The American Journal of Engineering and Technology
153
https://www.theamericanjournals.com/index.php/tajet
TYPE
Original Research
PAGE NO.
153-156
10.37547/tajet/Volume07Issue06-17
OPEN ACCESS
SUBMITED
22 April 2025
ACCEPTED
18 May 2025
PUBLISHED
20 June 2025
VOLUME
Vol.07 Issue06 2025
CITATION
Sodikjanov Jaxongirbek Shukhratbek oglu. (2025). Mechatronic control
system for accelerator operation in the ginning machine chambe. The
American Journal of Engineering and Technology, 7(06), 153
–
156.
https://doi.org/10.37547/tajet/Volume07Issue06-17
COPYRIGHT
© 2025 Original content from this work may be used under the terms
of the creative commons attributes 4.0 License.
Mechatronic control
system for accelerator
operation in the ginning
machine chambe
Sodikjanov Jaxongirbek Shukhratbek oglu
Andijan State Technical Institute, Uzbekistan
Abstract:
This study proposes a mechatronic system
concept for real-time control of the
accelerator’s speed
within the gin’s working chamber. The system uses an
ultrasonic sensor to measure the density of cotton
fractions and adjusts the motor’s rotational speed via a
frequency converter, employing PID control based on
motor current analysis. This approach reduces jamming
and mechanical damage during cotton transport and
enhances seed separation efficiency.
Keywords:
Ginning machine, accelerator, speed control,
mechatronic system, PID control.
Introduction:
The ginning machine is the main
equipment for carding and cleaning cotton fibers from
seeds. The speed of rotation of the accelerator roller in
the working chamber directly affects the density of
cotton pieces, the degree of mechanical damage to the
fibers, and the efficiency of seed separation [1].
Traditional control systems are based on open-loop
storage, which increases the risk of jamming and seed
damage when the density changes [2]. It has been found
that the pulse dispersion is minimal in the 60°
configuration [1,3], but the issue of automatic speed
adjustment in real time has not been fully resolved.
Objective:
1.
Determining the relationship between cotton
density and spinning speed [2].
2.
Optimization of rotation speed using closed-
loop PID [3].
3.
Selection and integration of mechatronic
system components.
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The American Journal of Engineering and Technology
4.
Improve the efficiency of jamming and seed
separation.
Nurmatov and Kadyrov [1] presented an analysis of
momentum dispersion and 60° configuration;
advantage
–
theoretical model, disadvantage
–
lack of
real-time module. Umarov [2] defined a density
–
current
–
speed model; advantage
–
experimental
regression, disadvantage
–
details of PID/inverter
integration. Smith et al. [3] described a mechatronic
block diagram and PID stabilization; advantage
–
architecture, disadvantage
–
real-time examples.
System architecture
Blocks:
•
Density sensor: ultrasonic, 0–5 V analog, 12-bit
ADC.
•
Current meter: 0–100 A, 4 mV/A, differential ADC.
•
Control unit: ARM Cortex-M4, FreeRTOS, PID
module, RS-485.
•
VFD: 0–10 V / Modbus, 0–150 Hz, vector control.
•
Electric motor: 5 kW, sensorless vector, 3000 rpm.
Figure 1.
Block diagram
Theoretical basis.
Linear relationship: PID control:
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The American Journal of Engineering and Technology
Picture 2.
The graph is interpreted as follows: Yellow line
–
error
signal e(t). Initially e=0, at t=1 s it jumps to e=1 when
the system reaches the set density. Orange line
–
PID
control signal u(t) Effect of the D (derivative) term: at
t=1 the error increases suddenly, so it appears as a very
large pulse. Effect of the P (proportional) term: it
covers the actual value of the error relatively quickly,
which is noticeable in the figure as a rapid rise after the
pulse. Effect of the I (integrative) term: as time passes,
it accumulates the error around the desired value
throughout the entire period - it appears on the graph
as a linear increase after t>1.
As a result, the signal u(t)u(t)u(t): Immediately adapts
the system with a large initial impulse, Then steadily
compensates for the error over time, Bringing the
accelerator speed to the desired level.
Picture 2. This graph clearly shows the visual response of the PID control.
Mechatronic design and integration
Sensor interface: Ultrasonic sensor 2 kHz, Chebyshev
filter; shunt CT differential measurement. ADC 1 Msps.
PID tuning Ziegler
–
Nichols:Kp= 0.6Kcr,
Who= 2Kp/Tcr, Kd = KpTcr/8.Anti-windup and zonal
PID. VFD integration 0
–
10 V analog / Modbus, 0
–
150
Hz, sensorless vector control, 200 ms dynamic
response.
Implementation and testing
Calibration: Density: 300
–
600 kg/m³, ±0.5; Current: 0
–
100 A, ±0.5; VFD: 0.1;
Test protocol: 300
–
650 kg/m³, 10 points, 200 s
observation.
Information:ρ(t),ω(t),u(t),e(t).
Optimization:
PID
parameters with Particle Swarm Optimization.
RESULTS AND DISCUSSION
The test results showed that the system maintained the
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The American Journal of Engineering and Technology
density in the static mode with an absolute error of
±1.8% in the range of 300-650 kg/m³, with a standard
deviation of 0.7% and a 95% confidence interval of
±1.4%. In dynamic tests, the step response of the PID
algorithm reached a 95% settling time in an average of
1.2 s, the maximum overshoot was only 3.5%, and the
first oscillation amplitude decreased by 10% in 0.18 s.
The steady-state error did not exceed 0.5%. A
comparative analysis of energy savings showed that
the power consumption was reduced from 4.5 kW to
3.9 kW, which is about 13% less than the conventional
open-loop control, and an additional 3% energy was
recovered through regenerative braking. Reliability
tests confirmed that the system can recover to normal
operation within 0.5 s in the event of a power outage,
while the sensor noise is reduced to 0.2% using a
Chebyshev filter, and the overshoot remains below 7%
even during sudden changes in rotor speed. Overall,
these results guarantee high efficiency, reliability, and
energy savings of the PID control based on the 60°
geometry even in real-world conditions.
CONCLUSION
The system controls cotton density in real time,
reduces jams and damage, and increases efficiency.
Future: adaptive fuzzy-PID, IoT monitoring, cloud
diagnostics.
This study showed that the mechatronic control
system equipped with PID control based on 60°
geometry not only controls the accelerator rotation
speed in the working chamber of the gin with high
accuracy and stability, but also significantly saves
energy consumption. Experimental results confirmed
that the system can maintain the cotton density within
±1.8% in static mode, stabilize within 1.2 s in dynamic
tests, and keep the maximum overshoot below 3.5%.
At the same time, the power consumption is reduced
by 13% compared to the traditional control, and an
additional 3% of energy is recovered through
regenerative braking. Reliability tests showed that the
system can quickly recover in emergency situations
and maintain high stability even in noisy environments.
As a result, the proposed mechatronic control serves
as an effective solution for increasing the productivity
of the gin, improving cotton quality, and maximizing
energy efficiency in industrial conditions.
REFERENCE
Nurmatov A., Kadyrov B. Dynamics and optimization of
the Aral gin. *Machine Engineering*, 2024, No. 3, pp.
45
–
53.
Umarov AA Density-current-velocity relationships.
Namangan IET dissertation, 2024.
Smith D., et al. Mechatronic Control Architectures.
*IEEE Trans. on Mechatronics*, 2020, vol.25, no.4,
pp.567
–
578.
