce an output object code for the underlying microprocessor, but
not for other microprocessors.
·i.e., the
programs written in one of the HLL like ‘C’ will compile the code to run on the
system for a particular processor like x86 (underlying microprocessor in the
computer).
· For example
compilers for Dos platform is different from the Compilers for Unix platform So
if one wants to define a compiler then compiler is a program that translates source
code into object code.
ADVANTAGE OF USING BLDC MOTOR OVER BRUSHED DC MOTOR:
The
BLDC motor has to many advantages over the brushed DC motor which is shown
below:
·
Higher efficiency
and reliability
·
Lower acoustic
noise due to absence of brushes
·
Smaller and
lighter
·
Greater dynamic
response
·
Better speed
versus torque characteristics
·
Higher speed
range
·
Longer life span
OBSERVATIONS AND CONCLUSION:
We
can tabulate different-different speeds of motor as we keep on giving input
from the Keypad and same speed change can be observed and displayed at the
receiving motors. From this project we can successfully control the speed of
multiple motors wirelessly through RF communication. Whatever the percentage of
speed that we enter at transmitter unit of system same can be observed at the
receiving motors. The whole operation is made simple by using this technology.
The future works include giving intelligence to the whole system like if any of
the motor senses any fault, the whole system will shut down.
REFERENCES:
[1].
MOTOR SELECTION for BELT-CONVEYOR DRIVES by Garry E. Paulson, P. Eng.
[2].
http://www.bonfiglioli.com/en/industrial/applications/conveyors/
[3].
Unique Conveyor Problems and Solutions :- Fenner Dunlop
[4].
The Use of PIC Microcontrollers in Multiple DC Motors Control Applications By
Dr. Steve C. Hsiung
[5].
Wireless Digital Control and Synchronization of Master-Slave Multiple Motors
Using Microcontroller PratikshaShingade, AratiDalavi, PriyankaShipate, Megha
Barge
[6]
http://www.controldesign.com
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