Application case of Lingchen PLC in automatic flow and precision machining between two grinding machines

In industrial manufacturing, efficiency and precision are the eternal core pursuits. When faced with complex workpieces requiring simultaneous machining of through-holes of varying sizes, traditional manual operations are not only inefficient but also difficult to maintain stable production over extended periods. Recently, Lingchen Technology, leveraging its advanced PLC control technology, successfully provided an efficient solution for a one-to-two grinding machine truss automation project, achieving unmanned operation throughout the entire process, from vibrating plate loading to collaborative machining and precise unloading between the two grinders.

Project core: dual grinder collaboration, fully automatic flow

The core goal of this project is to build an efficient gantry system to enable automated workpiece transfer and precision machining between two grinding machines:

Intelligent loading and unloading: Workers simply place the workpiece onto the vibrating plate, and the gantry gripper automatically retrieves the workpiece and precisely transports it to Grinder 1 for standby. Large hole machining on Grinder 1: After Grinder 1 completes machining, the gantry gripper removes the finished workpiece and then loads a new workpiece, initiating the large hole grinding process. Intelligent reversing and machining on Grinder 2: After large hole machining, the gantry gripper transfers the workpiece to the reversing device for orientation adjustment and then moves it to Grinder 2 for standby. Small hole machining follows the same process (unloading, loading, and starting). Automatic unloading: The finished workpiece is transported by the gantry gripper to a designated unloading area for release.

The entire machining process (loading → large hole grinding → reversing → small hole grinding → unloading) is seamlessly linked and centrally orchestrated by the Lingchen PLC, ensuring efficient and precise operation. The internal processing of each grinding machine is also divided into four steps: fast grinding, fine grinding, ultra-fine grinding, and rounding to ensure high-quality hole machining.

Technical Difficulties and Lingchen Solutions

The project placed stringent requirements on the truss gripper's motion control: a speed range of 0-1500 mm/s, multiple selectable speeds, a rate adjustable from 0-100%, support for four-axis manual wheel operation, and a dual-touch screen anti-stuck design.

Precise Manual Wheel Control (Key Highlight): Lingchen innovatively utilized the LC1008 PLC in conjunction with the LC5002 pulse input module. By collecting the manual wheel's gear position, magnification, and pulse signals, a free encoder axis was created within the program. Using electronic gear function blocks, the free encoder axis was precisely coupled to the truss's four real-world motion axes: X, Y, Z, and A. Principle: Handwheel rotation generates pulses (e.g., 1000 pulses/revolution). The PLC uses the pulse count (determining displacement, e.g., 0.001 mm/pulse), frequency (determining motion speed), and the A/B phase difference (determining direction) to achieve high-precision, real-time, synchronous control of all four axes, meeting fine-tuning positioning requirements.

Standardized Grinding Process: Lingchen engineers have encapsulated the complex grinding process (quick grinding → fine grinding → superfine grinding → rounding) into a reusable function block. This function block can be called multiple times after the grinder is started, significantly simplifying program development for both Grinder 1 and Grinder 2, improving efficiency and reducing errors. Reliable Hardware Architecture: Core Control: LC1008 PLC Signal Processing: LC5002 pulse input module, LC1486 input module, LC2486 output module, LC1188 input and output modules Communication Network: EtherCAT high-speed bus connects each axis drive, and RS485/RS232 connects the grinder's dedicated control system and hand crank.

A double leap in efficiency and reliability

Unleashing Capacity: Completely overcoming the physical and time constraints of manual operation, achieving 24-hour uninterrupted production, and automated loading and unloading significantly shortening the processing cycle for each piece. Precision Assurance: PLC precisely controls the truss motion trajectory and the grinding machine processing process, ensuring consistent and high-quality machining of large and small holes. Management Optimization: Reducing reliance on skilled workers, reducing labor costs and management complexity.

Conclusion

Lingchen Technology's successful implementation of the one-to-two grinding machine truss project not only validates the powerful control capabilities of its PLC products in complex automation scenarios but also highlights its service philosophy oriented towards technological innovation and customer needs. This solution sets a new benchmark for efficient, precise, and automated machining of similar workpieces.