Design and implementation of a PI controller for a metal casting machine

Abstract

Control and monitoring systems capabilities are unavoidable to improve product quality, reduce production time, and to the rapid adaptation to changes in production. Therefore, it is advantageous to develop control and monitoring systems, and maximize the use of the resources already available in machine tools, without high additional costs and hard implementations. The use of Programmable Logic Controllers (PLC) on industries is growing. This sort of controller has been an election tool to attend present day requirements. It has the necessary resources to acquire and manage the information and control of the machines, and easily interacts with SCADA systems. The objective of the study described in this paper was to develop a solution for monitoring a metal casting machine, which could replace an outdated system installed on it, and find a solution to control a metal pouring process. All programs that allow the PLC to control the machine movements, and also perform the casting process, were developed during the project implementation. The results show that the developed solution is able to control the machine without the need to invest in a PC, which is a more expensive solution and with a more limited life time.