2&CIMK_07 1

Mechatronics Control System on Hydraulic

Press for Joint of Homocinetics Axles


Edgar M. Jaimes Moreno, Jesus Alvarez, Omar Lengerke, Max Suell Dutra, Armando C. de P. Filho

answered are: How to prepare industry for this change? How

Abstract— The application of automation to industrial
processes has created a need for constant improvement, and
development of new technologies based on autonomous systems,
which are the basis of this work. The purpose of this article is
mechatronic design and implementation of automatic control
system in the Barmag press, to carry out tension and
compression test for general production of homocinetic axle in
the automotive industry. Mechatronic design includes: the
accomplishment of the automatic control system for assembling
parts and traction test of the press; the implementation of a
novel tool for detecting disassembly or assembly error of the
homocinetic axle; the adaptation of anchorage system to assure
that the piece should be kept in its position during the test; and
the development of press control system, in order to adapt it to a
position of the beginning of standard work.
to implement the new technology?
The automotive industry has accepted this challenge,
opening action field for the investigation and development of
new projects directed to the modernization of its plants,
improvement of processes and production. This creates
opportunities to the new generation of professionals able to
assume the responsibility of achieving this change.
The present project intends to improve the process of
assembly of homocinetic axles, which is carried out on
hydraulic press in the homocinetic axles production line [4]–
[5], implementing a mechatronic control system for
assembling parts and the traction test, thus creating a tool of
high performance that benefits the industry [6]–[7].

Index Terms—Automatic control, barmag press, homocinetics

axles, hydraulic press, industrial automation, industrial II. MECHATRONICS DESING
mechatronics project, mechatronics design.
Mechatronic design is based on systematic process for the
identification of potential design failure of product or process
I. INTRODUCTION before it occurs, with the purpose of eliminating or
minimizing the risk, called Failure Mode and Effect Analysis
N owdays diverse industries are taking their production
processes at a technological level coming closer and to
(FMEA) [8]–[9]. By means of this process error, we analyze
causes, detection processes and measures proposals to give an
the Total Integration of the Industrial Automation (TIIA),
appropriate development to the project (Fig. 1).
what represents a great challenge for all their elements. This
process has created the necessity to have human resources
qualified to confront this task, inside those that the field of
action of Mechatronics Engineer is developed, either
changing the processes with new technologies, or improving
them with integration among their current technology and
novel control systems [1]–[2]–[3].
The industrial automation is centered on organizing,
directing, executing, and controlling productive tasks in the
industrial sector, according to technological specifications
and production volumes. Among the questions that must be

Manuscript received July 29, 2009. This work was supported in part by the
Autonomous University of Bucaramanga, Colombia.
E. M. Jaimes Moreno Autonomous University of Bucaramanga, Colombia.
E-mail: emjaimes@unab.edu.co. Fig. 1. Mechatronic design scheme.
O. Lengerke, Autonomous University of Bucaramanga, Colombia.
Mechatronic Systems & Robotics Research Group – COPPE/UFRJ – Rio de
Janeiro, RJ, Brazil, E-mail: olengerke@ufrj.br. Hydraulic press is a tool that has as its purpose to achieve
M.S. Dutra, Mechatronic Systems & Robotics Research Group – the permanent deformation or even to cut or to assemble a
COPPE/UFRJ Postal Box 68.503 – CEP 21.945-970 – Rio de Janeiro, RJ, specific material, by means of application of a load [10]. One
Brazil, E-mail: max@mecanica.coppe.ufrj.br.
 2&CIMK_07 2

of the causes that has made possible the production and homocinetic axle. This problem occurred because the valve
popularity of many objects of daily and deluxe use is the for control of traction and compression was of closed center
growing application of presses to mass production. One of the type, forcing the system to release the pressure through the
most remarkable examples of this application is the relief valve (Fig. 3). The valve constantly open produced
development of the automotive industry production. constant friction between the fluid and the valve, causing
Currently, the presses are substituting others machines for overheating [11].
mass production.
Hydraulic presses are produced in several types and sizes,
and can be provided of almost unlimited capacity. The use of
hydraulic cylinders allows the application of forces in several
points.
A. Press Operation - Analysis
The Barmag hydraulic Press is a device belonging to
homocinetic axles production line. Due to its importance in
the process, it is necessary to make adjustments, changing the
original electro-mechanic control system, for a new automatic
control system implemented in this project. In the course of
the first programmed days of test, the problems that occurred
were analyzed and an appropriate study for corrections and
implementation of the control system was carried out.
1) Hydraulic System: the analysis began at 8:00 until a
failure was detected in the pressure of compression and
traction test. We noticed that the reading in the pressure
began to vary critically approximately five hours after having Fig. 3. Hydraulic system project previous.
put the system into press operation (Fig. 2).
2) Traction Test (Axle Disassembly): we observed that the
COMPRESSION absence of a system would detect the moment that the tulip
N
9300
disassembles the intermediate shaft. In some cases, it was not
9200 easy to notice that the snap ring disadjustment of intermediate
9100 shaft.
9000 3) Position work initiation: by means of the analysis
8900 obtained during days of test, we noticed the absence of an
8800
initial position of work, what allowed that each axle to be
8700
tested from different positions, changing the measurement
8600
08:00 09:12 10:24 11:36 12:48 parameters.
Time (hours) 4) Anchorage Devices: in the moment of the homocinetic
TRACTION axle test, a control failure was evident on the anchorage
N
12400
device, allowing to realize the test without assuring the parts,
12350 what represents a danger for the operator.
12300 5) Control System: when the previous control system was
12250 revised, we found several failures to control this process
12200
12150
appropriately. The system did not perform cycle in an
12100 automatic method, allowing the operator to work the press in
12050 a position without control.
12000
08:00 09:12 10:24 11:36 12:48 B. Solution
Time (hours)
Fig. 2. Compression and traction measurements.
In order to analyze the available proposals, we took into
consideration very important production factors for the
industry, such as: the work should be carried out online,
Analyzing this phenomenon, we verified that the problem
allowing that the press to be used by homocinetic line in the
in hydraulic system was an overheating in the hydraulic fluid
production of axles without inconveniences, and the press
(Rando oil 68), which produces loss of viscosity, allowing
performance was analyzed to detect possible future problems
leakage through the piston seals and valves, with considerable
in the systems. The solution is the implementation of a
waste of pressure, for compression test performed in
programmable logic controller (PLC), because this device
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represents a quick, flexible, economic, and efficient side [14]. When we introduce a metallic part in the magnetic
alternative [12]. field, currents of Foucault that influence the oscillator take
The automation of machinery and industrial process should place and they generate a weakening of the oscillatory circuit.
contemplate all the possible states. It should not only be As consequence, a decrease of the oscillations amplitude takes
contemplated in the program the normal operation, but the place. A circuit detects this variation of amplitude and
failure situations, emergency stop, processes of rearms and determines a commutation on signal given by the sensor (Fig.
setting in march of schemes and manual control. All PLC 6).
program should contemplate these cases, with the objective of
reducing to the minimum the time of stopping of machinery
and to perform the restart process and changes in operation
mode, for example to pass of manual control to automatic
control.
The GEMMA (Guide d`Etude des Modes de Marches et
d`Arrêts), Design Guide for Start and Stop Modes, is an
organized representation in all the modes or state in that the
production process can be automated [13]. GEMMA also
represents the state part control is out of service, i.e., the
system is without supply or stopped. GEMMA was developed
for the project application (Fig. 4), detailing all the possible
stops that can occur during a work shift, as well as the normal
process of press operation.

Fig. 5. Representation of sequential system of the press using GRAFCET

method.

Resonant
circuit LC Comparison
and and
oscillator Commutation
HF

Target to Ferrite Supply and

detect nucleus Sinal

Fig. 6. Operation scheme of an inductive detector of proximity.

Fig. 4. Design guide for start and stop modes (GEMMA).
Based on research carried out on GRAFCET method and
supported on FMEA, the design of the flow diagram for the
sequential control that is applied to the press was
implemented, where the states and actions are shown for a
correct operation during the work or operation cycle,
accomplished on each homocinetic axle. We also need to
describe the conditional and sequential group events, which
must respect the evolution rules; otherwise, the automation or
the event group would not be necessary in analysis of
GRAFCET (Fig. 5).
C. Model and Mathematical Calculations of Inductive
Sensor
The The operation principle consists in the possibility of
influencing from the exterior an oscillator HF completed with
a resonant circuit LC. A ferrite nucleus with an oscillatory
coil generates a variable magnetic field above the sensitive
Analyses and calculations applied for the configuration of
an inductive sensor can be used from mathematical model of
a resonant circuit LC [15]–[16]. The approximate inductance
of a coil of a single layer to the air can be calculated from (1).
((d )2 *(n) 2 ) (1)
L 
(18*(d )  40*(I ))*0.394
Where, L is inductance (  H ), d is coil diameter ( in ), I
is coil longitude ( in ) and n is spirals number. Applying (1)
can calculate the sensor theoretical inductance, as follows:
((1.2) 2 *(50) 2 ) (2)
L   32.32 H
(18*(1.2)  40*(5.6))*0.394
The material thickness (  ), where the currents are
induced, should be sufficiently higher compared with the
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profundity of penetration. This is represented in (3).

caudal maximum 12
1
  0.0923 liters rev  9.23 cm rev (7)
2
velocity 1300
  ( f  ) (3)
This is the theoretical cylinder capacity, however the
Where,  is conductivity of the material,  is pumps have a volumetric performance and it can be
permeability and f is frequency. Applying (3) we obtain (4). considered in 90%, and the necessary cylinder capacity to
1 give the required caudal is obtained by (8).
  ( * 25Hz *800* 9.96*106 ) 2  1.26-6 m (4)
9.23 (8)
 10.26cm / rev
The previous results provide a theoretical approach on 0 .9
which we can select the appropriate sensor. The data can vary
because the taken values are represented under ideal For the calculations of electric motor, the power necessary
conditions of work, without considering the temperature for operation of the pump is calculated according to (9).
work, humidity, and other external factors that could
influence a change on real measurement. Pow  Q * P (9)
t
D. Calculation of Components of Power Hydraulics
For the circuit design is indispensable the exact The compression power ( Powc ) and traction ( Powt ) are
knowledge of necessities and works to accomplish elements, obtained by (10) and (11) respectively.
such as: velocity, force, time, etc. This project demanded a
reengineering of the hydraulic system and is very important 12 * 14
for the adaptations outlined in the correct operation and Powc   312.03 Watts  0.42 Hp (10)
analysis of objectives of the press. The component of circuit
0.88
hydraulic used on calculation of power is the stroke hydraulic
cylinder of 500 mm, taking into consideration the time of 12* 18 (11)
Powt   401.18W  0.54 Hp
process (compression and traction) and the necessary 0.88
pressures for tests. The compression pressures ( Pc ) and
Table I presents the parameters obtained during the
traction ( Pt ) are obtained by using (5) and (6) respectively. calculations.

TABLE I
Force 1000 (5) PARAMETERS OBTAINED FOR THE MOVEMENTS OF THE PRESS
Pc    13.99 Kgf /cm 2
Surface  *(R 2  r 2 )
Time Force Stroke Pressure caudal
Movement
(s) (Kgf) (mm) (Kgf/cm2) (liters/min)
1350 Compression 10 1000 250 14 12
Pt   17.19 Kgf /cm2 (6) In rest 0.5 1000 0 14 0
 *52 Traction 20 1350 500 18 12
In rest 0.5 1350 0 18 0
The pump will be able to resist the pressure of 17.19 Total 41 18 12
kgf/cm2, so that a pump of 20 kgf/cm2 should be used. For
 
caudal, the cylinder annular area is  R 2 -r 2 =71.47cm 2 ,
E. Automation Process and Adaptation of the Barmag Press
each centimeter for compression will require 71.47cm 2 of
fluid. Thus, to move 250 mm, 71.47cm2 were needed by 25 The bypass using a valve 2/2 normally open allows a
cm = 1.79 liters. This displacement occurred in 10 seconds, communication with tank when the press is not carrying out
what indicates that the pump will give a minimum flow of 2 the cycle test, closing during the process test (Fig. 7). This is
liters in 10 seconds, or 12 liters per minute. For displacement the implemented solution, since it avoided the overheating
500 mm in 20 seconds, the cylinder area is and did not present failure of pressure in the circuit.
 * R2  78.54cm2 . Necessary volume to accomplish this We preferred the implementation of an inductive sensor,
travel will be  * R 2  78.54cm2 *50cm  3.93liters . As this positioned in the inferior block of the press (Fig. 8), and its
volume is needed in 20 seconds, in one minute the pump will programmed time to send signal to a visual help installed in
give 11.79liters min  12liters min . The necessary flow in the the control panel, which indicates to the operator that the axel
pump for the pressure and traction is the same, consequently is not well-assembled. For the implementation of the
it is not necessary to put flow constrains in none of the inductive sensor we chose reference Siemens 3RG40 22-
phases. 0KB00, which has a normally open contact, operation
The pump used an electric motor of 1300 rpm; the distance of 4 mm, since this is a wise distance to protect the
cylinder capacity of the pump is given by (7).
 2&CIMK_07
sensor against collisions, with an operation voltage range of
20-265 VAC.
Fig. 7. Hydraulic system implemented.
Home Sensor Disassemble Sensor
Fig. 8. Home and disassembly sensors.
For initial position work, the implementation of an
inductive sensor is selected, located in the inferior block of
the Press (Fig. 8), and its time is programmed to locate the
block in a defined position standard. A sensor is used with the
same characteristics to traction test (axel disassembly).
In the anchorage devices, two inductive sensors are used,
positioned in the superior block of the press (Fig. 9 and Fig.
10), which detect the instant in that the parts are anchored
and in condition to carry out the cycle. If the anchorage is not
detected, the test is not performed, since it is a condition of
beginning the cycle. For the implementation, we selected two
inductive sensors reference Siemens 3RG40 12-0KB00,
which usually have open contact, operation distance of 2 mm,
since this is a wise distance to protect the sensors against
collisions and operation voltages range of 20-265 VAC.
In control system, for robust controller election, we
realized flexible and new adaptations, with handling capacity
for components and with protection against to eddy
frequencies present in work environment. A PLC Siemens
5
reference LOGO! 230 RC6ED1053–1FB00–0BA2 with power
supply 115–230 VAC, twelve digital input 115-230 VAC,
eight output 10 Amperes is selected. For the PLC
programming, the software LOGO Soft de Siemens is used.
Fig. 9. Anchorage sensors.
Fig. 10. Anchorage systems.
III. DESCRIPTION OF THE PRESS PROCESS
The process consists on assemblage of fixed and mobile
joints of homocinetic axle, and accomplishment of the
traction and compression tests. The automatic cycle is
generated when the operator gives the order by the push-
button located on control panel, checking the press is in
automatic or manual mode. The program automatically
checks its safety line, which corresponds to verifying if the
press is in initial position work established by the sensor.
Immediately afterwards, the program checks if the axle was
anchored. In case of not being anchored, the press will not
continue its work cycle. Stopping the exam of the fulfillment
 2&CIMK_07
of the safety line, it proceeds to carry out the assembly and
compression test, where the program provides the service
letters necessary for suitable assembly, which has two
programmed alarms, indicating if the press reaches the
maximum and minimum. If these values are reached, the
press continues working, otherwise, the press will not
continue the process of traction test
When the traction test is carried out, as in the
compression test, a force established by the appropriate
service letters for a error test or satisfactory assembly, which
has two programmed alarms, indicates if the press exceeds
the maximum or does not reach the minimal pressure. If the
maximum exceeds the disassembly sensor, it sends a signal
producing the intermittent ignition of a light that is on
control panel, and the press will not continue its work cycle.
If the force is in the necessary range, it means that the
assembly, the traction test and the compression test are
correct. After the press comes back to its standard beginning
position and the press does not anchor the axle, the operator
proceeds to withdraw the axle from its homocinetic axle.
Figures 11 and 12 present the general process scheme of test
and assembly of homocinetic axle.
Fig. 11. Barmag press.
IV. CONCLUSION
With the implementation of the valve on hydraulic circuit,
the overheating and pressure loss of compression were
avoided, achieving a few parameters of standard test for all
homocinetic axles. With the adjustment of the new control
system for the Barmag Press, the production of assembly of
homocinetic axles increased, avoiding time of rework and
manual review by the operator. The press anchorage system
6
performed a function of ideal safety in assembly, due to its
priority to begin the test cycle. With the beginning work
position, the press always will work with the same point of
reference, what indicates that it also will work with the same
parameters of calibration. With the installed visual help that
was programmed to indicate the operator if the
accomplishment of traction test was satisfactory or not, the
operator wasted less time in reviewing the homocinetic axle
LOGO
Fig. 12. General systems scheme.
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[1] R. H. Bishop, The Mechatronics Handbook, CRC Press, New York.
2002.
[2] J. V. Amerongen, “Mechatronic design,” Mechatronics, vol. 13, issue 10,
2003, pp. 1045-1066.
[3] O. Lengerke, C. V. Martinez, M.S. Dutra, M.J.M. Tavera, F. L. E. Silva,
“Mechatronics Design Of A Low-Cost Packaging And Dosing Machine
For Doughy Products,” Brazilian Society of Mechanical Science and
Engineering. ABCM Symposium Series in Mechatronics. Rio de Janeiro,
Brazil, vol. 3, 2008, pp. 717-725.
[4] H.L Stewart, Hydraulic and Pneumatic Power for Production, Industrial
Press, Inc., Fourth Edition, New York, USA, 1977.
[5] L. W. Mays, Hydraulic Design Handbook, McGraw-Hill, USA, 1999.
[6] J. A. Ferreira, P. Sun, J. J. Grácio, “Design and Control of a Hydraulic
Press”, IEEE International Symposium on Intelligent Control, 2006, pp.
814–819.
[7] P. Sun, J.J. Grácio, J.A. Ferreira, “Control System of a Mini Hydraulic
Press for Evaluating Springback in Sheet Metal Forming,” Journal of
Materials Processing Technology, vol. 176, issues 1-3, 2006, pp. 55-61.
[8] D. H. Stamatis, Failure Mode and Effect Analysis: FMEA from Theory to
Execution, Second Edition, ASQ Quality Press, USA, 2003.
[9] C.F. Eubanks, S. Kmenta, K. Ishii, “System Behavior Modeling as a Basis
for Advanced Failure Modes and Effects Analysis,” in Proceedings of the
1996 ASME Design Engineering Technical Conferences and Computers
in Engineering Conference, Irvine, California, 1996, pp. 1-8.
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[10] J.A. Ferreira, P. Sun, J.J. Grácio, “Close Loop Control of a Hydraulic
Press for Springback Analysis,” Journal of Materials Processing
Technology, vol. 177, issues 1-3, 2006, pp. 377-381.
[11] G.K. Adam, 2004, “Design and Control of A Mechatronic Hydraulic Press
System,” in Proceedings of the IEEE International Conference on
Mechatronics, 2004. pp. 311–315.
[12] K.T. Erickson, “Programmable Logic Controllers”, IEEE Potentials, vol.
15, issue 1, 1996, pp. 14–17.
[13] G. Cloutier, J.J. Paques, “GEMMA, the Complementary Tool of the
GRAFCET,” in Conference Proceedings Programmable Control and
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Canadian, 1988, pp. 12A1-5/1-10.
[14] J. S. Wilson, Sensor Technology Handbook, Newnes Elsevier, USA,
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[15] W. Boyes, Instrumentation Reference Book, Butterworth-Heinemann,
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[16] J.G. Webster, The Measurement Instrumentation and Sensors Handbook,
CRC Press, 1998.

Edgar Mauricio Jaimes Moreno Mechatronics Engineer graduated in 2007

(UNAB, Colombia). Automation Industrial specialist graduated in 2008.

Jesus Alvarez Mechatronics Engineer, graduated in 2007 (UNAB, Colombia).

Omar Lengerke M.Sc. in Control and Automation of Manufacture Systems,

obtained in 2002 (ITESM-CEM, Mexico), Computational Systems Engineer,
graduated in 1999 (UNAB, Colombia). D.Sc. candidate in Mechanical
Engineering in Robotics since 2006 at Federal University of Rio de Janeiro
(COPPE/UFRJ, Brazil) under advising of Professor Dr.-Ing. Max Suell Dutra.
Professor of UNAB, Colombia. http://fis.unab.edu.co/docentes/olengerke. More
than 20 works published in national and international congresses and journals in
the last 3 years. CV: http://lattes.cnpq.br/2942398586405793

Max Suell Dutra Dr-Ing. in Robotics, obtained in 1995 (UNI-DUISBURG,

Germany). M.Sc. in Mechanical Engineering in Robotics, obtained in 1990
(COPPE/UFRJ). Mechanical Engineer, graduated in 1987 (UFF, Brazil).
Professor of COPPE/UFRJ, heading a research group in Automation and
Robotics. Chief of the Robotics Laboratory. http://www.labrob.coppe.ufrj.br.
More than 60 works published in national and international books, congresses
and journals in the last 3 years. C.V.: http://lattes.cnpq.br/7801915818734316

Armando Carlos de Pina Filho. D.Sc. in Mechanical Engineering in Robotics,

obtained in 2005 (COPPE/UFRJ). M.Sc. in Mechanical Engineering in Robotics,
obtained in 2001 (COPPE/UFRJ). Industrial Mechanical Engineer and
Technician, graduated in 1995 (CEFET-RJ). Professor of POLI/UFRJ, heading
the research group ARMS (Automation, Robotics and Modeling of Systems).
One book about humanoid robots edited in 2007. More than 40 works published
in national and international congresses and journals in the last 3 years. CV:
http://lattes.cnpq.br/4389013951914878.