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Research on servo motor motion control system based on Beckhoff PLC

To cite this article: Shuai Zhang 2021 J. Phys.: Conf. Ser. 1852 022002

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AICNC 2020 IOP Publishing
Journal of Physics: Conference Series 1852 (2021) 022002 doi:10.1088/1742-6596/1852/2/022002

Research on servo motor motion control system based on

Beckhoff PLC

Shuai Zhang1,*
1
North China University of Technology,College of Mechanical and Material
Engineering, Beijing,100144, China
*Corresponding author E-mail: [email protected]
Abstract. In order to meet the requirements of high precision, reliability and real-time
control of biaxial motion.Taking Beckhoff PLC CX9020 and Yaskawa ∑ - 7S series
AC servo controller as the control core, using Yaskawa SGM7J series motor and servo
driver matching, the X-Y double axis servo motion control system is designed, and the
overall hardware design of the control system is carried out。This paper focuses on the
parameter setting, analog and digital acquisition, programming and HMI interface
setting of servo motor control system. The debugging operation shows that the system
runs stably and meets the control requirements of accurate positioning.

keyword：PLC, servo control , Parameter setting

1. Introduction
With the rapid development of modern industry, PLC as a new technology is widely used in many
aspects, especially in the servo motor motion control system. Now the test equipment has higher and
higher requirements on the response time, stability and other performance indicators of the control
system. Wei Lingzhi [1] in 2006, using Mitsubishi PLC parameter setting, programming and
debugging, designed the electrical control schematic diagram to control two servo motors, through the
sensor to detect the position of the workpiece, to achieve the control of shaft speed. Xu Xiaoguang [2]
uses Siemens PLC to control the speed and position of four axes. The system has high servo precision
and can be used in different applications. Shen Ting [3] introduced the characteristics and application
scenarios of servo motor technology, and pointed out that the future development of motor will be
intelligent and information-based. Xu Miaoling [4] applied PLC technology in industrial automation,
through which analog quantity was collected and data processing was realized;Zhang Jingya [5]
designed PLC AC servo motion control device, which greatly improved the fault tolerance of the
system; Li Jun [6] studied the effective control of single and double motors in order to improve the
motion control level of PLC servo motor. Jin Yongzhou [7] studied the servo motor motion control
system, used the servo motor of SGDV-2R8A01A drive module, and realized the control of dual motor
operation by using ladder diagram programming.Fan Qiming [8] designed a three-axis motion control
system based on Mitsubishi intelligent positioning module QD75MH4. Liu Xiongping and Wang
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AICNC 2020 IOP Publishing
Journal of Physics: Conference Series 1852 (2021) 022002 doi:10.1088/1742-6596/1852/2/022002

Gaoli [9-10] introduced the application and development trend of servo motor. According to the
functional requirements of the equipment, Beckhoff PLC CX9020 and Yaskawa ∑-7S series AC
servo unit are selected as the control core. The advantages of PLC technology and servo control are
combined to achieve higher precision of motion. With the development of industry 4.0, multi axis
servo is very important, so the system has good application.

2. Hardware composition and working principle of servo system

2.1. hardware composition of servo control system

Beckhoff PLC CX9020 can select the appropriate module according to the demand. The test
equipment needs to collect bending moment signal, so the torque sensor of Kistler is selected. The
maximum range of the sensor is 20NM. Since the torque sensor collects voltage signal, EL3002
module is selected, which can collect dual channel voltage signal. The device also needs to collect the
angle value, so Omron photoelectric encoder is selected. The resolution of the encoder is 2000P/R.
because the encoder collects digital quantity, EL5101 module is selected. Through EL2521, the
high-speed pulse module sends pulses to Yaskawa servo. The module can change the frequency of
binary signal and send it in the form of E-bus electrical isolation. The maximum frequency of EL2521
is 500KHz, and the default is 50KHz. Table 1 is the definition of each channel: port 1 and port 5 are
connected with positive and negative of phase a, port 2 and port 6 are connected with positive and
negative phase B, so that they can work after wiring; if shielded wire is used, the shielding layer can
be connected to port 8; ports 3 and 7 are two additional inputs, and port 4 is the GND of these two
additional inputs. There are also EL1008 eight channel input module, which inputs digital signal
through limit switch; EL2008 has two outputs corresponding to X-axis and Y-axis. Therefore, to
consider the damage of PLC caused by over current, we add two intermediate relays at the output of
EL2008 to control the large current through small current. As shown in Figure 1.
Table 1. EL2521 channel definition
Terminal point NO. Comment
Output +A 1 Output +A
Output +B 2 Output +B
INPUT T 3 INPUT T
T.Z.GND/T.Z. Ref.GND 4 Signal ground for outputs
Output -A 5 Output -A
Output -B 6 Output -B
INPUT Z 7 INPUT Z
SHIELD 8 SHIELD

The main function of motor is to convert electrical energy into mechanical energy, which is widely
used. With the improvement of the level of electronic power, the intelligent characteristics of the
motor are demonstrated. Through the coordinated development of the processor and digital servo
system, the calculation performance of the numerical control system is improved correspondingly, and
the time is greatly reduced. We chose Yaskawa SGM7J-04FC6S The servo motor controls the control
accuracy of the motor through a rotary encoder. The encoder in the digital AC servo motor system is a
24 bit incremental encoder. At this time, the motor rotates for one cycle, receiving 16777216 pulses,
and the pulse impulse is 0.00001246°. When the motor rotates, the encoder outputs pulse feedback to
the servo driver to form a closed-loop control. The motor power is 750W, the main circuit power
supply voltage is AC200 ~ 240V, 50 / 60Hz, the rated speed is 3000rpm, the maximum speed is
6000rpm, and the rated torque is 1.27NM.

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AICNC 2020 IOP Publishing
Journal of Physics: Conference Series 1852 (2021) 022002 doi:10.1088/1742-6596/1852/2/022002

Figure 1. El2008 output wiring diagram

Yaskawa SGD7S-5R5A servo driver is selected,,L1 / L2 / L3 is connected to the main circuit power
supply UVW. If it is single-phase, only L1 / L2 can be connected,L1C / L2C is connected to control
circuit power supply, CN1 to upper computer, CN2 to motor encoder, and CN3 to digital operator.The
main circuit of the system is single-phase electric connection air switch, and then through the main
contact of AC contactor, it is finally connected to the L1 / L2 of servo system. The UVW of servo
controller is connected with U1, V1 and W1 of motor, as shown in wiring diagram 2, and the wiring
diagram of the whole system is shown in Fig. 3.

Figure 2. main circuit wiring diagram

Figure 3. wiring diagram of the whole system

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AICNC 2020 IOP Publishing
Journal of Physics: Conference Series 1852 (2021) 022002 doi:10.1088/1742-6596/1852/2/022002

2.2 working mode and parameter setting of servo system

The working mode of servo system is divided into position control mode, speed control mode and
torque control mode. In this paper, the position control is adopted. The upper computer PLC generates
pulses to servo control the motor rotation. The number of pulses determines the rotation angle of the
servo motor, and the frequency of the pulse determines the speed of the motor. CN1 has 50 pins, each
pin has its own definition. This paper uses 7, 8, 11, 12, 31, 32, 40, 47, in which 7 and 8 pins are
defined as pulse input command, 11 and 12 pins are symbol command input, 31 and 32 are servo
alarm output, and 40 and 47 are servo enable on. Among them, 7, 8, 11, 12 are connected with el2521
and 31, 32 and el1008 are connected. As shown in Figure 4. For servo drives, up to 500KHz pulses
(differential input) can be received. The output torque of the motor is determined by the load. The
greater the load, the greater the output torque of the motor. Of course, the rated load of the motor
cannot be exceeded. Rapid acceleration or loading may cause the main circuit to be too large to affect
the power device.
We use sigma Win + software of Yaskawa to set parameters. The main servo parameter settings of
system design are shown in Table 2.
(1) The servo motor of this project is mainly used for precise positioning control.
(2) According to the connection mode of the interactive I / O signal between CPU and servo, the
setting value of input and output parameters is determined.
(3) The pulse number and electronic gear ratio are determined according to the position control
accuracy.
Table 2. part of Yaskawa servo setting parameter table
Parameter No. Parameter name Setting value describe
Pn000.0 Rotation direction selection 0 Take CCW as the
forward turning
direction
Pn000.1 Control mode selection 1 position control
Pn00B.2 Power input selection of 1 Single phase power
servo unit input
with three phase input
specifications
Pn200A Pitch number of external 0 Symbolic + pulse
encoder
Pn200A Pitch number of external 2500
encoder
Pn20E Electronic gear ratio 16777216
molecule
Pn210 Denominator of electronic 10000
gear ratio

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AICNC 2020 IOP Publishing
Journal of Physics: Conference Series 1852 (2021) 022002 doi:10.1088/1742-6596/1852/2/022002

Figure 4. CN1 wiring diagram

After setting the servo parameters, set the corresponding parameters on EL2521, as shown in
Table 3.
Table 3. corresponding parameters on EL2521
8001:01 Users switch-on-value RW 8
8001:02 Base frequency 1 RW 32767
8001:03 Base frequency 2 RW 100000
8001:04 Rising RW 1000
8001:05 falling RW 1000
8001:06 Frequency factor RW 100
8001:07 Slowing down frequency RW 50
8001:08 emerency RW 1000
8000:0E Operating mode RW Pulse-dir

After setting the parameters, start the off axis test run, set a frequency value to observe the speed of
the shaft.

2.3 Programming of PLC part

Since the encoder is 2000p / R, the driver has 4-fold frequency technology, so a circle of 8000 pulses
corresponds to 360 degrees. The range of torque sensor is 20NM, which is subdivided into 32767, so
the corresponding formula is as follows：
angle  (x / 8000 * 360) / 180 * 3.14 (1)
NM  ((niuju3/32 767) * 20) (2)
Where x is the uint unsigned variable and Niuju is also the unsigned variable. Angle and NM are
real variables.
Declare some variables as follows:
X AT %I*: INT;
OUTPUT1 AT %Q*: BOOL;
OUTPUT2 AT %Q*: BOOL;
POWER: BOOL;
angle :REAL;
X1: REAL;
yspeed1: LREAL;

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AICNC 2020 IOP Publishing
Journal of Physics: Conference Series 1852 (2021) 022002 doi:10.1088/1742-6596/1852/2/022002

yspeed AT %Q*:INT;
wx AT %Q*: INT;
qulv: LREAL;
niuju1 AT %I*: INT;
niuju2 AT %I* : INT;
niuju: INT;
NM: REAL;
niuju3: REAL;
St language is used for programming, some of which are as follows:
OUTPUT1:=POWER;
OUTPUT2:=POWER;
X1:=INT_TO_REAL(X);
angle:=(x1/8000*360)/180*3.14;

2.4 Design of HMI interface

Beckhoff software designs HMI interface by adding visualization in Twincat3 main program. As
shown in Figure 5, two rectangular design button controls are designed to enable, forward rotation,
reverse rotation, origin and emergency stop. Then it is connected with the corresponding variable.
Through forward rotation, the shaft rotates in the forward direction, and reverses in the reverse
direction. If the emergency stop is pressed, the shaft stops rotating; if the origin is pressed, the axis
returns to the original position.

Figure 5. HMI interface

3. Conclusion
To sum up: in this paper, the data acquisition and the speed and position control of the two axes are
successfully realized through Beckhoff PLC and its various modules. The servo driver is controlled by
Beckhoff PLC HMI for forward rotation, reversal, origin and function to realize multi axis movement,
which can easily realize the quasi synchronous operation of multiple axes.

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AICNC 2020 IOP Publishing
Journal of Physics: Conference Series 1852 (2021) 022002 doi:10.1088/1742-6596/1852/2/022002

References
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[5] Zhang Jingya, Luo Yuwen, Fu Maosheng. Design of AC servo motion control device based on
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