360 Encoder Designs

The goal of the project is to create a table that can be used at traveling conventions that showcase the unique abilities of the encoders the EPC offers. 25SP/58TP, A58HE/A58SE, 15T/H/S or TR1/2/3, and 30M. The user will be able to interact with each module via HMI and PLC in order to fully showcase the functionality of each encoder.

=Problem Definition= The purpose of this project is to highlight the unique functions of each encoder that EPC creates by creating unique functions that each encoder carries out that can be easily duplicated and can be used at road shows around the world.

Background
An encoder is a sensing device that provides feedback. Encoders convert motion to an electrical signal that can be read by some type of control device in a motion control system, such as a counter or PLC. The encoder sends a feedback signal that can be used to determine position, count, speed, or direction. A control device can use this information to send a command for a particular function. This project focuses on three different types of encoders: programmable, absolute, the Model 15 encoder, and Model 30M.

The programmable encoder allows the user to change the resolution by coding in the desired resolution anywhere from 1 tick per revolution to 65,536 ticks per revolution. The absolute encoder will always remember its position in space. Even if it gets unplugged it will move 1 tick and know its location.. The Model 15 is EPC's most popular encoder because it is cheap, reliable, and easy to mount. Finally the Model 30M uses a sin wave instead of a traditional square wave, which results in a more precise encoder.

Deliverables
Overall, our deliverables consist of only a few things:
 * 1) Completed logbooks.
 * 2) prototypes for each design that we are able to do.
 * 3) Completed project folder.
 * 4) Fully functional designs that meet the requirements that EPC has laid out.

Specifications
The final project should have these considerations in mind.


 * The final product should weight no more than 125 pounds.
 * All displays should be able to be swapped out with any encoder as desired.
 * It should be able to be plugged into a standard 120V outlet.
 * It should be portable and be able to fit through a standard doorway
 * All encoders should be plugged into one centralized HMI+PLC/GUI.
 * The display should be able to run for an 8-hour day.
 * The display should be eye-catching and be able to attract a crowd.

=Design Considerations= Design 1
 * Our first project that we had was to highlight the programability of EPC's Model 58TP by creating a game where the user would change the resolution of the 58TP and use that to move a linear actuator and try to get within a specified distance (within a small margin of error). How this is set up is we have a linear actuator that has a platform that is connected to a motor and the encoder. On the side of the platform is the Model TR2, which is a linear encoder that is used to measure distance. This will be used as a feedback system so the user will know exactly how far they have moved the linear actuator. The motor is attached to our HMI+PLC, which is the user interface that allows the user to guess how many revolutions they will need in order to move the platform to the desired distance. By changing the resolution of the encoder, the user can see how precise the 58TP can get.



Success Routines
 * Upon getting within the required distance, a random success routine will happen to keep the user engaged and keep the project exciting. One example of a success routines is if they are close but still within the margin of error, LED lights will start to flash and music will play, along with that, the PLC will display congratulations, you did it! on the screen. Another success routine is if they are spot onto the desired distance then a motor attached to a food dispenser will go off and dispense candy.



=Project Learning= A lot of the project learning has come from the electrical engineering and computer science side. We first had to learn how the encoders worked and programming the Unitronics GUI (Graphical User Interface) language to work with both the encoder and the motors that are all attached to the GUI. Also learning how to work with a client has presented its own sets of challenges; as more people are becoming involved in our project, more ideas are being presented and it has been a challenge to pick apart what is possible for us to do and which is out of our realm of possibility.

We have also learned more about how to do 3D modeling in programs such as Solidworks, which we have used to make renders, animations, and 3D models of our project which we can use to effectively communicate our design plans. Also we have learned how to use a design shop, which has been useful for us for when we have needed to make modifications to the linear actuator that were not possible by simply ordering a new part. We had to custom design parts and attach them to the linear actuator. for example, the plate that is attached to the moving platform, the rail, and the TR2 mount were all put on by utilizing the shop.

The picture on the right shows the flow of logic that will be going through the Unitronics GUI, the linear actuator, and a Windows tablet/computer. As shown, everything is going through a program button that can be switched to either on or off. When the button is on, the Windows tablet will be able to set the resolution of the programmable encoder. When the switch is off, then the Unitronics unit is on and that is where the user can set how many revolutions they want to go and where they will enter their values. All this is going to be fed into the encoder and motor attached to the linear actuator. Finally, the TR2 attached to the linear actuator will give a feedback of how far the user actually went back to the Unitronics unit.

=Final Design=

=Validation=

=Team Members=

=Additional Documentation=

Project Schedule



Meeting Minutes

Presentations



Client Interview



 Budget