Mohammed, H., Salman Abed, K., Reja, A. (2024). Control system design of a Pin-on-Disc wear machine using PLC. , 42(8), 1155-1168. doi: 10.30684/etj.2024.150091.1756
Huda J. Mohammed; Khansaa D. Salman Abed; Ahmed H. Reja. "Control system design of a Pin-on-Disc wear machine using PLC". , 42, 8, 2024, 1155-1168. doi: 10.30684/etj.2024.150091.1756
Mohammed, H., Salman Abed, K., Reja, A. (2024). 'Control system design of a Pin-on-Disc wear machine using PLC', , 42(8), pp. 1155-1168. doi: 10.30684/etj.2024.150091.1756
Mohammed, H., Salman Abed, K., Reja, A. Control system design of a Pin-on-Disc wear machine using PLC. , 2024; 42(8): 1155-1168. doi: 10.30684/etj.2024.150091.1756

Control system design of a Pin-on-Disc wear machine using PLC

Engineering and Technology Journal
Volume 42, Issue 8, August 2024, Pages 1155-1168    PDF (1.18 M)
Document Type: Research Paper
DOI: 10.30684/etj.2024.150091.1756
Authors
Huda J. Mohammed* ; Khansaa D. Salman Abed; Ahmed H. Reja
Electromechanical Engineering Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.
Abstract
This study presents the design and implementation of a control system for a Pin-on-Disc wear testing machine using a Programmable Logic Controller (PLC). The novel approach employed involves adjusting the applied pressure on the pin, rather than the conventional method of altering weights, to evaluate the impact of varying loads on the wear rate. This method enhanced the accuracy of wear results by 25% compared to traditional techniques. The control system was developed and implemented with a Human-Machine Interface (HMI) that interacts with the PLC to control and monitor key parameters, including applied load, temperature, rotational speed, sliding time, and friction force. Key wear parameters such as the coefficient of friction (COF), wear rate, and temperature were calculated. The wear tests were conducted under varying conditions, with rotational speeds ranging from 300 to 900 rpm, applied loads from 5 to 25 N, and sliding times from 5 to 25 minutes. The results indicated that an increase in applied load led to higher wear rates and temperatures, while the COF decreased. Conversely, an increase in rotational speed reduced the wear rate but increased both the COF and temperature. Prolonged sliding time resulted in higher wear rates and temperatures, while the COF decreased. Additionally, it was observed that the wear rate of the aluminum alloy AA6061 was higher than that of the CK45 steel alloy. The study utilized various software tools, including AutoCAD 2018, SoMove AC Drive Software, EcoStruxure Machine V1.2 VP1, Vijeo Designer 6.2, Ifs – Conf RTD, and MATLAB.

Highlights
  • Variable applied pressure to the pin improved the wear rate by 2% over the traditional method in an intelligent design.
  • Additional development and compression testing were done because the operating system and components are open-source.
  • The control system used an HMI and PLC to monitor load, temperature, rotating speed, and friction force.
  • The coefficient of friction, specific wear rate, and temperature were determined.
  • Wear tests varied factors like rotating speed (300-900 rpm) and applied load (5-25 N).
Keywords
Pin-on-Disc; PLC; Touch screen; AA6061 alloy; CK45 steel alloy
Supplementary Files
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