Thursday 31 May 2012

CNC Machines

Emergency stop alarms and how to troubleshooting machine Estop conditions

Machine Emergency stop checks and troubleshooting?

  1. Check that the conveyor is plugged in and check the cable for damage. Often this occurs right after cleaning the coolant tank. If there is no conveyor check to make sure the dummy plug is connected in its place.

  2. Push in and Pull out all emergency stops. Make sure you check conveyor, Gantry, high pressure unit and barfeeder and for any fuses blown in electrical cabinet.

  3. Are any axes near the overtravels? Some machines have hard over travel switches that throw the machine into Emergency stop state. Turn ballscrews by hand to move away or find switches and see if they are made. All axes usually will contain them and they will all be wired in series in the estop string or interlock module.

  4. Check door interlock module or any other interlock modules in electrical cabinet. Sometimes fuses are mounted under the covers or in the face. Make sure at least one LED is lit on them which usually says power or something.

  5. Check all your power supplies. If you find one of the LEDs are dim or off try removing the wires from it and see if the led changes if it does you have a short. Refer to procedure below for troubleshooting shorts.

  6. Worst case scenario follow the E-stop string in the electrical prints. It will be a series circuit, all you have to do is follow this down with a meter and find out were the voltage is not. This is usually a very easy thing to do even for a novice maintenance person. Hardest part is finding it in the electrical book and the points.

  7. There also could be a short somewhere drawing the voltage down in the estop string

Wednesday 30 May 2012

FM Wireless Mike

FM Wireless Mike:
FM wireless Mike is a small electronic project based on a radio transmitter. It is a wonderful idea to make a wacky talky through which you can talk to your friend, next door. Just speak or play into the microphone and you’ll broadcast to an FM receiver at distances up to 50 feet (maybe 100 feet if the wind is right). Use a standard FM radio to receive the sound.
Circuit Operation:-
The circuit is a combination of a Microphone preamplifier and a FM transmitter.

Microphone Preamplifier is a simple audio amplifier. Transistor Q1 is operated in Voltage Divider Mode. We use a dynamic microphone in the amplifier. The small alternating current produced in the microphone is amplified and fed in to the FM transmitter.
FM transmitter is a tuned collector radio frequency oscillator. The coil and trimmer is in parallel tank circuit. We specify the value of trimmer and size of the coil such that the resonant frequency will be near 88-108 MHz (in the FM radio Band). The oscillator oscillates with a constant resonant frequency and we can change the operating frequency by changing the trimmer capacitance. This frequency is the center frequency of the FM. If we want the FM as a modulation we have to apply the modulating signal (audio signal from amplifier) to the base of the transistor of the oscillator. We all know the base-emitter junction acts like a diode. If we apply the signal the voltage across the junction will change and this particular transistor have some property of changing base capacitance according to the applied input voltage. Thus we change the capacitance which is in series with the resonant tank circuit causing a change in operating frequency. This is actually the FM modulation. Now the modulated signal will be transmitted via a small radio antenna.

 
Circuit Diagram:-
FM Wireless Mike Circuit Diagram
Component Required:-
Parts List for FM Wireless Mike
  B1 - 9.V battery, Type 2U6
  C1 - 0.05.uF, 3.V DC capacitor
  C2 - 20.uF, 3 V DC electrolytic capacitor
  C3 - 5.uF, 12 V DC electrolytic capacitor
  C4 - 47.pF, 25 V DC capacitor
  C5 - 5.30 pF trimmer capacitor
  C6 - 6.3.pF ceramic capacitor
  C7 - 0.01.uF, 10 V DC capacitor
  L1 - see pictorial detail
  MIC - Crystal or ceramic microphone element
  Q1,Q2 - npn transistor HEP - 720
  R1 - 47,000.ohm, 1/2. watt resistor
  R2 - 33,000.ohm, 1/2. watt resistor
  R3 - 1500.ohm, 1/2. watt resistor
  R4 - 3300.ohm, 1/2. watt resistor
  R5 - 100,000.ohm, 1/2. watt resistor
  R6 - 470.ohm, 1/2. watt resistor
  S1 - SPST switch
 
Testing:- Use standard RF wiring precautions and make coil L1 exactly as shown. Best speech clearly is obtained by using crystal or ceramic mike. For music reproduction, substitute a dynamic mike element.

The unit can be assembled on a cardboard using push in terminals for tie points. The case must be metal to prevent hand capacitance from continuously changing the output frequency. Pass the 6-in. solid ware antenna through the metal case using 1/4th- in. whole and a matching rubber grommet for an insulator.
 
Application:- Use the circuit to broadcast your voice to your neighborhood. Talk to your friend next door. One thing you should keep in your mind -don't tune in a frequency where a station is broad casting otherwise you may disturb other FM listeners in your neighborhood.

Simple UPS

Simple UPS:
UPS as the name suggests means Uninterrupted Power Supply. The function of a UPS is to keep the supply voltage as it is even during power cuts.
Let me explain how it works. In side a UPS ( which we use for personal computer) there is a storage cell or battery, an electronic switch, an inverter and a battery charger. Normally, when we start a UPS the main supply is present. The out put line is directly connected to the main supply and the battery is charged if necessary. During power failure, the main supply suddenly goes to zero then the electronic switch which is mainly a power transistor, changes over to the inverter. The inverter turns on immediately and the stored charge in the battery is inverted to get the required A.C. supply. This voltage obtained by the inverter is fed to the load.
Circuit Diagram:-
Simple UPS
Component Required:-
Parts List for Simple UPS
  B1-  6V lantern battery
  C1-  100µF, 16 V DC electrolytic capacitor
  D1, D2-  Silicon rectifier rated 25 PIV at 1 A or higher
  Ry1-  Relay, 6V DC approximately 20mA (Potter & Brumfield RS5D or equiv)
  T1-  12.6V center-tapped filament transformer rated 1A or higher.
  R1-  250kΩ, potentiometer for testing then replace with appropiate value.
  R2-  The output load
  L2-  Inductor. 22 Gauge, 10 -25 turns on a 1cm. Dia Soft Iron core.
Circuit Operation:- In this project we are constructing a simple UPS an the basis of the idea behind a real UPS. This simple UPS does not contain any charger and inverter. So, DC voltage is obtained and there is no rechargeable battery.
The simple UPS contain a step down transformer, a rectifier and a filter to get a stable 6V DC supply from 230V AC mains. Then instead of a electronic switch we use a mechanical switch, a relay. The normally closed (NC) terminal is connected to the 6V battery and the normally open (NO) terminal is connected to the out of the 6V DC regulated power supply. The out put load is taken from the common terminal. We add an inductor at the out put to maintain the current during cut-off.
When the UPS is turned on the main 230 V power is present. So the AC supply is step downed then rectified then filtered to get a ripple free 6V DC supply. This voltage is fed to energies the relay coil. The relay switch comm is now connected to the normally open terminal and the load is directly connected to the DC source. When power goes off the relay coil is de-energized and the comm  terminal is switched over to the normally closed terminal. That means now the current is taken from the battery. In the mean time if main power is restored, the relay coil again be energized and the comm terminal will be connected to the rectified DC terminal and the battery will be disconnected. As we all know inductance prevents the current to change rapidly in a circuit, we add an inductance in series with load. We may add a small value capacitor across the NC and Comm and NO and comm terminal of relay to prevent sparks.
Testing:- A high value resistance should be connected in series with the relay coil. So, that the standby current would be as minimum as possible. The resistance will be chosen such that it must pass the least current required for the relay to energized its input coil. We may use a pot of 100kΩ. The inductor is obtained by a thick copper wire wound on a soft iron core. The more the value of inductor the more the stable will be the current in the load during disturbance.
Application:- We can use the simple UPS with any electronic devices operated in DC power supply like radio walkman, audio systems or lights. You can construct the circuit for 3-18V DC if you get proper step down transformer and battery.

Phase Locked Loop (PLL)

 


PLL Block DiagramDEFINITION OF PLL ::

The Phase-Locked Loop (PLL) is a feedback system that may be used to extract a base band signal from a FM carrier, especially under low SNR conditions. Thus PLL tracks the phase and the frequency of the carrier component of an incoming signal.
A PLL has three basic components: -
  1. A voltage-controlled oscillator (VCO)
  2. A multiplier, serving as a phase detector or a phase comparator
  3. A loop filter having response H(s)

The operation of PLL is similar to that of a feedback system except that the quantity feedback and compared is phase, but not amplitude.

OPERATION OF VCO ::
An oscillator whose frequency can be controlled by an external voltage is a Voltage Controlled Oscillator (VCO). In a VCO, the oscillation frequency varies linearly with the input voltage. If a VCO input voltage Eo(t), its output is a sinusoid of frequency given by,
ωVCO = ωc + Ceo(t)
Where C is a constant of the VCO and ωc is the free-running frequency of the VCO. The multiplier output is further low pass filtered by the loop filter and then applied to the input of the VCO. This voltage changes the frequency of the oscillator and keeps the loop locked, i.e. the frequency and phase of the input and output sinusoidal signals becomes identical.


OPERATION OF PHASE COMPARATOR ::
  A Phase Comparator is a device with two input ports and a single output port. If periodic signals of identical frequency but with a timing difference are applied to the inputs, the output is a voltage, which depends on the timing difference. After phase comparator the signal is low pass filtered to get the error voltage.
PLL ACTING AS A DEMODULATOR ::
In PLL the output Eo(t) of the loop filter H(s) acts as an input to the VCO. The free-running frequency of the VCO is set at the carrier frequency ωc. The instantaneous frequency of the VCO is given by,
         ωvcoc + Ceo(t) ---------(1)

If the VCO output is, Bcos [ωct + θo(t)],
then its instantaneous frequency is ct + d(θo(t))].
Therefore, d(θo(t)) = Ceo(t) ----------(2), where C and B are constants of the PLL.
Let the incoming signal be, Asin [ωct +ωi (t)]. At the multiplier this incoming signal and the VCO output are fed so that the output X(t) is given by,
X(t) =
A B sin(ωct +θi)cos(ωct +θ0)
=[½AB {sin (θi -θ0) + sin(2ωct +θi +θ0)}]   ---------(3)
The sum frequency term is suppressed by the loop filter, Hence the effective input to the loop filter is [½AB {sin (θi(t) -θ0(t))]. If h(t) is the unit impulse response of the loop filter,
eo(t) = h(t) * [½ABsin{θi(t) -θ0(t)}] = [½(AB)]0t h(t – x)sin[θi(t) -θ0(t)]dx -(4)
Substituting eq.(2) in eq.(4) we get d(θo(t)) = AKth(t – x)sin[θe(x)]dx ----------------(5)
where K =CB and θe (t) is the phase error, defined as θe (t) = θi(t) – θo(t).
When the incoming FM carrier is Asin[ωct +  θi(t)],

θi(t)= kf-αtm(α)dα -------------(6)
Hence,
θo(t) = [kf-αtm(α)dα] – 0e(t)
and assuming a small error e(t) we get from eq.(2)

eo(t) =1/c[d(θo(t))]~ 1/ckf m(t) ---------------(7)

Thus, the PLL acts as an FM demodulator

Power Ratings

DEVICE          WATTAGE                                 MONTHLY ELECTRICITY       ONE UNIT IN HRS
                                                                              CONSUMPTION (KWH)
                                                                                 1HR/DAY    6HRS/DAY
       
CAPACITY

Bulb
25 0.75 4.5 40 hrs
40 1.2 7.2 25 hrs
60 1.8 10.8 16 hrs 40 min
100 3 18 10 hrs
CFL
5 watt 7 0.21 1.26 143 hrs
9 watt 11 0.33 1.98 90 hrs
11 watt 13 0.39 2.34 77 hrs
25 watt 27 0.81 4.86 37 hrs
Fluorocent
Tube Light 48"
Copper
Choke
55 1.65 9.9 18 hrs 11 min
Electronic
Choke
35 1.05 6.3 28 hrs 11 min
Night Lamp 15 0.45 2.7 66 hrs 40 min
Ceiling fan
36/48" 11 0.33 1.98 90 hrs
56" 60 1.8 10.8 16 hrs 40 min
60" 71 2.1 12.6 14 hrs 17 min
Table Fan
12"/16" 40 1.2 7.2 25 hrs
Electronic Iron
Domestic 45/ 700 13.5
to 21
81
to 126
2 hrs 13 min
1 hr 25 min
Dhobi 1000 30 180 1 hr
Immersion Iron 1000 30 180 1 hr
Geyser
Storage 15 - 50 lit 2000 60 360 30 min
Instant 3000 90 540 20 min
AC
1 ton 1400 42 252 43 min
1.5 ton 1800 54 324 33 min
Air cooler 170 5.1 30.6 5 hrs 53 min
Refrigerator
Small 225 2 unit/day
Big 1800 54 324 33 min
Toaster 800 24 114 1 hrs 15 min
Hot Plate 1000 30 180 1 hr
Elecric Kettle 1000/
2000
30 to
60
180 to
360
1 hr 30 min
Mixer - Juicer (Big) 450 13.5 81 2 hrs 13 min
Washing Machine
Automatic 325/
1000
13.5
to 21
81
to 126
3 hrs 5 min
to 5hrs
Semi-Automatic 200 6 36 5 hrs
Vacuum Cleaner 700
- 750
21
to 22.5
126
to 135
10 hrs 26 min
1 hrs 20 min
Radio 15 0.45 2.7 66 hrs 40 min
Tape Recorder 20 0.6 3.6 50 hrs
TV 60 to
120
1.8
to 3.6
10.8
to 21.6
16 hrs 40 min
to 8 hrs 20 min
Video 40 1.2 7.2 25 hrs
Mosquito Repellant 5 0.15 0.9 200 hrs
Water Purifier 25 0.75 4.5 40 hrs
Computer 100/
150
3 to
4.5
18 to
27
10 hrs to
6hrs 40 min