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1. Ny a ares O OINO O N1 5 S O 0 iO RO O o O o RI O o R2 H o o S1 0 e s2 ol o lo ol s3 o o S4 o o o e SH S O o lo ol 5 o fe c H412 o o C MOTION 1 1 L12 l O 2 2 O 3 3 4 4 O 5 5 O 6 6 AINO OPWR COM ORUN AIN1 OENB COM AOUTO COM AOUT1 COM SYSTEMS S4520 ELECTRONICS O GROUP INC SLOT 01 O 2 2l 2 2 2 Figure 6 84520 Motion Controller Pin outs HSL WISVCUP User s Manual 34 SYSTEMS Electronics Group SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE The Windows based set up program is menu driven allowing the user to easily view data alter set up variables or set machine timing machine offset timing signal locations etc using a PC running the Windows 95 98 ME 2000 XP NT operating system The set up variables are used to configure and tune the M4510 to match the configuration and performance of the specific bodymaker see section 2 9 HSL WISVCUP Set Up
2. ino ZJ int FLT ed o o O Omo else jo o 1 O OINI o 2 jo RO O 3 O 3 o 4 o 4 RI o 5 ol5 rI IG ole ol6 S1 o 7 O 7 0 10 0 10 S2 o 11 ol11 S3 0 12 0 12 S4 lol 13 0 13 lo 14 joy 14 ay o 15 ol15 10 16 Oo 16 a o7 ou7 H12 0 o MaS MOTION 1 i O O 2 2 O 3 3 4 4 O 5 5 O 6 6 7 7 10 10 OPWR 11 11 12 12 Baa 13 13 14 14 15 15 16 16 wey Whe Io Jel SYSTEMS M es 4520 4568 4568 SLOT 01 SLOT 10 SLOT 11 O GROUP INC O Figure 2 M4510 Configuration HSL WISVCUP User s Manual SYSTEMS Electronics Group 16 SECTION 2 INSTALLATION 2 9 HSL WISVCUP SET UP The HSL WISVCUP is shipped from the factory with the PLC program HSLSCUP loaded in the main processor of the M4510 module PLC section and the PLS channel set point file TMGSCUP loaded in the PLS section of the M4510 module Program SRVCUPR is loaded in the S4520 motion controller located in slot 01 of the M4510 These are the standard programs used to implement the standard HSL WISVCUP servo cupfeed algorithm In some cases the following user variables and timing channels may have to be altered to tune the HSL WISVCUP to the actual bodymaker it is controlling Once the HSL WISVCUP is installed and the control system is powered back up perform the following to set up and tune the HSL WISVCUP The set up is performed using a PC running the set up program See section 4 or 5 for a description of the me
3. Note The stator wiring must be connected exactly as shown on the schematic any other combination of connections will cause the motor either to jerk or stall SYSTEMS Electronics Group 97 SECTION 7 TROUBLE SHOOTING 8 Verify the main crank resolver reference wiring connections see schematic 9 Verify resolver reference signal for servo motor is correct by measuring the voltage between R1 and R2 on the 4520 RDC using a DVM see schematic This can be measured between the ORG and WHT wires on the UMSTBHK connector on the upper left corner of the HSL WISVCUP back panel The voltage should read 3 7Vrms Note The frequency of this signal is 2500HZ For this reason some DVMs may read this voltage slightly low 10 Verify resolver reference signal for the main crank is correct by measuring the voltage between R1 and R2 on the M4510 using a DVM This should be measured between the R1 and R2 terminals on the 8 pin resolver connector on the M4510 The voltage should read 1 45Vrms Note The frequency of this signal is 2500HZ For this reason some DVMs may read this voltage slightly low 11 Verify the cupfeed cam and main crank resolvers see sections 2 9 3 and 2 9 5 12 Verify the tension on the cupfeed cam belt If the belt is too loose the cam will oscillate which causes the following faults If it is too tight the cupfeed cam bearing will wear prematurely causing a variation in the load and thus oscillation and f
4. System Message Faults Active in PLC ONLNE 10 19 2003 10 39AM _ HSL WISVCUP User s Manual SYSTEMS Electronics Group 62 HSL WISVCUP User s Manual SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Cupfeed Servo PID Gains Proportional P Gain The proportional gain is used to create an error term which is proportional to the difference between the main crank position and servo motor position For a specific amount of error the higher the P gain the higher the torque generated to null the error Note By itself the P term cannot null the error to zero since a torque is only generated when there is a difference between the main crank position and servomotor This P gain is used in conjunction with the other gains to define the system stability and responsiveness A higher the P gain will cause the servo motor to be more responsive Too high of a P gain will cause the motor to become unstable oscillate because the system cannot respond quickly enough Excessive current will also be drawn which is undesirable Too low of a gain will cause excessive following error to the point of instability depending on where the 1 gain is set The P gain can also be used to overcome high frictional loads higher P for higher friction Integral I Gain The integral gain is used to create an error term which is proportional to the cumulative difference error between the main crank position and
5. Windows Setup Program Reference or section 5 2 DOS Setup Program Reference for complete details 7 Download the PLS timing set points and setup data to the M4510 See section 4 2 4 Windows Setup Program Reference or section 5 2 DOS Setup Program Reference for complete details ASL WISVCUP User s Manual SYSTEMS Electronics Group OTs SECTION 2 INSTALLATION 2 10 5 DOWNLOAD SRVCUPR PROGRAM AND SET UP DATA TO S 4520 RDC IN SLOT01 Perform the following to download the SRVCUPR application program to the S4520 RDC motion control processor as well as download the previously saved set up data 1 2 3 4 5 6 7 8 Power up the HSL WISVCUP and the PC used to interface with the HSL WISVCUP Connect an RS 232 cable from the computer COM port to the MOTION port on the S4520 RDC in slot 01 Execute the setup program WISVCUP for Windows based systems HSL SCUP for DOS based If using the HSL SCUP setup program select the bodymaker B M number that is being interfaced to If using the WISVCUP setup program open a previously saved setup data table file Select Cupfeed Set up S4520 Slot 01 MOTION PORT Download the SRVCUPR application program to the 4520 Confirm your choice to start the download See section 4 2 3 Windows Setup Program Reference or section 5 3 DOS Setup Program Reference for complete details Download the previously saved set up data to the S4520 RDC See s
6. 5 The previous steps will automatically set the Cupfeed Cam Home Position by calculating the cupfeed cam offset relative to the main crank position ASL WISVCUP User s Manual SYSTEMS Electronics Group 20 HSL WISVCUP User s Manual SECTION 2 INSTALLATION 2 9 7 VERIFY CUPFEED TRACKING By inching the machine verify that the cupfeed does track follow the main crank Verify that the cupfeed is correctly in time with crank in all crank positions If the cupfeed oscillates wildly or does not follow the crank verify that the PID gains are set correctly see section 2 9 1 Default Set up Variables If the gains are set correctly verify that the motor stator wiring and feedback wiring are correct see schematic at the back of this manual If they are correct verify that the analog command reference from the S4520 RDC to the B25A20 is not swapped see schematic at the back of this manual 2 9 8 VERIFY MACHINE OPERATION Run the machine in normal production both at low and high speeds where practical and verify that the cupfeed cam does track the main crank in both inch and continuous modes Note After power up the cupfeed cam will automatically time itself when the machine is first run in inch or continuous The cupfeed cam will rotate at a slow speed until it passes the timing sensor and then will start tracking the main crank Verify that the cupfeed cam does stop immediately at the detection of a short c
7. 45 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 3 3 EDIT SET UP PASSCODE The edit Set up Passcode is an Online function only This allows the user the ability to directly change the value of the Set up Passcode Once selected an input box is displayed allowing the user to view the current Passcode setting and to change the value if necessary Keypad Set up Passcode x Please Enter New Passcode 0 65535 Cancel If the passcode is set to zero passcode entry is disabled The operator can press the Set up key on the Keypad Display and simply press the lt ENTER gt key to gain access to the set up parameters without having to enter a zero If the value of the Passcode is set somewhere between 1 and 65 000 Passcode Entry is enabled This requires the operator to enter in the Correct passcode to gain access to the set up parameters Note Passcode entry is only in effect when the Set up Enable selector switch is in the Disable position If an invalid value is entered the passcode value will not be reset and a message box notifying the user of the error is displayed ASL WISVCUP User s Manual SYSTEMS Electronics Group 46 HSL WISVCUP User s Manual SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 4 THE VIEW MENU The View menu allows the user to perform the following functions e View the Target Board Inte
8. Acquire Data By clicking this command button the 4520 initiates collecting the data signatures for one stroke Once completed the data collected is displayed in the chart to the right Note The Acquire Data function is only enabled when the set up program is Online with the processor SYSTEMS Electronics Group 67 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual Print Data By clicking this command button the user can obtain a printout of the data displayed Once executed the Print Setup dialog box is displayed allowing the user to choose a printer device as well as define the size and orientation of the paper This printout also displays the current settings of the PID gains Save Data By clicking this command button the user can save the data to a Cupfeed Data file This allows the user to easily save different sets of acquired data signatures Open Data By clicking this command button the user can open an existing Cupfeed Data file This allows the user to examine previously saved acquired data signatures while not Online with the processor Export Data By clicking this command button the user can export the displayed data to a Text file format This allows the data to be easily used by other windows programs such as Microsoft Excel or Microsoft Word Any program that can open a Text file format can have access to this d
9. This selection is used to time the cupfeed and zero the main crank in the 4520 slot 01 In addition this menu displays the main crank position and servo cupfeed motor position This is useful for trouble shooting purposes The Cupfeed Time Position Diagnostics menu contains the following selections Systems HSL WISVYCUP Servo Cupfeed Set up Menu Version 1 2 Cupfeed Cam Time Position Diagnostics Menu elected Bodymaker 1 Zero Main Crank Position Auto Offset 2 Set Cupfeed Cam Home Position Enter Selection ESC to exit Main Crank Position Reference for Cupfeed Main Crank Offset 4095 2998 Actual Main Crank Position 4095 0000 Cupfeed Cam Home Position Timing PRK Off to On 2304 Cupfeed Cam Offset 0 4095 0919 Actual Cupfeed Cam Position 4095 0230 Main Crank to Cupfeed Absolute Error Counts 0230 The following selections set the corresponding parameters 1 Zero Main Crank Position Auto Offset This selection zeros the main crank position by calculating the required offset to make the current position zero This would be done when a new S4520 board has been installed To zero the main crank position set the ram at Back Dead Center and select this selection A prompt asking are you sure is displayed Press Y to zero the position or N to abort The main crank offset will be calculated and the Actu
10. HSL WISVCUP User s Manual SYSTEMS Electronics Group 50 HSL WISVCUP User s Manual SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 5 1 THE BODYMAKER MAIN DISPLAY WINDOW The bodymaker Main Display window is used to display the general state of the control system This window is selected from the Bodymaker menu Messages l r Machine Speed SPM Machine Position o System Message All Faults Normal ONLINE 10 19 2003 10 25AM _ The following is a list of the functions of the Main Display window Messages The Messages display is continuously updated It displays alarm and status messages specific to the M4510 as well as the current Online or Offline status of the set up program By simply scrolling the display the user is able to view all active alarm and status messages If no alarm or status messages are active a default message is displayed Machine Speed SPM This display is only active while Online and displays the current speed of the machine in Strokes Per Minute Machine Position This display is only active while Online and displays the current position to the main crank resolver in degrees SYSTEMS Electronics Group 5 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual 4 5 2 THE BODYMAKER SET UP PARAMETERS WINDOW The bodymaker Set up Parameters window is used to
11. Note The set up program is an on line communications program used to interface with the M4510 module The data displayed and set in the windows is communicated directly to the module while in the Online edit mode Therefore prior to going online with the processor make sure an RS 232 cable is connected from the COM port on the computer to the PROG or MOTION port on the M4510 The variables displayed while in the Online edit mode are read directly from the processor Data is saved to a Set up Data file sdt whenever changes are made to a parameter or if the data is uploaded from the processor Messages r Machine Speed SPM Machine Position o 24 System Message All Faults Normal o ONLINE 10 19 2003 10 25AM _ HSL WISVCUP User s Manual SYSTEMS Electronics Group 35 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual 4 1 GENERAL DESCRIPTION Title Bar At the top of the window is the Title Bar The title bar is used to display the name of the working Set up Data file as well as the name of the active Window The title bar is dark if the window is active and grayed if another window is active The color depends on the settings of the Display Properties of the Control Panel Status Bar At the bottom of the window is the Status Bar The status bar is used to display system messages online or offli
12. Set up parameters timing channel set points and shift data to the M4510 or S4520 from the set up Data File This function is accessed from the File menu and the user is given the choice of the following options 2 WISYCUP unnamed BM Main Display File Edit View Bodymaker Serov Cupfeed Help New Ctrl N Open Ctri 0 Save Ctrl S Save As Export Shift Data Ctrl lt Upload save Data gt Speed SPM a Machine Position Download Program gt 4520 Motion Control Print Report Ctrl P ee Exit ONLINE 10 19 2003 10 284M 7 System Message All Faults Normal M4510 PLC This option downloads set up parameters machine timing set points and shift data to the M4510 only 4520 Motion Control This option downloads set up and tuning parameters to the S4520 Motion Control Board only Note Only the values contained within the current data file are used If the validity of the current data file is questionable review the data in an Offline mode prior to download SYSTEMS Electronics Group 42 HSL WISVCUP User s Manual SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 2 5 PRINT REPORT The Set up program allows the user to generate a Report printout of all the set up parameters timing channel set points and shift data This function is accessed from the File menu At the top of each page the report
13. Trimmer Idle Speed CPM This parameter determines the speed the trimmer will run at when the bodymaker is stopped de clutched Note This parameter is used to provide the speed reference when the bodymaker speed is zero When the bodymaker is running the trimmer speed reference is proportional to the speed of the bodymaker SYSTEMS Electronics Group 53 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual 4 5 3 THE MACHINE TIMING WINDOW The Machine Timing window is used to invoke the PLS programming command menus From this window the user can view or adjust the following parameters e Adjust Timing Channel set points e Set the Main Crank resolver offset e Clear or Recall a PLS timing channel e View the current PLS configuration e Reset the PLS configuration to default settings 2 WISYCUP unnamed Machine Timing File Edit View Bodymaker Serov Cupfeed Help M Timing Channels PLS Configuration ON OFF BDC High Timing CHOO 150 170 H Number of PLS Channels EEA BDC Low Timing CHOI 180 200 4 PLS Program 0 Short Can Check Timing CH02 155 4 175 H Speed Compensation advance Sensor Check Timing CHO3 110 4 130 CHOO msec 0 Cupfeed Timing CHo4 270 H 30 f CHOI msec 0 Air Strip Low Timing CHO5 150 4 200 CHO2 msec 0 Air Strip High Timing CHOG 120 4 130 CHO msec 0 P
14. error detected as the cupfeed cam rotates This is updated once every 1 5 seconds while the machine is running Negative Peak Error Counts This is the maximum negative peak error detected as the cupfeed cam rotates This is update once every 1 5 seconds while the machine is running The above diagnostic error data can be used to judge how well the cupfeed cam motor is tuned and how well the cupfeed cam is tracking the main crank SYSTEMS Electronics Group 82 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE CUPFEED SET UP MENU 4 Download Cupfeed Program to 4520 This selection is used to download the SRVCUPR application program to the 4520 in slot 01 This should only be performed when either replacing the S4520 in slot 01 or when the program has been changed To download the program perform the following Note Program download cannot be performed while the bodymaker is running Control of the Cupfeed servo motor ceases during program downloaded The bodymaker should be stopped before the download takes place 1 Connect the RS 232 cable from the COM port on the computer to the MOTION port on the 4520 in slot 01 2 Select the 3 Cupfeed Set up S4520 slot 01 MOTION PORT selection from the HSL WISVCUP Main Menu 3 Select 4 Download Cupfeed Program to S4520 The current program ident revision and checksum for both the program on disk and already loaded in the board will be displayed A prompt wil
15. CO CPU Resolver 8 input 8 output 10 30VDC I O Board Brushless Servo Amplifier 12 Amp 300 Watt Power Supply Positively Guided Relay Systems Electronics Group Inc Custom Servo Motor Inc Advanced Motion Controls Inc 87 SYSTEMS Electronics Group SECTION 6 RECOMMENDED SPARE PARTS This Page Intentionally Left Blank ASL WISVCUP User s Manual SYSTEMS Electronics Group 88 SECTION 7 TROUBLE SHOOTING The following is provided as a quick reference to aid in the troubleshooting of the HSL WISVCUP Typical faults include cups not loading properly cupfeed cam does not move cupfeed cam oscillates wildly or jerks when attempting to follow the main crank etc The following is a general trouble shooting procedure which should minimize the time to determine the source of the fault 7 1 CUPS DO NOT LOAD PROPERLY If the cupfeed cam appears to track the main crank correctly but cups do not load properly most likely the cupfeed cam is out of time Perform the following 1 Verify the main crank zero see section 2 9 4 2 Time the cupfeed cam to the main crank see section 2 9 6 3 Cupfeed timing sensor may have failed causing the cupfeed cam to only turn slowly see section 7 2 below 7 2 CUPFEED CAM ONLY TURNS SLOWLY WHEN MACHINE IS STROKED If the cupfeed cam only turns slowly when the clutch is activated and never syncs in with the main crank then most likely the cupfeed timing sensor has fail
16. MV Reference Profile deg SYSTEMS Electronics Group 69 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE This Page Intentionally Left Blank ASL WISVCUP User s Manual SYSTEMS Electronics Group 70 HSL WISVCUP User s Manual SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE The DOS based HSLSCUP set up program is a menu driven program that allows the user to easily view data or alter the set up variables using a laptop or personal computer In addition the set up program can be used to tune and test the cupfeed servo motor The set up variables are used to configure and tune the control system to match the configuration and performance of the specific bodymaker see section 2 9 HSL WISVCUP Set Up Note The HSLSCUP program is an on line communications program used to interface with the M4510 module and 4520 Motion Control board The data displayed and set in the menus is communicated directly to the M4510 and S4520 Therefore prior to selecting any of the menu selections make sure an RS 232 cable is connected from the COM port to the respective port PROG or MOTION port on the M4510 The following sections are a complete description of the HSLSCUP setup program selections and menus 5 1 MAIN MENU The main menu of the HSLSCUP set up program incorporates the following menu selections le HSLSCUP EXE Systems HSL WISYCUP Servo Cupfeed Set up Menu Versio
17. OFF Install the S4568 in Slot1 0 fifth slot from the left of the M4510 chassis Install the cover back over the M4510 making sure all the board connectors protrude through the slots in the cover Tighten the three captive screws on the lower front of the cover and the two captive screws on each side of the chassis Mount the M4510 chassis to the HSL WISVCUP back panel using four 8 32 screws With power off install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4510 The connector on the cable is polarized and should mate with the connector on the M4510 only one way Install the respective field wiring arms on all the I O boards of the M4510 I O slots0 1 and 1 0 Make sure all the field wiring connectors are fully mated in the M4510 Power up the M4510 module and download the HSLSCUP program to the M4510 main processor see section 2 10 4 Download the SRVCUPR program and data to the S4520 RDC in slot0 1 see section 2 10 5 SYSTEMS Electronics Group 24 HSL WISVCUP User s Manual SECTION 2 INSTALLATION 2 10 2 P4500 POWER SUPPLY INSTALLATION To install the P4500 perform the following steps 1 Mount the P4500 to the HSL WISVCUP in the mounting holes next to the M4510 left side using two 8 32 screws 2 Install the P4500 power supply cable to the 5 C 12 C 12 connector on the M4510 The connector on the cable is polarized and should mate with the connector on the M4510 only o
18. OK verify the B25A20 amplifier is functional as follows a Re activate the motor as was done in steps 26 through 29 With the motor stalled at a specific location measure the DC voltage on all three stators the VDC range on this check is 100VDC Two of the three stators should have some DC voltage these may be anywhere between 5 to 100 volts and may vary significantly while one stator should essentially have no voltage b Disable the motor C1 contactor off and move the cam 180 degrees or so Re activate the motor again and measure the stator voltages The stator that had no voltage on the previous reading should now read some DC voltage while one of the other stators no longer reads a voltage c This test verifies that all three stators are driven by the amplifier and thus if voltage can be read at each stator at some position of the cam the amplifier is OK Note Only two stators are driven at a time Therefore the cam will have to move to different positions to verify that each stator is active at some position d If this test checks out OK then most likely the motor is bad Replace the motor and retry the Servo Amplifier Motor test steps 26 through 32 ASL WISVCUP User s Manual SYSTEMS Electronics Group 96 HSL WISVCUP User s Manual SECTION 7 TROUBLE SHOOTING 7 4 CUPFEED CAM DOES NOT TRACK PROPERLY Intermittent following faults high running errors Any number of problems can account f
19. These steps need only be performed in the event the M4510 module P4500 power supply or B25A20 servo amplifier need to be replaced Refer to the M4500 User s Manual for general details on installing the M4510 and P4500 2 10 1 M4510 MODULE INSTALLATION To install the M4510 module perform the following 1 Remove the cover from the M4510 chassis retained with three captive screws on the lower front of the cover and two captive screws on each side of the chassis Z M4510 MOTION CONTROLLER SLOT 00 SLOT 01 SLOT 02 SLOT 03 SLOT 10 SLOT 11 SLOT 12 SLOT 13 m ON ON if ON m m 12 122 1 2 Swi Swi Swi IS4520 RDC S4568 S4568 MOTION DC IN OUT DC IN OUT CONTROL SOURCE SOURCE CUPFEED OPTIONAL Figure 5 84520 and 84568 Dip Switch Settings HSL WISVCUP User s Manual SYSTEMS Electronics Group 93 2 SECTION 2 INSTALLATION HSL WISVCUP User s Manual 2 3 4 5 6 7 8 Install S4520 RDC SLOTO 1 Set the slot address dip switches SW1 on the S4520 RDC to the following positions slot1 S4520 RDC SW1 switch ON SWI switch2 OFF Install the S4520 RDC in Slot0 1 second slot from the left of the M4510 chassis Install S4568 SLOT1 0 Set the slot address dip switches SW1 on the 4568 to the following positions slot0 S4568 SW1 switch OFF SW1 switch2
20. displays the name of the set up file being printed At the bottom of each page is the date and time the document was printed as well as the page number To printout a report of the settings contained in the set up Data File perform the following 1 From the File menu select Print Report or press Ctrl P 2 This displays the Print Setup dialog box allowing the user to select a printer as well as the paper size and orientation Once the user selects OK the report is generated and sent to the specified printer device Note This function makes use of the windows print manager which allows the user to continue with their work while the document is being printed SYSTEMS Electronics Group 43 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual 4 3 THE EDIT MENU The Edit menu allows the user to perform the following functions e Enable Disable Offline Editing e Set up the Comm Port e Edit the Set Up Passcode WISYCUP unnamed BM Main Display File Edit View Bodymaker Serov Cupfeed Help Comm Port Set up Passcode Machine Speed SPM Machine Position System Message All Faults Normal ONLINE 10 19 2003 10 29AM 4 4 3 1 ENABLE OFFLINE EDITING This function allows the user to perform Offline editing on the currently loaded set up data file This allows the user the ability to make
21. of the HSL WISVCUP Servo Cupfeed control package This includes the functional description alarms detected interlocks between the control package and the existing control system etc 1 1 FEATURES e Provides Servo motor driven positive cupfeed cam control for APM Positive cupfeed cam upgrade e Interfaces directly with cupfeed cam servo motor machine mounted main crank resolver and existing control system to accurately cam cupfeed with main crank in all modes and all speeds e Immediate cupfeed cam stop at detection of short can or tear off protects valuable tooling by preventing the feeding of an additional cup e Completely automatic synchronization of cupfeed cam with main crank shaft when clutch is engaged to reduce down time and reduce operator manual interaction e Optional high speed logic functions add on performs additional high speed control functions of Ragsdale Bodymaker including cupfeed solenoid control air strip control as well as die protection short can detection e Alarm detection cupfeed following fault cupfeed servo motor o temp cupfeed motor amplifier fault e Provided with Windows and DOS based set up software packages This allows all user selectable parameters to be set using easy to use menus as well as download the respective application programs and set up data e Based on the high performance M4510 PLC PLS Motion control module This allows easy trouble shooting and user customization usi
22. servo motor position Thus for a fixed amount of error the torque generated due to the integral error term will continue to increase at a rate proportional to the I gain The higher the integral error term the faster the torque generated to null the error will increase This term is used to null a fixed error to zero since a torque of whatever amplitude will be generated to null the error to zero Note Without the other gains P and D the system would be unstable As with the P gain a higher I gain will cause the servo motor to be more responsive Note Too high of an I gain will cause the motor to be unstable oscillate because the system cannot respond quickly enough Too low of an I gain will cause excessive following error since at low 1 gains the P gain would than be mostly responsible to null the error The system will not be unstable if the I gain is set to zero SYSTEMS Electronics Group 63 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Derivative D Gain The derivative D gain is used to create an error term which is proportional to the rate of change of error between the main crank position and servo motor position Thus for a fixed amount of error the torque generated due to the derivative error term will be zero rate of change is zero This error term is only generated when the amount of error is changing The higher the rate at which the error changes the higher the deri
23. the following to time the cupfeed cam with respect to the main crank 1 Inch or bar the ram to the position where the punch has just opened to the point where the cup could first be loaded this is when the ram is on the back stroke See figure 3 CUP BEING FED a REDRAW SLEEVE yt The J DIRECTION lt DF PUNCH MOVEMENT F mt CUP LOCATOR TOOL PACK Figure 3 Location of Ram at Cupfeed Time Position HSL WISVCUP User s Manual 19 SYSTEMS Electronics Group SECTION 2 INSTALLATION 2 Using the Manual Cupfeed push button feed one cup into the cupfeed cam and rotate the cam by hand until the cup is fully loaded into the cam Rotate the cupfeed cam with the cup loaded into the position where the cup would first be loaded into the cup locator see figure 4 INFEED TRACK CUPFEED CAM CUP LOCATOR CUP BEING FED Figure 4 Location of Cupfeed Cam at Cupfeed Time Position 3 With the cupfeed cam located as described above press the Home Cupfeed Cam push button inside the HSL WISVCUP enclosure Make sure the cupfeed cam does not slip from the cupfeed time position when performing this step 4 At this point in time the cupfeed cam is timed with respect to the main crank such that when the machine is running the cupfeed cam will be in sync with the main crank and load the cup when the ram has just opened up
24. this signal is 2500HZ For this reason some DVMs may read this voltage slightly low 20 Verify the cupfeed cam and main crank resolvers see sections 2 9 3 and 2 9 5 ASL WISVCUP User s Manual SYSTEMS Electronics Group 92 SECTION 7 TROUBLE SHOOTING Commutation Test Note Make sure the C1 contactor is off guards open through out the following test 21 With the C1 contactor off guards open jumper 210 to 211 on the N O contact of C1 22 With the C1 contactor off guards open enable the Servo Amplifier Motor Test by performing the following a Invoke the HSLSCUP setup program b Select 2 Cupfeed Set up S4520 Slot 01 c Select 3 Tune Cupfeed Servo Motor d Select 4 Servo Amplifier Motor Test Mode e Enable Servo Test Mode 1 enable f Are you sure This enables the B25A20 Amplifier The LED on the amplifier should be green 23 Rotate the cupfeed cam one revolution by hand and verify that the LED on the B25A20 stays green the entire revolution If it turns red at any time during the revolution the commutation is not correct If it stays green through the entire revolution the commutation HALL signals from the S4520 RDC are OK 24 Disable the Servo Amplifier Motor Test mode by performing the following a Select 4 Servo Amplifier Motor Test Mode b Enable Servo Test Mode 0 disable The LED on the B25A20 should be red 25 Remove the jumper bet
25. view and adjust the set up parameters This window is selected from the Bodymaker menu 2 WISVCUP unnamed BM Set Up Parameters File Edit View Bodymaker Serov Cupfeed Help Brake Wear Compensation Enable Brake Ware Compensation I Desired BDC Stop Position low speed ie Desired BDC Stop Position high spee d Maximum Allowed Stopping Response degrees 300 Bodymaker Running Speeds Trimmer Speed References Low Speed SPM 250 High Speed SPM J 350 4 Maximum Speed full scale calibration 375 Idle Speed w l stopped 250 System Message All Faults Normal ONLINE 10 19 2003 10 36 AM Brake Wear Compensation 1 Brake Wear Compensation Enable This is used to enable or disable the brake wear compensation To disabled click the checkbox and remove the checked state If the compensation is to be enabled click the checkbox to set the checked state 2 Desired BDC Stop Position Low Speed This is the desired stopping location in degrees for a BDC stop at low speed when the brake wear compensation is enabled This is typically set to 000 degrees back dead center Note This parameter is automatically disabled whenever Brake Wear Compensation is disabled SYSTEMS Electronics Group 52 HSL WISVCUP User s Manual 3 4 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Desired BDC Stop Position Low Speed This is the
26. 32 hardware Wire the MOTOR A B and C stator leads to the P2 connector along with the high power and ground leads Be sure to connect the MOTOR A B and C stator leads per the schematic at the back of this manual otherwise the motor will not run correctly jerk or stall Connect the P1 Molex connector to the P1 connector of the B25A20 SYSTEMS Electronics Group 26 SECTION 2 INSTALLATION 2 10 4 DOWNLOAD HSLSCUP PROGRAM AND SET UP DATA TO M4510 Once the M4510 is installed perform the following to download the HSLSCUP application program to the M4510 main processor as well as download the previously saved set up data and timing channel set points 1 Power up the M4510 and the IBM PC or compatible used to interface with the HSL WISVCUP 2 Connect an RS 232 cable from the computer COM port to the PROG port on the M4510 3 Execute the setup program WISVCUP for Windows based systems HSL SCUP for DOS based 4 Ifusing the HSL SCUP setup program select the bodymaker B M number that is being interfaced to If using the WISVCUP setup program open a previously saved setup data table file 5 Select Bodymaker set up M4510 PROG PORT 6 Download the HSLSCUP application program to the M4510 The current program ident revision and checksum for both the program to be loaded on disk and for the program already loaded in the M4510 will be displayed Confirm your choice to start the download See section 4 2 3
27. A This function allows the user to go Online with either the M4510 or S4520 This is accessed by the View menu by selecting Online Data or by simply pressing the F3 function key Note The user can be toggled between Offline and Online by simply double clicking on the Online or Offline panel displayed in the status bar at the bottom of the window Once invoked the set up program will to open the Comm port and attempt to communicate with the processor If unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the operation If the operation is canceled and communication with the processor cannot be established the system will be placed in an Offline mode Note Anytime while the set up program is Online with the processor and communication is interrupted a warning message will be displayed 4 4 3 VIEW OFFLINE DATA This function allows the user to place the set up program in an Offline mode This is accessed by the View menu by selecting Offline Data or by simply pressing the F4 function key All values displayed in Offline edit mode reflect the actual values contained in the currently loaded set up data file Note The program can be toggled between Online and Offline by simply double clicking on the Online or Offline panel displayed in the status bar at the bottom of the
28. CAM AT ALL TIMES DURING THE SERVO AMPLIFIER TEST 5 Acquire Data Signatures One Stroke This selection is used to acquire the current error actual cam profile and reference profile data for one stroke This data is sampled every millisecond for one complete stroke uploaded and saved in a text file This file can be imported into an Excel worksheet and then viewed in a chart as well as scaled and summarized This is used for tuning while the machine is running as well as trouble shooting The data is saved in the text file in four columns as follows Current Error Actual Profile Reference Profile The total number of samples taken in one stroke is equal to the period of the stroke in milliseconds up to a maximum of 255 samples The text file created has the same file name as the program loaded into the S4520 RDC default file name is SRVCUPR with the extension TXT ASL WISVCUP User s Manual SYSTEMS Electronics Group 81 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual In addition to the selections listed above and the corresponding parameters set by these selections the following diagnostic data is displayed in the Cupfeed Servo Motor Tune menu Instantaneous Absolute Error Counts This is the current instantaneous absolute magnitude difference between the main crank position and the cupfeed cam position Positive Peak Error Counts This is the maximum positive peak
29. CUP User s Manual A 2 t t HSLSCUP SYSTEMS Electronics Group
30. Cam Resolver 19 2 9 6 Time Cupfeed Cam to Main Crank 19 2 9 7 Verify Cupfeed Tracking 21 2 9 8 Verify Machine Operation 21 2 10 Module Servo Amplifier Installation Replacement 23 2 10 1 M4510 Module Installation 23 2 10 2 P4500 Power Supply Installation 25 2 10 3 B25A20 Servo Amplifier Installation 26 2 10 4 Download HSLSCUP Program and Set Up Data to M4510 27 2 10 5 Download SRVCUPR Program and Set Up Data to S4520 RDC in Slot01 28 ASL WISVCUP User s Manual SYSTEMS Electronics Group HSL WISVCUP User s Manual 3 Tuning the Servo Loop 4 3 1 3 2 3 3 3 4 3 5 Description of PID Servo Loop Proportional P Gain Integral I Gain Derivative D Gain Tuning the Servo Motor with Machine Running WISVCUP Windows Based Set up Program Reference 4 1 4 2 4 3 4 4 4 5 4 6 General Description The File Menu 4 2 1 The Set Up Data File 4 2 2 Upload save Data 4 2 3 Download Program 4 2 4 Download restore Data 4 2 5 Print Report The Edit Menu 4 3 1 Enable Offline Editing 4 3 2 Set Up Comm Port 4 3 3 Edit Set Up Passcode The View Menu 4 4 1 Target Board Interface 4 4 2 View Online Data 4 4 3 View Offline Data The Bodymaker Menu 4 5 1 Main Display Window 4 5 2 Set Up Parameters Window 4 5 3 Machine Timing Window 4 5 4 Shift Data Window 4 5 5 I O States Window The Servo Cupfeed Menu 4 6 1 Set Up Parameters Window 4 6 2 Tuning Window 4 6 3 Diagnostics Window 4 6 4 Acquire Data Signatur
31. Channel command button the completely clear the selected channel Note Ifa channel has been cleared or the On and Off setpoints have the same setting the set point will be displayed as cokkk k 29 Resetting the PLS Configuration As an aid to the user the current PLS configuration is displayed as part of this window The PLS configuration should only need to be reset if a new module has been installed To reset the PLS configuration click the Reset PLS Config command button This function only resets the PLS configuration to the default settings for the bodymaker HSL WISVCUP User s Manual SYSTEMS Electronics Group 56 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 5 4 THE SHIFT DATA WINDOW This window is used to view the Current Shift data Last Shift data Low and High speed brake responses and to invoke the End of Shift data transfer na O x Current Shift p Last Shift Total Good Cans 1855 Total Good Cans o Total Short Cans Total Short Cans aaa Brake Response degrees End of Shift Low Speed ea Transfer Data High Speed EE System Message All Faults Normal ONLINE 10 19 2003 10 37AM _ Current Shift Total Good Cans This is the total number of good cans produced so far into the current shift This is essentially a can counter Current Shift Total Short Can Faults This is the total number of shor
32. ENCE 3 Select Bodymaker B M number to Set up This selection is used to select the bodymaker that will be interfaced to In most cases the set up parameters from one bodymaker to another bodymaker will vary depending on the actual performance of that bodymaker This selection allows the setup program to interface with all the bodymakers in the plant saving the set up data for each bodymaker in separate files Note Be sure to select the respective Bodymaker number prior to modifying any of the parameters this should be the first step performed when the program is invoked The data file for Bodymaker number 00 contains the recommended defaults for the HSL WISVCUP package 5 2 BODYMAKER TRIMMER SET UP MAIN MENU The Bodymaker Trimmer Set up main menu of the set up program incorporates the following menu selections le HSLSCUP EXE Systems HSL WISVCUP Servo Cupfeed Set up Menu Version 1 2 Bodymaker Trimmer Set up Main Menu Selected Bodymaker Set Bodymaker Trimmer Set up Parameters Set Machine Timing Shift data Brake Response Download Program to M4510 Download Set up data to M4510 Upload Save Set up data from M4510 Enter Selection ESC to exit ACE OMe NOTE Before selecting one of the six selections listed above connect an RS 232 cable from the COM PORT on the computer to the PROG PORT on the M4510 Note All the selections above with the exception of selection 4 are used with the HSL WI6 option only
33. HE SERVO MOTOR WITH MACHINE RUNNING Once the servo motor is approximately tuned by using the default PID gains the servo loop can be further tuned by observing the response while the machine is running This can be done by observing the positive and negative peak position error using the set up program see section 4 6 2 Windows Setup Program Reference or 5 3 DOS Setup Program Reference The PID gains are generally adjusted to achieve the minimum peak errors Note Higher gains which are used to minimize the error also require more motor current This will cause additional heating in the motor Therefore use the lowest possible gains to achieve acceptable running error In addition the Acquire Data Signatures selection can be used to acquire the current error actual profile and reference profile for one stroke while the machine is running This data is sampled every millisecond and saved to a text file This file can be uploaded into an Excel worksheet and viewed in a chart as well as scaled and summarized This allows the corresponding waveforms to be observed and analyzed SYSTEMS Electronics Group 33 SECTION 3 TUNING THE SERVO LOOP REF 4 AMPLIFIER COMMAND AGND DIAGNOSTIC OUTPUT lt AGND NC CURR MON SGND s INO at FLT IN1 DEUNTOOMNMDALRGIN ROU Oo oo Ns AEA SS HTT THRM POR IN THRM PWR OUT THRM THRM HOME HOME
34. HSL WISVCUP Ragsdale Bodymaker Servo Cupfeed Control User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 www sea seg com 01 2004 HSL WISVCUP Ragsdale Bodymaker Servo Cupfeed Control User s Manual Copyright 2001 Systems Engineering Associates Inc All Rights Reserved Revised 27 January 2004 WARNING To ensure that the equipment described by this User Manual as well as the equipment connected to and used with it operates satisfactorily and safely all applicable local and national codes that apply to installing and operating the equipment must be followed This includes the National Electrical Code in the USA and other applicable legislation regulations and codes in practice elsewhere Since codes can vary geographically and can change with time it is the user s responsibility to determine which standards and codes apply and to comply with them FAILURE TO COMPLY WITH APPLICABLE CODES AND STANDARDS CAN RESULT IN DAMAGE TO EQUIPMENT AND OR SERIOUS INJURY TO PERSONNEL Persons supervising and performing installation or maintenance must be suitably qualified and competent in these duties and should carefully study the User Manual and any other manuals referred to by it prior to installation and or operation of the equipment The manufacturer accepts no liability for any consequences resulting from inappropriate ne
35. LC Clock Timing CHOz 180 H 0 CHO4 msec 0 CHOS msec 0 Resolver Offset PLS Channel CHOE msec n o 4 lo Recall Channel CHO msec moa Set Offset Clear Channel Reset PLS Config RPM 0 Position 24 Offset 238 Scale 360 System Message All Faults Normal ONLINE 10 19 2003 10 37AM The following parameters are displayed at the bottom of this window RPM This is the current speed in Revolutions per Minute of the main crank resolver Position This is the current Position in degrees of the main crank resolver Offset This is the current resolver offset set in degrees SYSTEMS Electronics Group 54 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Scale This is the scale factor of the resolver or the number of divisions in one revolution Zeroing the Machine setting the resolver offset To set machine zero perform the following 1 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4510 2 From the Bodymaker menu select Machine Timing 3 From the View menu select Online Data 4 Observe the Position field at the bottom of the window Verify that as the machine is rotated forward that the position increases linearly from 0 through 359 degrees If not swap the S1 and S3 leads at the resolver connector on the M4510 Then verify that the position does indeed increase with f
36. M port on the computer to the MOTION PORT on the 4520 in slot 01 SYSTEMS Electronics Group 75 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE CUPFEED SET UP MENU 1 Set Cupfeed Set up Parameters This selection is used to set the cupfeed set up parameters When selected the Cupfeed Set up Parameters menu is invoked The Cupfeed Set up Parameters menu contains the following selections le HSLSCUP EXE Systems HSL WISYCUP Servo Cupfeed Set up Menu Version 1 2 Cupfeed Set up Parameters Menu Selected Bodymaker 00 1 Set Cupfeed Cam Stop Position at Short Can Detection 2 Set Synchronization Error Limits Enter Selection ESC to exit Cupfeed Stop Position at Short Can Counts 1950 Synchronization Error Limits Max Error for Out of Sync Disable 100 Max Error to Enable Cupfeed Synchronization 500 Max Error for Following Error Alarm 5 The following selections set the corresponding parameters 1 Set Cupfeed Cam Stop Position at Short Can Detection Cupfeed Stop Position at Short Can Counts This is the position the cupfeed cam will stop at when a short can alarm occurs This should be set to the trailing edge of the short can check timing signal such that when a short can is detected the cupfeed cam will immediately stop and not continue following the ram ASL WISVCUP User s Manual SYSTEMS Electronics Group 76 HSL WISVCUP Use
37. N 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Servo Amplifier Test Mode When selected the user is prompted to confirm their choice to enable servo amplifier test mode If enabled the servo amplifier test outlined in the trouble shooting section section 7 3 Cupfeed Cam Does Not Move can be performed Note This is only used to verify the servo amplifier and motor The machine cannot be run with the test mode enabled For this reason due caution must be used when performing this test WARNING IN THE TEST MODE THE SERVOMOTOR IS EXCLUSIVELY CONTROLLED WITH THE TEST OFFSET POT 4 ON THE B25A20 STAY CLEAR OF THE CUPFEED CAM AT ALL TIMES WHEN IN THE SERVO AMPLIFIER TEST MODE 4 6 3 THE CUPFEED DIAGNOSTICS WINDOW This window displays both the main crank position 0 to 4095 and cupfeed servo motor position 0 to 4095 This is useful for trouble shooting purposes to observe the resolver feedback is correct for both correct direction and linear 2 WISYCUP unnamed Cupfeed Position Diagnostics File Edit View Bodymaker Serov Cupfeed Help Main Crank position reference for cupfeed Actual Main Crank Position 0 4095 l 3340 Main Crank Offset 0 4095 l 3746 Cupfeed Cam Actual Cupfeed Cam Position 0 4095 l 227 Cupfeed Cam Offset 0 4095 l 919 Home Position timing PRX off to on 2304 Main Crank to Cupfeed Cam Absolute Error counts l 982 System Message Fault
38. See the HSL WI6 User s Manual for more details ASL WISVCUP User s Manual SYSTEMS Electronics Group 73 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual BODYMAKER TRIMMER SET UP MENU 4 Download Program to M4510 This selection is used to download the application program to the M4510 module This should only be performed when replacing the module see section 2 10 1 M4510 Module Installation or when the program has been changed Note Program download cannot be performed while the bodymaker is running All outputs on the M4510 are turned off and no program execution is performed The bodymaker should therefore be stopped prior to program download This selection can also be used to verify the program ident revision and checksum without downloading the program Perform steps 1 through 3 below but instead of initiating the download in step 3 simply press the lt ESC gt key to abort the download To download the program perform the following 1 Connect the RS 232 cable from the COM port on the computer to the PROG port on the M4510 2 Select the 1 Bodymaker Trimmer Set up M4510 PROG PORT selection from the HSL WISVCUP Main Menu 3 Select 4 Download Program to M4510 The current program ident revision and checksum for both the program on disk and already loaded in the module will be displayed A prompt will be displayed asking to continue or abort To continue p
39. WISVCUP If SYSdev was purchased with the HSL WISVCUP package and is not already installed on the your computer install SYSdev onto the hard drive of your computer following the steps in outlined in the SYSdev Program Development manual 2 6 4 APPLICATION PROGRAM INSTALLATION The application program is a SYSdev based program loaded into the M4510 module and the 4520 motion control board These programs perform the HSL WISVCUP logic The programs are written in a combination of Ladder logic and High level If the user desires to make program changes or perform on line monitoring of the programs that constitute the HSLWISVCUP program the application programs will have to be loaded onto the hard drive of the PC used to support the system The SYSdev Program Development Software will also have to be loaded on the PC To install this program perform the following 1 Install the PROGRAMS disk into the drive 2 For each of the HSLSCUP directories created in section 2 6 2 copy all the files from the disk to each of these subdirectories ASL WISVCUP User s Manual SYSTEMS Electronics Group 13 SECTION 2 INSTALLATION 2 7 MODIFY EXISTING PLC PROGRAM Modify the existing control system PLC program to interface with the HSL WISVCUP by incorporating the following into the existing PLC ladder logic 1 Add the Run Mode output into the existing PLC logic This should be Continuous Mode OR d with Inch Mode ANDed with
40. a problem does exist in the servo system Perform the following steps to isolate the problem ASL WISVCUP User s Manual SYSTEMS Electronics Group 90 HSL WISVCUP User s Manual SECTION 7 TROUBLE SHOOTING Verify HSL WISVCUP Installation 5 Verify power is applied to enclosure and that CB1 is not tripped or none of the fuses are blown 6 Verify that PWR and RUN LEDs on M4510 and 4520 RDC are on and FLT LED is off 7 Verify all inputs from existing system clutch on Run mode alarm reset and CRA CRB CRC safety circuits to HSL WISVCUP function correctly 8 Verify that the M4510 and S4520 RDC are loaded with the correct programs see section 2 10 4 and 2 10 5 9 Verify dip switches on S4520 RDC and S4568 are set correctly see section 2 10 1 10 Verify PID gains are set correctly see section 2 9 1 11 Verify dip switches on B25A20 amplifier are set correctly see section 2 10 3 12 Verify Current Limit POT and Reference In POT on B25A20 are turned fully clockwise at least 14 turns or until stop in pot clicks for maximum gain 13 Verify Loop Gain POT on B25A20 is turned fully counter clockwise at least 14 turns or until stop in POT clicks for minimum loop gain 14 Verify all field wiring connectors to M4510 S4520 RDC S4568 and B25A20 are installed in the correct location and fully seated see schematic 15 Verify stator wiring at cupfeed cam motor terminals and Cl
41. al Main Crank Position will now read o SYSTEMS Electronics Group 78 HSL WISVCUP User s Manual SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE Note Activating this selection will zero the main crank position in the 4520 slot 01 only The M4510 main crank position is not set from this selection To set both simultaneously zero the main crank position per section 2 9 4 Set Main Crank Zero 2 Set Cupfeed Cam Home Position This selection is used to set the Cupfeed Cam Home Position This is the position of the cupfeed cam when a cup is loaded into the cup locator The cupfeed cam is timed such that it will be in sync with the main crank and load the cup when the ram has just opened up The position is set when the user presses the Home Cupfeed Cam push button inside the HSL WISVCUP enclosure In addition to the selections listed above the following data is displayed in the menu Main Crank Offset This is automatically set when the main crank position is zeroed Actual Main Crank Position 0 4095 This is the current main crank position with reference to a scale factor of 4096 for one complete revolution of the main crank This is used as the primary reference for the cupfeed PID servo loop Cupfeed Cam Home Position This is the position of the cupfeed cam when a cup is loaded into the cup locator Cupfeed Cam Offset 0 4095 This is set automatically when the cupfeed is initially timed after p
42. an or tear off no longer in sync with the ram The position the cupfeed will stop at is set by the Cupfeed Stop Position at Short Can parameter see section 4 6 1 Windows Setup Program Reference or section 5 3 DOS Setup Program Reference Verify that the cupfeed solenoid feeds cups properly Note The positive cupfeed sequence is different than that of the standard cupfeed With the positive cupfeed the first can is punched on the second stroke after the cupfeed is opened Two additional strokes will have to be made with air strip and die protect enabled after the cupfeed is turned off to process the cups in the cam Modify the existing PLC die protect and cupfeed logic as necessary to achieve this The HSL WI6 high speed logic option performs the cupfeed logic as outlined in the preceding sequence SYSTEMS Electronics Group 21 SECTION 2 INSTALLATION HSL WISVCUP User s Manual Verify that the Cupfeed Cam is disabled in BAR mode Activate the clutch in Bar mode and verify that the C1 contactor for the servo amplifier is not activated This makes sure that the Cupfeed servo motor is disabled while activating the clutch in Bar mode The Machine Is Now Set Up And Ready To Run SYSTEMS Electronics Group 22 SECTION 2 INSTALLATION 2 10 MODULE SERVO AMPLIFIER INSTALLATION REPLACEMENT The following is provided only as a reference These steps are performed by the factory prior to shipping the HSL WISVCUP
43. and not the bodymaker set up data To download the cupfeed set up data perform the following 1 Connect the RS 232 cable from the COM port on the computer to the MOTION port on the 4520 in slot 01 2 Select the 3 Cupfeed Set up S4520 slot O1 MOTION PORT selection from the HSL WISVCUP Main Menu 3 Select 5 Download Cupfeed Set up data to S4520 A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key 4 Once data download is initiated the current address being downloaded will be displayed 5 Once set up data download is complete press any key to return to the HSLSCUP main menu ASL WISVCUP User s Manual SYSTEMS Electronics Group 84 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE CUPFEED SET UP MENU 6 Upload Save Cupfeed Set up Data from 4520 This selection is used to save the cupfeed set up variables from the S4520 to the hard drive current directory selected This should be performed anytime any of the set up variables have been changed Note When the set up variables are changed they are changed directly in the 4520 not on the file in the computer By uploading saving the set up variables to disk they can be downloaded to the 4520 in the event the board must be replaced The set up data consists of the cupfeed set up parameters for the currently selected Bodymaker To upload the set up
44. any necessary changes to the set up parameters while offline with the processor If offline editing is not enabled the user is only able to view the set up parameters and shift data When the program is first invoked the default setting is offline editing disabled The user will need to specifically select Enable Offline Editing from the edit menu or press function key F2 to enable disable this feature SYSTEMS Electronics Group 44 HSL WISVCUP User s Manual SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 3 2 SET UP COMM PORT This function allows the user to specify the serial communications port and rate to communicate with the M4510 The PROG and MOTION communicates at 9600 baud ia Comm Port Settings x Comm Port Port Speed l Com 1 9600 Pena C1920 C Com4 Cancel The option to select the 19200 baud rate is to allow the user to communicate via the 4516 serial communications board In most cases the user will only need to specify the communications port and leave the baud rate at 9600 If communication problems occur make sure there is a secure connection from the PC to the PLC Then check the Comm port In most cases the user will only need to select a new Comm port If communication problems persist there may be another program causing a conflict with the port Check the port configuration from the Settings folder SYSTEMS Electronics Group
45. ata Note Data displayed can also be copied to the windows clipboard Simply select the desired data press Ctrl C and the data will be copied to the windows clipboard The user can then open another windows program such as Microsoft Excel and paste the contents of the clipboard into the new worksheet SYSTEMS Electronics Group 68 HSL WISVCUP User s Manual SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Graph Data By clicking this command button the user is able to graph the acquired data This function displays another window allowing the user to graph the different data signatures against one another and obtain a printout of the graph This printout also displays the current settings of the PID gains Graph Data Signatures X Servo Cupfeed Current Error Z Profile Data Signatures Default cfd 61A 4 94 3 64 2 44 1 24 f 0 04 0 0 3o BO gos J20 150 180 210 240 270 300 J3 J607 Main Crank Position m Options gt IV Current Amps I A eg Actual F rohle deg f Print Ok IV Eror deg l Reference Profile deg _ Bint Graph Data Signatures x Servo Cupfeed Current Error Z Profile Data Signatures Default cfd 31 6 61A 25 3 13 0 12 6 s s at oo 0 30 BO 30 20 150 80 210 lt 240 270 300 330 J60 Main Crank Position i Print Ok IV Eror deg
46. contactor are tight and are correct see schematic Note The stator wiring must be connected exactly as shown on the schematic any other combination of connections will cause the motor either to jerk or stall SYSTEMS Electronics Group 9 SECTION 7 TROUBLE SHOOTING 16 Verify the resolver feedback wiring at the cupfeed cam motor terminals and connector in HSL WISVCUP enclosure are tight and wired correctly see schematic Note The resolver feedback wiring must be connected exactly as shown on the schematic any other combination of connections will effect the motor commutation and cause the motor to stall jerk or oscillate 17 Verify the main crank resolver reference wiring connections see schematic 18 Verify resolver reference signal for servo motor is correct by measuring the voltage between R1 and R2 on the 4520 RDC using a DVM see schematic This can be measured between the ORG and WHT wires on the UMSTBHK connector on the upper left corner of the HSL WISVCUP back panel The voltage should read 3 7Vrms Note The frequency of this signal is 2500HZ For this reason some DVM s may read this voltage slightly low 19 Verify resolver reference signal for the main crank is correct by measuring the voltage between R1 and R2 on the M4510 using a DVM This should be measured between the R1 and R2 terminals on the 8 pin resolver connector on the M4510 The voltage should read 1 45Vrms Note The frequency of
47. control system such that when the main disconnect of the existing control system is turned off all power to the HSL WISVCUP is also turned off 2 3 MOUNTING THE HSL WISVCUP Mount the HSL WISVCUP NEMA 12 enclosure in proximity to the existing control cabinet Mount the MPM892FRMM B cupfeed servo motor on the mounting bracket supplied with the mechanical portion of the Ragsdale servo cupfeed upgrade package Mount the Bi4 M12 AP6X H1141 timing sensor on the mounting bracket supplied with the mechanical portion of the servo cupfeed upgrade package 2 4 WIRING THE HSL WISVCUP Referring to the electrical control schematic at the back of this manual wire the HSL WISVCUP as follows 1 Incoming Power 115VAC Wires 803 801 900 and 24VDC Wires 501 and 500 2 Interlocks between existing control system and HSL WISVCUP Wires 544 545 546 547 550 557 FLT1 and FLT2 3 Clutch interlock wiring Wires 512 513 518 519 and 526 4 Cupfeed timing sensor Wires 510 501 and 500 SYSTEMS Electronics Group SECTION 2 INSTALLATION 5 Cupfeed Motor both stator and feedback using supplied 4 conductor and 8 conductor cable Note Individual conduit runs Liguidtight should be provided for the 4 conductor motor leads and the 8 conductor resolver feedback cable to reduce EMI pick up on the resolver leads Figure 1 shows an example of using a T conduit fitting to separate the two conduits If only one Liquid tight run is
48. data perform the following 1 Connect the RS 232 cable from the COM port on the computer to the MOTION port on the 4520 in slot 01 2 Select the 3 Cupfeed Set up S4520 slot O1 MOTION PORT selection from the HSL WISVCUP Main Menu 3 Select 6 Upload Save Cupfeed Set up data from S4520 A prompt will be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key 4 Once data upload is initiated the current address being uploaded will be displayed Note The S4520 program execution is not ceased therefore data upload can be performed while the machine is running 5 Once set up data upload is complete press any key o return to the HSLSCUP main menu ASL WISVCUP User s Manual SYSTEMS Electronics Group 85 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE This Page Intentionally Left Blank ASL WISVCUP User s Manual SYSTEMS Electronics Group 86 HSL WISVCUP User s Manual SECTION 6 RECOMMENDED SPARE PARTS The following are recommended spares for the HSL WISVCUP These parts are available through Systems Engineering Assoc Inc Quantity Part Number jea lea lea lea qea qea 2ea Manuf M4510 SEG P4500 SEG 4520 RDC SEG S4568 SEG B25A20 AMC PS300W 96V SEG SH04 31 NSW AEG Manufacturers Index SEG CSM AMC Description PLC PLSProcessor Chassis SEG Power Supply Motion Control
49. desired stopping location in degrees for a BDC stop at high speed when the brake wear compensation is enabled This is typically set to 000 degrees back dead center Note This parameter is automatically disabled whenever Brake Wear Compensation is disabled Maximum Allowed Stopping Response This defines the maximum allowed brake response before the Brake Response Too Long alarm is generated If the actual brake response number of degrees from when the brake is activated to the position where the press ends up at rest when a BDC stop is performed is longer than this number the alarm is generated If the actual brake response is less the alarm is not generated Set this parameter to the value where the brake response is considered too long and service to the brake should be performed typically 270 to 300 degrees Bodymaker Running Speeds 1 2 Running Bodymaker Low Speed SPM This is the speed in strokes per minute the bodymaker will run when in low inch speed Running Bodymaker High Speed SPM This is the speed in strokes per minute the bodymaker will run when in high cont single speed Trimmer Speed References 1 2 Trimmer Maximum Speed CPM The Trimmer Maximum Speed is used to scale the 0 10VDC analog output such that when the bodymaker is running at the speed entered the analog output is 10 volts This is typically set to the running high speed of the Bodymaker or slightly higher
50. determine whether the servo loop is stable under damped over damped or critically damped or unstable oscillatory Each individual P 1 and D gain is used to generate an individual error term The summation of these three error terms is the torque command that is applied to the servo amplifier which drives the motor In general the gains are determined empirically by observing the response of the system both step response and while running continuously and adjusting the gains until the desired response and required torque are achieved The gains are set using the set up program The following describes the individual P I and D gains and corresponding error terms 3 2 PROPORTIONAL P GAIN The proportional P gain is used to create an error term which is proportional to the difference between the main crank position and the servo motor position The higher the proportional error term the higher the torque generated to null the error For a specific amount of error the higher the P gain the higher the torque generated Note By itself the P term cannot null the error to zero since a torque is only generated when there is a difference between the main crank position and servo motor SYSTEMS Electronics Group 30 SECTION 3 TUNING THE SERVO LOOP The P gain is used in conjunction with the other gains to define the system stability and responsiveness The higher the P gain the higher th
51. different revision of the software The set up Data File is similar to that of a word processing file When the program first starts a default file is loaded and the user is able to make any changes as desired The set up program is unaware of the settings and parameters that exist within the processor Therefore to normalize the set up program the user should define or open an existing file then upload All variables from the processor This allows the user to either create a backup of the data or maintain an existing file The user can even open a data file for another bodymaker save the file to a new name make the necessary changes and simply download the new parameters to another processor The following functions can be accessed any time from any set up or display windows New To create a New data file select New from the File menu or press Ctrl N This creates a completely new file loaded with the default variables and the word unnamed is displayed in the title bar If any changes were made to the existing file the user is prompted to save changes to the existing file Open To Open and existing data file select Open from the File menu or press Ctrl O This displays a dialog box allowing the user to select an existing data file to open The name of the file will be displayed in the title bar If any changes were made to the existing file the user will be pr
52. e cupfeed cam motor will be a function of this error ASL WISVCUP User s Manual SYSTEMS Electronics Group 66 HSL WISVCUP User s Manual SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 6 3 THE ACQUIRE DATA SIGNATURES WINDOW This selection is used to acquire the current error actual cam profile and reference profile data for one stroke This data is sampled once every millisecond for one complete stroke and uploaded from the processor This is used for tuning while the machine is running as well as trouble shooting amp WISYCUP unnamed Acquire Data Signatures Default cfd File Edit View Bodymaker Serov Cupfeed Help Data Signatures Current Amps Error deg Profile de 4 Data Samples Per Stroke 147 2 56 27 30 8 2 08 26 30 2 1 04 26 30 6 Options 1 36 23 30 2 1 84 2 1 29 9 Acquire Data 1 52 1 9 29 7 0 48 1 6 29 2 Graph Data 1 12 13 28 8 Print Data 0 88 1 28 5 0 16 0 6 27 8 Save Data 0 0 5 27 4 0 24 0 4 27 2 Dpen Data 0 8 0 4 26 9 0 88 0 3 26 5 Export Data 072 0 4 262 0 48 0 2 25 8 0 4 0 25 3 0 32 0 1 25 o AE ae ia System Message Faults Active in PLC ONLINE 10 19 2003 10 40AM 7 The total number of samples taken in one stroke is equal to the period in milliseconds up to a maximum of 255 samples This value is displayed in the Data Samples per Stroke field The following functions can be executed from this window
53. e responsiveness Note Too high of a P gain will cause the system to be unstable oscillate because the system cannot respond quick enough Excessive current will also be drawn which is undesirable Too low a gain will cause excessive following error to the point of instability depending on where the I gain is set In general the P gain is used to overcome high frictional loads higher P for higher friction 3 3 INTEGRAL I GAIN The integral I gain is used to create an error term that is proportional to the cumulative difference error between the main crank position and servo motor position Thus for a fixed amount of error the torque generated due to the integral error term will continue to increase at a rate proportional to the I gain The higher the integral error term the faster the torque generated to null the error will increase This term is used to null a fixed error to zero since a torque of whatever amplitude will be generated to null the error to zero Note Without the other gains P and D the system would be unstable As with the P gain the higher the integral gain the higher the responsiveness Note Too high of an I gain will cause the system to be unstable oscillate because the system cannot respond quick enough Too low an I gain will cause excessive following error since at low 1 gains the P gain would be mostly responsible for nulling the error The system will not be unstable if
54. e rungs should be added to the existing PLC logic In addition to the rungs shown the Machine RUn Enable output B101 0 from the HSL WISVCUP should be added as an input to the existing PLC logic and interlocked to the BDC stop logic When B101 0 in ON the machine is enabled to run when it is off the machine should be stopped at BDC The Cupfeed Cam in Sync output B101 5 from the HSL WISVCUP should also be added as an input and interlocked with the cupfeed snable logic When B101 5 is off the cupfeed cam is not in sync with the ram and the cupfeed should be closed when B101 5 si ON the cupfeed cam is in sync with the ram and the cupfeed can be opened when other conditions permit Outputs B101 1 thru B101 4 are alarm conditions that can also be added as inputs to the existing PLC logic to indicate the cupfeed cam fault if desired Activation of any one of these alarms will turn the Machine Run Enable output B101 0 off HSL WISVCUP User s Manual SYSTEMS Electronics Group A 1 APPENDIX A PLC PROGRAM MODIFICATIONS EXAMPLE Run Cont Not Bar Mode Mode X000 0 x000 5 Run Mode BO100 2 OS 7 ER i i ell Cont Inch Mode X000 1 1 Inch Alarm Reset PB X000 2 2 24 Ja F RunMode Pat HSLSCUP Alarm Reset BO100 3 Reset Short Can Alarm F000 f t HSLSCUP Short Can Alarm B0100 4 384 lean ShrtCan HSL WISV
55. e setup program and how to obtain technical support SYSTEMS Electronics Group 36 HSL WISVCUP User s Manual SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 2 THE FILE MENU The File menu allows the user to perform the following functions Create a New set up Data File Open an existing Data File Save any changes made to the current Data File to disk Upload save Data from the Processor Download a SYSdev sdv program to the processor Download restore Data from the current set up Data File to the processor e Print a Report of the current set up parameters e Exit the set up program SYSTEMS Electronics Group lt 37 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual 4 2 1 THE SET UP DATA FILE The set up Data File sdt is a binary access file designed for fast file I O operation When the set up program is first invoked the default set up parameters are loaded into memory If changes are made to any of the set up parameters either online or offline as well as shift data the user will be flagged to Save Changes upon exit of the program Note Any windows based Set up program can open a set up Data File however the data tables will not be properly aligned The user will be alerted to the problem if a set up data file has been created by either a different set up program or a
56. ection 4 2 4 Windows Setup Program Reference or section 5 3 DOS Setup Program Reference for complete details Verify that the cupfeed cam is timed correctly to the main crank see section 2 9 6 The HSL WISVCUP is now ready to run loaded with the application programs timing set points and set up data previously saved for the respective bodymaker HSL WISVCUP User s Manual SYSTEMS Electronics Group 28 SECTION 3 TUNING THE SERVO LOOP This section describes the PID servo loop in general as used with the cupfeed motor provides definitions of the PID gains plus tips on tuning the servo loop Note The defaults PID gains have been determined to be the optimum gains The PID gains should only be changed by qualified personnel familiar with closed loop servo control Instability oscillation of the servo motor can result if the PID gains are set incorrectly 3 1 DESCRIPTION OF PID SERVO LOOP In the servo cupfeed application the intention is to have the cupfeed track follow the main crank position as accurately as possible This is accomplished using an individual 4520 motion controller implementing a PID servo loop for the cupfeed cam Essentially the PID loop determines the difference between the main crank position and the actual servo motor position and generates a torque to null the difference to zero or as minimal as is practical This is done continuously through out the main crank stroke Full acc
57. ectronics Group 60 HSL WISVCUP User s Manual SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 6 1 THE CUPFEED SET UP PARAMETERS WINDOW This selection is used to set the cupfeed set up parameters When selected the servo cupfeed Set up Parameters window is invoked amp WISVCUP unnamed Cupfeed Set Up Parameters File Edit View Bodymaker Serov Cupfeed Help Cupfeed Stop Position at Short Can counts 1950 r Synchronization Error Limits Max Error for Dut of Sync Disable counts 100 Max Error to Enable Cupfeed Synchronization counts 500 Max Error for Following Error Alarm counts 50 System Message Faults Active in PLC ONLINE 10 19 2003 10 38AM _ The servo cupfeed Set up Parameters window contains the following selections Cupfeed Stop Position at Short Can Counts This is the position the cupfeed cam will stop at when a short can alarm occurs This should be set to the trailing edge of the short can check timing signal such that when a short can is detected the cupfeed cam will immediately stop and not continue following the ram Max Error for Out of Sync Disable This is the maximum amount of error allowed between the ram and the cupfeed to enable the cupfeed to open If the running error is less than this threshold the cupfeed is in sync with the ram and the cupfeed can be opened If the running error is greater than th
58. ed Replace the cupfeed timing sensor and try again If problem persists verify the wiring from the sensor to the HSL WISVCUP enclosure see schematic ASL WISVCUP User s Manual SYSTEMS Electronics Group 89 SECTION 7 TROUBLE SHOOTING 7 3 CUPFEED CAM DOES NOT MOVE Motor stalled jerks or oscillates Any number of faults can account for a failure of the cupfeed cam to move jerk or oscillate Prior to replacing any components perform the following Verify the Problem 1 Disconnect the Cupfeed Timing sensor cable from the Cupfeed Timing sensor 2 With the guards closed C1 contactor on press the Home Cupfeed Cam push button inside the HSL WISVCUP enclosure 3 The cupfeed cam should smoothly rotate forward about 2 revolutions slowly for about 5 seconds in an attempt to time itself After two revolutions it will stop on a following fault This process is normal and indicates that the servo system servo motor amplifier cables etc is functioning correctly The following fault at the end of the two revolutions simply indicates that the timing sensor was never located It is not necessary to perform the following steps if this is the case Instead perform the steps in section 7 4 4 If on the other hand a following fault is detected immediately without making the two revolutions once the Home Cupfeed Cam push button is pressed the motor may jerk forward or backwards or may not move at all then
59. eed Help New Ctrl N Open Ctl 0 Save Ctrl S Save As Export Shift Data Ctrl lt Upload save Data ls Machine Position Download Program gt 54520 Motion Control Download Data gt Print Report Ctrl P Exit System Message All Faults Normal ONLINE 10 19 2003 10 26AM _ ASL WISVCUP User s Manual SYSTEMS Electronics Group 39 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE M4510 PLC This option uploads reads set up parameters machine timing set points and shift data from the M4510 only 4520 Motion Control This option uploads reads set up and tuning parameters from the 4520 Motion Control Board only 4 2 3 DOWNLOAD PROGRAM The Set up program allows the user to Download any SYSdev program file to either the M4510 or S4520 amp WISYCUP unnamed BM Main Display ioj x File Edit View Bodymaker Serov Cupfeed Help New Ctrl N Open Ctri O Save Ctrl S Save As Export Shift Data Ctrl x lt Upload save Data gt IGneed SPM Machine Position Download Program ei Download Data gt 54520 Motion Control 24 Print Report Ctrl P Exit System Message All Faults Normal ONLINE 10 19 2003 10 26 AM Note To Download a SYSdev program to the processor the program must be Online If Online mode cannot be achieved program download
60. es Window CONTENTS SYSTEMS Electronics Group Aie CONTENTS 5 HSLSCUP DOS Based Set up Program Reference ___n11 5 1 Main Menu 71 1 Bodymaker Trimmer Set up M4510 Prog Port 72 2 Cupfeed Set up S4520 Slot 01 Motion Port 72 3 Select Bodymaker B M number to Set up ss 7 5 2 Bodymaker Trimmer Set up Main Menu 73 4 Download Program to M4510 74 5 3 Cupfeed Set up Main Menu 75 1 Set Cupfeed Set up Parameters 76 2 Time Cupfeed Position Diagnostics 78 3 Tune Cupfeed Servo Motor 80 4 Download Cupfeed Program to 4520 83 5 Download Cupfeed Set up Data to 84520 __8 6 Upload Save Cupfeed Set up Data from 84520 ___ 85 6 Recommended Spare Parts 87 7 Trouble shooting ___ 89 7 1 Cups do not load properly 89 7 2 Cupfeed Cam only turns slowly when Machine is stroked 89 7 3 Cupfeed Cam does not move 90 7 4 Cupfeed Cam does not track properly 97 LIST OF FIGURES Figure 1 Cupfeed Motor Conduit Routing 9 Figure 2 M4510 Configuration 16 Figure 3 Location of Ram at Cupfeed Time Position 19 Figure 4 Location of Cupfeed Cam at Cupfeed Time Position __ 20 Figure 5 84520 and 84568 Dip Switch Settings 23 Figure 6 S4520 Motion Controller Pin outs 34 APPENDICES Existing PLC Program Modifications Example Appendix A Drawings Appendix B HASL WISVCUP User s Manual SYSTEMS Electronics Group iii HSL WISVCUP User s Manual SECTION 1 GENERAL DESCRIPTION This section describes the features
61. ess to the PID gains allows the servo loop to be tuned to provide the optimum balance between acceptable error and minimum running current The servo motor control is implemented with a high speed 0 5msec update PID servo loop The main crank position is used as the reference for the servo loop with the servo motor position used as the feedback Both main crank position and servo motor positions are generated with resolvers to provide the highest degree of reliability and noise immunity Both resolver format signals are converted to digital with a resolution of 12 bits 0 4095 The PID servo loop is implemented in the 4520 motion control processor of the M4510 This board interfaces to the servo amplifier which drives the motor The 4520 motion controller provides a 10 Volt analog signal to the amplifier which is essentially a torque command ASL WISVCUP User s Manual SYSTEMS Electronics Group 29 SECTION 3 TUNING THE SERVO LOOP HSL WISVCUP User s Manual The servo amplifier will supply a current to the servo motor which is proportional to the 10 Volt analog command The servo motor in turn generates a torque to the load which is again proportional to this current Thus the 10 Volt analog signal from the 4520 can be considered a torque command both positive and negative torque to the motor The stability and responsiveness of the servo motor is defined by the combination of the PID gains These gains
62. gligent or incorrect installation operation or adjustment of the equipment The contents of the User Manual are believed to be correct at the time of printing however no responsibility is assumed for inaccuracies In the interests of a commitment to a policy of continuous development and improvement the manufacturer reserves the right to change the specification of the product or it s performance or the contents of the User Manual without notice Copyright 2001 Systems Engineering Associates Inc All rights reserved CONTENTS 1 General Description 1 1 1 Features 1 1 2 Functional Description 2 1 3 Cupfeed Cam Servo Motor Control 2 1 4 Alarm Detection 3 1 5 Interlocks to Existing Control System 4 1 6 Interlocks from Existing Control System 4 1 7 Optional High Speed Logic 5 2 Installation 7 2 1 What s Included 7 2 2 Power Required 8 2 3 Mounting the HSL WISVCUP 8 2 4 Wiring the HSL WISVCUP 8 2 5 Mounting the RSV34 MS1 Resolver 10 2 6 HSL WISVCUP Software Installation 11 2 6 1 Windows Based Setup Program Installation s 11 2 6 2 DOS Based Setup Program Installation 12 2 6 3 SYSdev Program Development Software Installation 13 2 6 4 Application Program Installation 13 2 7 Modify Existing PLC Program 14 2 8 Power Up HSL WISVCUP 15 2 9 HSL WISVCUP Set Up 17 2 9 1 Default Set Up Variables 17 2 9 2 Verify Servo Cupfeed Set Up Parameters 18 2 9 3 Verify Main Crank Resolver 18 2 9 4 Set Main Crank Zero 18 2 9 5 Verify Cupfeed
63. has exceeded user preset e Trimmer speed reference 0 10volt analog output provides reference to trimmer proportional to speed of bodymaker user scalable SYSTEMS Electronics Group SECTION 1 GENERAL DESRIPTION HSL WISVCUP User s Manual e Data Acquisition Total number of good cans produced and total number of short can faults for both the current shift and last shift e Built in 2 Line X 40 character sealed display with 24 key membrane keypad allows local viewing of collected data good can count short can count brake response by operator and set up of some user variables passcode protected by authorized personnel e Built in PLS provides all machine timing eliminating need for additional PLS The HSL WI6 consists of an additional I O board which is added to the M4510 module pre wired field wiring arm for the I O board D4591 Keypad Display HSL WI6 User manual and the high speed logic program HSLSCUP6 which is loaded into the main processor of the M4510 replacing the HSLSCUP program The HSL WI6 option package can be used to enhance the performance of the APM Bodymaker or to reduce the program modifications required to the existing PLC when upgrading a standard from a standard cupfeed to the positive cupfeed SYSTEMS Electronics Group HSL WISVCUP User s Manual SECTION 2 INSTALLATION The HSL WISVCUP package is provided in a self contained NEMA 12 enclosure for mounting adjacent to the existi
64. ighest degree of reliability and noise immunity Both resolver format signals are converted to digital with a resolution of 12 bits 0 4095 The PID servo loop nulls the error difference between the main crank and cupfeed positions to zero or as minimal as is practical Full access to the PID gains allows the servo loop to be tuned to provide the optimum balance between acceptable error and minimum running current At the detection of a short can or tear off the cupfeed cam is immediately stopped to prevent the feeding of an additional cup which protects valuable tooling The cupfeed cam automatically synchronizes with the main crank when the machine is re started to minimize down time and eliminate manual timing by the operator SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION The cupfeed cam is activated by the clutch solenoid control of the existing control system The HSL WISVCUP is interlocked to the existing clutch solenoids via redundant positively guided relays with self check to maximize safety The cupfeed servo motor is enabled via a contactor driven by these relays and thus incorporates the same level of safety typically provided with dual clutch solenoids with hardware interlocks 1 4 ALARM DETECTION The package detects the following alarms Cupfeed Following Fault This alarm occurs when the cupfeed cam following error difference between main crank position and cupfeed cam position exceeds a user defined p
65. in Run Mode Add the Clutch On output as well which should be on when the clutch is activated 2 Add the Alarm Reset output This should be driven directly by the Alarm Reset push button of the existing system 3 Add the Short Can Alarm output This should be driven directly by the short can alarm detection logic of the existing system and should go on immediately when the short can is detected and should stay on until reset 4 Add the Machine Run Enable input from the HSL WISVCUP into the existing system This sums all the HSL WISVCUP alarms into one input that should disable the cupfeed and stop the machine at BDC In addition outputs from the HSL WISVCUP are available for each individual alarm These can be input to the existing PLC as well so they can be displayed on the existing alphanumeric display etc 5 Add the Cupfeed Cam In Sync input from the HSL WISVCUP into the existing system This is on when the cupfeed cam is in sync with the main crank and should be interlocked with the cupfeed enable logic to prevent the feeding of cups when off Refer to the suggested existing PLC ladder logic at the back of this manual as an example of how the existing PLC ladder logic might be modified for the previous interlocks ASL WISVCUP User s Manual SYSTEMS Electronics Group 14 HSL WISVCUP User s Manual SECTION 2 INSTALLATION 2 8 POWER UP HSL WISVCUP With the wiring to the HSL WISVCUP complete appl
66. is is an input to the HSL WISVCUP controller which can be mapped from an output of the existing PLC and should be on while the Alarm reset push button of the existing system is depressed Clutch On This is an input to the HSL WISVCUP which can either be mapped from an output of the existing PLC which is on when the clutch is on or can be derived directly from one of the clutch solenoids assuming 24VDC solenoids are used 1 7 OPTIONAL HIGH SPEED LOGIC In addition to performing the standard cupfeed cam control the HSL WISVCUP package can be upgraded to perform additional high speed logic functions of the bodymaker by purchasing the optional HSL WI6 package The HSL WI6 option package performs the following e Additional high speed functions of the Ragsdale Bodymaker including cupfeed solenoid control air strip control as well as die protection short can detection e Accurate short can detection to a resolution of 1 4 can length Short can detection incorporates immediate stop of the cupfeed cam and cupfeed solenoid to prevent the feeding of an additional cup e Highly repeatable air strip control to reduce can stripping and blow out problems e Brake Wear compensation Auto BDC timing programming algorithm to stop press at BDC regardless of brake response Brake response determination allows displaying of actual brake response in degrees Brake response alarm to indicate when brake stopping response in degrees
67. is threshold the cupfeed will be disabled SYSTEMS Electronics Group 61 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Max Error to Enable Cupfeed Synchronization This threshold is used to synchronize the cupfeed with the main crank when the clutch is activated Once the main crank is within this error threshold of the cupfeed the cupfeed will than sync in with the main crank and then track the ram using the PID servo loop Max Error for Following Error Alarm This is the maximum amount of error allowed between the ram and the cupfeed before a Following Error fault is generated This is enabled once the cupfeed is in sync with the main crank The Following Error alarm is filtered to allow short errors in excess of this threshold to occur without generating the alarm This threshold is primarily used to detect instability in the cupfeed servomotor or peak current limit conditions excessive frictional loads in the cupfeed 4 6 2 THE CUPFEED TUNING WINDOW This selection is used to tune the servo cupfeed motor When selected the servo cupfeed Tuning window is invoked Cupfeed Servo PID Gains Test Mode Proportional Gain P 15 fine o 4 Enable Servo Amplifier Test Integral Gain I 100 Derivative Gain D 25 Cupfeed Actual Running Error Instantaneous Absolute Error counts l 982 Positive Peak Error counts l 0 Negative Peak Error counts l 230
68. l be displayed asking to continue or abort To continue press any key except the lt ESC gt key To abort press the lt ESC gt key If a prompt stating that the SRVCUPR file could not be opened is displayed then the SRVCUPR application program is not installed in the current directory 4 Once program download is initiated S4520 program execution will cease the current address being downloaded will be displayed and the RUN LED on the 4520 will flash continuously 5 Once the download is complete the RUN LED on the 4520 will illuminate solid and program execution in the 4520 will resume Press any key to return back to the HSLSCUP main menu ASL WISVCUP User s Manual SYSTEMS Electronics Group 83 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE 6 This selection can also be used to verify the program ident revision and checksum without downloading the program Perform steps 1 through 3 above but instead of initiating the download in step 3 simply press the lt ESC gt key to abort the download once the ident revision and checksum have been displayed CUPFEED SET UP MENU 5 Download Cupfeed Set up Data to 4520 This selection is used to download the previously uploaded saved cupfeed set up variables for the currently selected Bodymaker to the S4520 This should only be performed when replacing the 4520 board in slot 01 Note This set up data consists of the cupfeed set up parameters only
69. le the Servo Amplifier Motor Test mode by performing the following a Select 4 Servo Amplifier Motor Test Mode b Enable Servo Test Mode 0 disable The LED on the B25A20 should be red Servo Motor Stator Windings Check 33 If the Servo Amplifier Motor test is not passed verify the motor stator windings as follows a With the C1 contactor off guards open measure the impedance of the R S and T stator windings against each other at the T1 T2 and T3 terminals of the C1 contactor The impedance from any stator to any other stator should be 6 ohms b Ifany stator to any other stator is open then measure the impedance of the stators to each other at the R S and T terminals inside the motor If these measure OK then one of the leads of the cable from C1 to the motor is bad If the measurements at the motor terminals are not OK the motor itself is bad c Ifthe stator to stator readings check out OK then measure the impedance from each stator to ground These should read as an open If this is not the case disconnect the motor leads at the motor and read the impedance from each stator to ground at the motor terminals If these read OK the cable from the Cl contactor to the motor is bad If the readings are not OK the motor itself is bad ASL WISVCUP User s Manual SYSTEMS Electronics Group 95 SECTION 7 TROUBLE SHOOTING B25A20 Servo Amplifier Check 34 If the motor stator windings check out
70. made to the motor run it to the nearest junction box and then separate the two runs a CUPFEED SERVO MOTOR 3 4 NPT 3 4 LIGUIDTIGHT FOR STATOR CABLE 4 CONDUCTOR A 3 4 CONDUIT 3 4 LIGUIDITIGHT FOR RESOLVER FEEDBACK CABLE 8 CONDUCTOR Figure 1 Cupfeed Motor Conduit Routing HSL WISVCUP User s Manual SYSTEMS Electronics Group SECTION 2 INSTALLATION HSL WISVCUP User s Manual 6 Main Crank Resolver If machine is already equipped with a resolver parallel resolver wiring with existing PLS R2 of the M4510 is reference ground If machine is not equipped with a resolver see section 2 5 Mounting the RSV34 MS1 Resovlver In general when wiring the HSL WISVCUP keep all 24VDC and resolver wiring away from high voltage wiring 2 5 MOUNTING THE RSV34 MS1 RESOLVER The HSL WISVCUP is designed to interface to a resolver not encoder for machine timing If the machine is not already equipped with a resolver then the existing encoder will have to be removed and an RSV34 MSI1 resolver will have to be mounted in it s place If this is the case refer to the RSV34 MS1 data sheet for details on mounting the resolver Use the RSV RSCBLE cable to connect the resolver to the HSL WISVCUP Route the resolver cable in a separate conduit away from all other high voltage and control wiring Wire the cable directly to the 8 pi
71. n 1 2 Main Menu Bodymaker Trimmer Set up M4510 PROG PORT Cupfeed Set up 4520 Slot 1 MOTION PORT Select Bodymaker B M number to Set up Whe Selected Bodymaker 00 Enter Selection ESC to exit SYSTEMS Electronics Group 71 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE 1 Bodymaker Trimmer Set up M4510 PROG PORT This selection is used to interface with the main processor of the M4510 This includes Wh Set up of the basic bodymaker and trimmer parameters HSL WI6 option Downloading the application program to the M4510 Downloading uploading the set up data and saving these parameters on disk en selected the Bodymaker Trimmer Set Up Main Menu is invoked see section 5 2 Bodymaker Trimmer Set Up Main Menu 2 Cupfeed Set up S4520 Slot 01 MOTION PORT This selection is used to interface with the Cupfeed 54520 motion control processor in slot 01 of the M4510 chassis This includes Set up of the cupfeed motion control parameters Timing of the servo cupfeed motor Tuning the servo cupfeed PID loop gains Downloading the SRVCUPR application program to the 4520 Downloading uploading the servo cupfeed parameters and saving these parameters on disk When selected the Cupfeed Set up Main Menu is invoked see section 5 3 Cupfeed Set Up Main Menu HSL WISVCUP User s Manual SYSTEMS Electronics Group 72 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFER
72. n resolver connector on the M4510 SYSTEMS Electronics Group 10 SECTION 2 INSTALLATION 2 6 HSL WISVCUP SOFTWARE INSTALLATION Follow the steps below to install either the Windows or DOS based setup programs and PLC application program on a PC used to support the HSL WISVCUP control system 2 6 1 WINDOWS BASED SETUP PROGRAM INSTALLATION The WISVCUP setup program is compatible with Windows 95 98 ME 2000 XP operating systems and is used to 1 Setup tune the user adjustable variables 2 Adjust the timing channel set points 3 Download the application programs to the M4510 and S4520 4 Download restore or upload save the user setup variables 5 View Shift data To install the set up software perform the following steps 1 Insert the HSL WISVCUP CD into the drive 2 From the Windows desktop Click Start and then select run 3 From the Run dialog box Click the Browse button 4 Select the drive with HSL WISVCUP CD Select the setup exe file and Click Open and then Ok 5 This will initiate the installation process Follow the instructions that appear on the screen to complete the installation process The WISVCUP setup program can be executed from the Systems folder located in Programs ASL WISVCUP User s Manual SYSTEMS Electronics Group ll SECTION 2 INSTALLATION 2 6 2 DOS BASED SETUP PROGRAM INSTALLATION The HSL WISVCUP set up software is used to 1 Dow
73. ne mode as well as the current time and date as set by the operating system The system messages panel displays general information about operation of the system The Online Offline mode panel displays the status of the current set up program mode of operation The mode of operation can be changed by simply double clicking the online offline mode panel Hot Keys Hot keys are activated by holding down the ALT key and simultaneously pressing the underlined letter of the desired function Almost every function can be activated by either pressing a series of hot keys or using the TAB key to move between fields Online Offline Modes The set up program allows the user to make changes while Online with the processor The Offline mode is used to preset parameters prior to download All functions are available to the user while Online however specific Online functions are disabled in the Offline edit mode Note Offline changes can only be made by enabling Offline Editing accessed under the Edit menu Getting Help The entire contents of the user s manual is contained within the help file Pressing Ctrl H will display the help file window Pressing the F1 key will display the contents file Hot spots allow jumps to other topics to display additional information as desired Selecting About WISVCUP from the Help menu will display a dialog box listing information about the current revision of th
74. ne way 3 With power to the P4500 L N G field wiring connector off connect this connector to the P4500 input power connector SYSTEMS Electronics Group 25 SECTION 2 INSTALLATION HSL WISVCUP User s Manual 2 10 3 B25A20 SERVO AMPLIFIER INSTALLATION To install the B25A20 Servo Amplifier perform the following steps 1 2 3 4 5 6 7 Set the dip switches on the B25A20 as follows 1 Test Offset OFF 2 Loop Gain ON 3 Current Scaling OFF 4 Vel Loop Integrator ON 5 Duty Cycle Feedback OFF 6 Velocity Feedback OFF 7 Velocity Direction OFF 8 Cont Current Reduction OFF 9 Integrate Cap OFF 10 60 120 Phasing ON Verify both the Current Limit and Ref In Gain potentiometers on the B25A20 are turned fully clockwise for maximum gain these are multi turn pots and should be turned clockwise at least 14 times to ensure they are at the maximum gain settings Verify Loop Gain potentiometer on B25A20 is turned fully counter clockwise 14 times for minimum loop gain Remove the cover of the B25A20 and verify that the J1 jumper on the PC board has been removed cut out This is a zero ohm surface mount resistor If it has not been removed carefully cut it out with a pair of side cutters This inverts the Inhibit input turning it into an enable input Install the cover back on the B25A20 Mount the B25A20 to the side of the PS300W 96V power supply using the supplied 8
75. ng SYSdev DOS based programming package SYSTEMS Electronics Group SECTION 1 GENERAL DESRIPTION HSL WISVCUP User s Manual 1 2 FUNCTIONAL DESCRIPTION The HSL WISVCUP Bodymaker servo cupfeed control package is an electronic upgrade package used in conjunction with the Ragsdale servo positive cupfeed upgrade It provides complete motion control of the servo cupfeed cam plus detection of the following alarms cupfeed motor over temp amplifier fault and cupfeed cam following fault The package interfaces directly to the machine mounted cupfeed servo motor cupfeed timing sensor main crank resolver as well as the host PLC via discrete DC I O The control system is not a dedicated black box but is instead implemented using the high performance SYSTEMS M4510 PLC PLS Motion control module This allows easy customization by either SEA or the end user The M4510 module is programmed using the DOS based SYSdev programming package This allows the module to be programmed in any combination of Ladder or High level subset of C as well as perform on line monitoring and trouble shooting 1 3 CUPFEED CAM SERVO MOTOR CONTROL The cupfeed cam motor control is implemented with a high speed 0 5msec update PID servo loop The main crank position is used as the reference for the servo loop with the cupfeed cam position used as the feedback Both main crank position and cupfeed cam positions are generated with resolvers to provide the h
76. ng control cabinet 2 1 WHAT S INCLUDED Verify that the following items are included when unpacking the HSL WISVCUP lea lea lea lea lea lea lea lea lea HSL WISVCUP NEMA 12 enclosure including the following lea M4510 PLC PLS module lea P4500 Power Supply lea B25A20 Servo Amplifier lea PS300W 96V Servo Power Supply MPM892FRMM B 3 Servo Motor Bi4 M12 AP6X H1141 Timing Sensor WK 4T 6 Sensor Cable 4 Conductor Servo Motor Power Cable 8 Conductor Servo Motor Feedback Cable HSL WISVCUP User s Manual M4510 User s Manual HSL WISVCUP Program Disk The following items can be purchased separately as required or desired All items are compatible with both the back panel mountable package or the NEMA 12 enclosed package lea lea lea HSL WI6 High Speed Logic Option RSV34 MS1 Resolver RSV RSCBLE XX Resolver Cable SYSTEMS Electronics Group SECTION 2 INSTALLATION HSL WISVCUP User s Manual 2 2 POWER REQUIRED The HSL WISVCUP is powered from 115VAC 50 60HZ and 24VDC The 115VAC is used to power the M4510 module and B25A20 Cupfeed Servo amplifier while the 24VDC is used to power the 24VDC I O sensors discrete interlocks etc Current required from the 115VAC line is 2 5 Amps with a 6 Amp peak at power up Current requirements from the 24VDC power source is less than 0 5 Amps The input power should be derived from the existing control system or at least interlocked with the existing
77. nload the program to the M4510 module 2 Tune set up the user adjustable variables of the HSL WISVCUP 3 Download restore and upload save the user set up variables To install the set up software perform the following steps 1 Create one directory off the root for the HSL WISVCUP called 2 3 4 HSL WISVCUP User s Manual HSLSCUP This will be used to store e The HSLSCUP EXE setup program e The HSL WISVCUP application programs e The HSLSCUP set up data for each bodymaker Create this directory by typing the following at the DOS prompt MD HSLSCUP lt ENTER gt Install the disk labeled HSL WISVCUP PROGRAMS into the drive switch to that directory and install the HSL WISVCUP programs by typing the following at the DOS prompt CD HSLSCUP lt ENTER gt A INSTALL lt ENTER gt Add the HSL WISVCUP set up program to your computer s menu software by creating a selection called B M SERVO CUPFEED The DOS commands executed for these selections should be For the B M SERVO CUPFEED selection CD HSLSCUP HSLSCUP CD To execute the servo cupfeed set up program simply select the corresponding B M SERVO CUPFEED selection from the menu software s menu SYSTEMS Electronics Group 12 SECTION 2 INSTALLATION 2 6 3 SYSdev PROGRAM DEVELOPMENT SOFTWARE INSTALLATION The SYSdev Program Development software is used to perform on line trouble shooting and program modifications to the HSL
78. nse for both high and low speeds is updated after each BDC stop SYSTEMS Electronics Group 58 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 5 5 THE I O STATES WINDOW The I O States window is provided to display states of the inputs and outputs The control boards the states of the timing channels as well as states of the M4510 are shown This includes the interrupt inputs INO and IN1 the analog I O and the resolver These values are displayed as read by the M4510 processor amp WISYCUP unnamed BM 170 Status File Edit View Bodymaker Seroy Cupfeed Help M4510 i Timing Channels Sloti0 Slot 11 INO off CHOO off B100 0 off B110 0 off IN1 off CHOI off B100 1 off B110 1 off CHO2 off B100 2 off B110 2 off Analog Input 0 0 CHO3 off B100 3 off B110 3 off Analog Input 1 0 CHO4 ON B100 4 off B110 4 off z CHO5 off B100 5 off B110 5 off pole foes nR CHOB off B100 6 off B110 6 off CHO7 off B100 7 off B110 7 off CH10 off B101 0 off B111 0 off Resolver POS 24 CH11 off B101 1 off B111 1 off Resolver RPM 0 CH12 off B101 2 off B111 2 otf Resolver Period 5000 CH13 off B101 3 off B111 3 off Scale Factor 360 CH14 off B101 4 off B111 4 off Offset 238 CH15 off B101 5 off B111 5 off l CH16 off B101 6 off B111 6 off CH17 off B101 7 off B111 7 off System Message All Fa
79. nus and variables and how to use the setup program 2 9 1 DEFAULT SET UP VARIABLES As shipped the set up variables for the S4520 RDC motion control processor in slot 01 are set to the following defaults Cupfeed Stop Position at Short Can 1950 Synchronization Error Limits Max Error for Out of Sync Disable 100 Max Error for Enable Cupfeed Synchronization 500 Max Error for Following Error Alarm 050 Cupfeed Servo PID Gains Proportional Gain P 15 0 Integral Gain I 100 Derivative Gain D 25 The above default set up variables are stored in the data file for Bodymaker 00 ASL WISVCUP User s Manual SYSTEMS Electronics Group 17 SECTION 2 INSTALLATION 2 9 2 VERIFY SERVO CUPFEED SET UP PARAMETERS Using the set up program verify that the user variables of the 4520 RDC in slot 01 of the M4510 are set to the defaults as out lined in section 2 9 1 If they are not download the default set up parameters for bodymaker 00 These may be changed once the servo cupfeed is run but should be set to the defaults to start out Refer to section 4 or 5 for details on observing these variables and downloading these variables using the setup program 2 9 3 VERIFY MAIN CRANK RESOLVER From the Cupfeed Cam Time Position Diagnostics menu of the setup program observe the actual main crank position Verify that the main crank resolver direction is correct and is linear by barring or inching the machine forwa
80. o the existing system when the cupfeed is synchronized with the main crank and thus if the existing system is ready cups can be feed into the machine This signal typical turns on within one stroke after the clutch is engaged in continuous or inch mode when the cupfeed has synchronized with the main crank and stays on until a short can is detected or the cupfeed cam is manually moved out of time with the crank 1 6 INTERLOCKS FROM EXISTING CONTROL SYSTEM The following interlocks must be provided by the existing control system Run Mode Wire 544 This is an input to the HSL WISVCUP controller which should be on when Cont or Inch mode is selected This can be mapped from an output of the existing PLC See the suggested existing PLC ladder logic in Appendix A Run Mode Wire 526 This is a hardware interlock which must be derived directly from the RUN BAR selector switch of the existing system This interlock disables the cupfeed servo motor contactor when in BAR mode and thus provides the function of safety interlock when bar mode is selected Short Can Alarm This is an input to the HSL WISVCUP which should be mapped from an output of the existing PLC and should be on when a short can is detected by the existing PLC This input stops the cupfeed cam immediately and prevents another cup from being fed into the machine SYSTEMS Electronics Group HSL WISVCUP User s Manual SECTION 1 GENERAL DESCRIPTION Alarm Reset Th
81. ollowing errors 13 Check the cupfeed cam belt for damage or wear Replace if necessary 14 Check the cupfeed cam bearing Excessive belt tension or coolant spray can cause premature wear or damage to the bearing resulting in oscillation and following faults Replace cupfeed cam bearing if necessary 15 Check the servo motor bearing Again excessive belt tension or coolant spray can cause premature wear or damage Replace servo motor if necessary ASL WISVCUP User s Manual SYSTEMS Electronics Group 98 APPENDIX A PLC PROGRAM MODIFICATIONS EXAMPLE The following ladder logic is generalized example showing how the PLC logic of the existing control system PLC should be modified to interface with the HSL WISVCUP package Note The following is merely suggested logic and may not accurately represent the logic of the existing system It is the ultimate responsibility of th nd user to ensure that the HSL WISVCUP is interlocked with the existing system properly The variables shown in the ladder logic are defined as follows F000 F001 Internal coil of existing PLC X0 0 X0 5 Existing Inputs to Existing PLC B100 2 B100 4 New Outputs between existing PLC and HSL WISVCUP package kkxkxkxkxkxkxkxkxkxkxkxkxkkxkxkkkkxkkkxkkxkkkxkkkkkxkxkkkkxkxkkkkxkxkkkkkkkkkkkkkkkxkkkxkxkxkkkxkkkkkxkxk This block shows the additional mode interlocks from the existing control system to the HSL WISVCUP that are required Thes
82. ompted to save any changes before terminating the program SYSTEMS Electronics Group 38 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Save To Save data file to disk select Save from the File menu or press Ctrl S This displays a dialog box allowing the user to select a folder and enter a name for the file The user will be notified if the file already exists and the extension sdt will automatically be added to the file name If this is a New file the user will be prompted to enter a file name Save As To save the data file to a new name select Save As from the File menu This displays a dialog box allowing the user to select a folder and enter in a new name for the file The user will be notified if the file exists and the extension sdt will automatically be added to the file name Export Shift Data This function allows the user to export the shift data to a Tab Delimited text file This allows the user to easily use the shift data to produce production reports 4 2 2 UPLOAD SAVE DATA The Set up program allows the user to upload blow off parameters timing channel set points and shift data from the M4510 and S4520 into a set up Data File This function is accessed from the File menu and the user is given the choice of the following options WISYCUP unnamed BM Main Display File Edit View Bodymaker Serov Cupf
83. or a failure of the cupfeed cam to track properly Intermittent following faults and high running errors positive or negative peak errors greater than 40 are due to a change or variation in the load thus changing the required tuning of the system This is generally due to a mechanical problem incorrect belt tension worn or damaged cupfeed cam bearing or motor bearing etc Prior to replacing any components perform the following 1 Verify PID gains are set correctly see section 2 9 1 2 Verify dip switches on B25A20 amplifier are set correctly see section 2 10 3 3 Verify Current Limit POT and Reference In POT on B25A20 are turned fully clockwise at least 14 turns or until stop in pot clicks for maximum gain 4 Verify Loop Gain POT on B25A20 is turned fully counter clockwise at least 14 turns or until stop in POT clicks for minimum loop gain 5 Verify all field wiring connectors to M4510 S4520 RDC S4568 and B25A20 are installed in the correct location and fully seated see schematic 6 Verify stator wiring at cupfeed cam motor terminals and Clcontactor are tight and are correct see schematic Note The stator wiring must be connected exactly as shown on the schematic any other combination of connections will cause the motor either to jerk or stall 7 Verify the resolver feedback wiring at the cupfeed cam motor terminals and connector in HSL WISVCUP enclosure are tight and are correct see schematic
84. orward movement 5 Position the machine at back dead center 6 Auto zero the resolver by entering 0 in the Resolver Offset field and clicking the Set Offset command button A message box will appear prompting the user to confirm their choice Select Yes to set the resolver offset 7 The M4510 will calculate the actual offset value required to make this the 0 position The new offset value will be displayed in the Offset field and the position will then read zero ASL WISVCUP User s Manual SYSTEMS Electronics Group 55 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Adjusting the Timing Channel Setpoints To set any of the timing signal setpoints perform the following Note Any changes made to the timing channel setpoints will be saved as part of the setup data file 1 Connect an RS 232 SYSdev cable from the COM port on the computer to the PROG port on the M4510 2 From the Bodymaker menu select Machine Timing 3 From the View menu select Online Data 4 Setpoints for a particular channel are either entered in the field or adjusted by using the increment decrement controls Note Only one set point per channel is used 5 Ifa channel needs to be Recalled or Cleared enter the desired channel number into the PLS Channel field Click the Recall Channel command button to recall the set point Click the Clear
85. ower up and is calculated based on the Cupfeed Home Position Actual Cupfeed Cam Position 0 4095 This is the current cupfeed cam position with a scale factor of 4096 for one complete revolution of the cupfeed cam This is used as the feedback to the cupfeed PID servo loop Main Crank to Cupfeed Absolute Error This is the absolute magnitude difference between the main crank position and the cupfeed cam When the PID servo loop is active the torque applied to the cupfeed cam motor will be a function of this error SYSTEMS Electronics Group 79 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE CUPFEED SET UP MENU 3 Tune Cupfeed Servo Motor This selection is used to tune the cupfeed motor The Cupfeed Servo Motor Tune menu contains the following selections le HSLSCUP EXE Systems HSL WISVYCUP Servo Cupfeed Set up Menu Version 1 2 Cupfeed Servo Motor Tune Menu Selected Bodymaker 00 Set Servo Proportional P Gain Set Servo Integral I Gain Set Servo Derivative D Gain Servo Amplifier Motor Test Mode Acquire Data Signatures One Stroke Enter Selection ESC to exit Cupfeed Servo PID Gains Proportional Gain P 915 08 intedral Gain Wicca ccs susie eae aaa ais 0100 Derivative Gain Di aser aaeeea e enana aa O29 OF ON Cupfeed Servo Amplifier Test Mode Enable Servo Amplifier Test Y N N Current Error Profile Data Signatures Data Samples pe
86. r s Manual SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE 2 Set Synchronization Error Limits Max Error for Out of Sync Disable This is the maximum amount of error allowed between the ram and the cupfeed to enable the cupfeed to open If the running error is less than this threshold the cupfeed is in sync with the ram and the cupfeed can be opened If the running error is greater than this threshold the cupfeed will be disabled Max Error to Enable Cupfeed Synchronization This threshold is used to synchronize the cupfeed with the main crank when the clutch is activated Once the main crank is within this error threshold of the cupfeed the cupfeed will than sync in with the main crank and then track the ram using the PID servo loop Max Error for Following Error Alarm This is the maximum amount of error allowed between the ram and the cupfeed before a Following Error fault is generated This is enabled once the cupfeed is in sync with the main crank The Following Error alarm is filtered to allow short errors in excess of this threshold to occur without generating the alarm This threshold is primarily used to detect instability in the cupfeed servo motor or peak current limit conditions excessive frictional loads in the cupfeed SYSTEMS Electronics Group Sai SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual CUPFEED SET UP MENU 2 Time Cupfeed Position Diagnostics
87. r Stroke 147 Cupfeed Actual Running Error Instantanuous Absolute Error Counts 0230 Positive Peak Error Counts 0000 Negitive Peak Error Counts 0 The following selections set the corresponding parameters See section 3 for details on tuning the PID servo loop 1 Set Proportional P Gain This is the proportional gain torque proportional to error of the PID servo loop 2 Set Integral I Gain This is the integral gain torque proportional to cumulative error of the PID servo loop 3 Set Derivative Gain D This is the derivative gain torque proportional to rate of change of error of the PID servo loop ASL WISVCUP User s Manual SYSTEMS Electronics Group 80 SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE 4 Servo Amplifier Motor Test Mode When selected the user is prompted to either enable or disable the servo amplifier motor test mode Enter 1 to enable or 0 to disable the step response test If enabled the servo amplifier test outlined in the trouble shooting section 7 3 can be performed Note This is only used to verify the servo amplifier and motor The machine cannot be run with the test mode enabled For this reason due caution must be used when performing this test WARNING IN THE TEST MODE THE SERVO MOTOR IS EXCLUSIVELY CONTROLLED WITH THE TEST OFFSET POT 4 ON THE B25A20 STAY CLEAR OF THE CUPFEED
88. rd The position should increment linearly through the range of 0 to 4095 If the direction is backwards reverse the S1 and S3 leads of the resolver where they connect to the M4510 module If the position is not linear increments up then down or does not increment through full range verify that the resolver leads are all connected correctly 2 9 4 SET MAIN CRANK ZERO Inch the main crank of the bodymaker to back dead center BDC and set the M4510 offset by pressing the Zero Main Crank push button inside the HSL WISVCUP enclosure ASL WISVCUP User s Manual SYSTEMS Electronics Group 18 SECTION 2 INSTALLATION 2 9 5 VERIFY CUPFEED CAM RESOLVER From the Cupfeed Cam Time Position Diagnostics menu of the setup program observe the actual cupfeed cam position Verify that the cupfeed resolver direction is correct and is linear by pulling the cupfeed cam forward by hand The position should increment linearly through the range of 0 to 4095 If the direction is backwards verify the resolver is wired per the schematic at the back of this manual If the position is not linear increments up then down or does not increment through full range verify that the resolver leads are all connected correctly 2 9 6 TIME CUPFEED CAM TO MAIN CRANK Prior to timing the cupfeed cam with respect to the main crank pull the cam forward through at least one complete revolution with the target on the cam passing the timing sensor Perform
89. reset This indicates either binding in the cupfeed cam miss tuning of the PID gains broken belt etc Cupfeed Amplifier Fault This fault is generated by the B25A20 Cupfeed amplifier directly Sources of this fault include amplifier output short circuit amplifier over voltage amplifier over temperature Cupfeed Motor Over Temp Activated by the thermostat in the cupfeed servo motor This fault occurs when the temperature of the motor exceeds 155 C The above alarms are available to the host PLC via discrete outputs These should be used to stop the machine and indicate the problem when any one of the alarms occurs In addition the alarms are summed into the Machine Run Enable output which is available to the host PLC via a discrete output This should be used to stop the machine when any one of the alarms occurs ASL WISVCUP User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESRIPTION HSL WISVCUP User s Manual 1 5 INTERLOCKS TO EXISTING CONTROL SYSTEM In addition to the alarms listed in section 1 4 the following interlocks are 24VDC Discrete signals which should be interlocked to the existing control system Machine Run Enable This signal is the summation of all the alarms in section 1 4 When ON all alarms are clear and the machine is enabled to stroke When off one or more of the alarms is active and the machine must be stopped and disabled from running Cupfeed Enable This signal indicates t
90. ress any key except the lt ESC gt key To abort press the lt ESC gt key Ifa prompt stating that the HSLSCUP file could not be open is displayed then the HSLSCUP application program is not installed in the current directory 4 Once program download is initiated M4510 program execution will cease the current address being downloaded will be displayed and the RUN LED on the M4510 will flash continuously 5 Once the download is complete the RUN LED on the M4510 will illuminate solid and program execution in the M4510 will resume SYSTEMS Electronics Group 74 HSL WISVCUP User s Manual SECTION 5 HSLSCUP DOS BASED SET UP PROGRAM REFERENCE 4 3 CUPFEED SET UP MAIN MENU The Cupfeed Set up main menu of the HSLSCUP program incorporates the following menu selections HSLSCUP EXE x Systems HSL WISYCUP Servo Cupfeed Set up Menu Version 1 2 Cupfeed Set up Main Menu Selected Bodymaker 00 Set Cupfeed Set up Parameters Time Cupfeed Position Diagnostics Tune Cupfeed Servo Motor Download Cupfeed Program to 4520 Download Cupfeed Set up data to 4520 Upload Save Cupfeed Set up data from 4520 Enter Selection ESC to exit ANSAN e NOTE Before selecting one of the five selections listed above connect an RS 232 cable from the COM PORT on the computer to the MOTION PORT on the 4520 in slot 1 Note Prior to selecting this selection make sure the RS 232 cable is connected from the CO
91. rface e View Online Data e View Offline Data WISYCUP unnamed BM Main Display File Edit view Bodymaker Serov Cupfeed Help Messa v Online Data F3 Offline Data Machine Speed SPM Machine Position _ System Message All Faults Normal ONLINE 10 19 2003 10 30AM 4 4 4 1 TARGET BOARD INTERFACE This function allows the user to view fault codes S3000 network communication error codes and review the current Ident and Revision of the application program This is accessed by the View menu by selecting Target Board Interface Once invoked the set up program will prompt the user to select a program The setup program will then attempt to communicate with the M4510 If unsuccessful a warning message will be displayed prompting the user to either Retry or Cancel the operation The Target Board Interface window will then be displayed SYSTEMS Electronics Group 47 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Target Board Interface rogram Ident Revision Set Network Address SetTime Date No Internal Fault has Ocurred No Internal Fault has Ocurred No Network Comm Error No Network Comm Error Target Board Interface HSL WISVCUP User s Manual SYSTEMS Electronics Group 48 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 4 2 VIEW ONLINE DAT
92. s Active in PLC ONLINE 10 19 2003 10 39AM _ HSL WISVCUP User s Manual SYSTEMS Electronics Group 65 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE This window contains the following selections Actual Main Crank Position 0 4095 This is the current main crank position with reference to a scale factor of 4096 for one complete revolution of the main crank This is used as the primary reference for the cupfeed PID servo loop Main Crank Offset This is set automatically when the main crank position is zeroed Actual Cupfeed Cam Position 0 4095 This is the current cupfeed cam position with a scale factor of 4096 for one complete revolution of the cupfeed cam This is used as the feedback to the cupfeed PID servo loop Cupfeed Cam Offset 0 4095 This is set automatically when the cupfeed is initially timed after power up and is calculated based on the Cupfeed Home Position Cupfeed Cam Home Position This is the position of the cupfeed cam when a cup is loaded into the cup locator The cupfeed cam is timed such that it will be in sync with the main crank and load the cup when the ram has just opened up The position is set when the user presses the Home Cupfeed Cam push button inside the HSL WISVCUP enclosure Main Crank to Cupfeed Absolute Error This is the absolute magnitude difference between the main crank position and the cupfeed cam When the PID servo loop is active the torque applied to th
93. t can faults that have occurred so far into the current shift Last Shift Total Good Cans This is the total number of good cans produced in the last previous shift This is essentially a can counter Last Shift Total Short Can Faults This is the total number of short can faults that occurred in the last previous shift ASL WISVCUP User s Manual SYSTEMS Electronics Group 57 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual Note The current shift data is transferred to the Last shift data when the end of shift input transfers from a 0 to a 1 This can be at the end of either an 8 or 12 hour shift This data can also be reset from this menu by clicking the Transfer Data command button Lo Speed Brake Response degrees This is the number of degrees from the when the clutch was de activated at the BDC Lo timing to where the bodymaker crankshaft came to rest when a BDC stop was performed at Low speed This can be used to determine the general condition of the brake and whether servicing of the brake is required Hi Speed Brake Response degrees This is the number of degrees from the when the clutch was de activated at the BDC hi timing to where the bodymaker crankshaft came to rest when a BDC stop was performed at high speed This can be used to determine the general condition of the brake and whether servicing of the brake is required Note The brake respo
94. the I gain is set to zero ASL WISVCUP User s Manual SYSTEMS Electronics Group 3 SECTION 3 TUNING THE SERVO LOOP HSL WISVCUP User s Manual 3 4 DERIVATIVE D GAIN The derivative D gain is used to create an error term which is proportional to the rate of change of error between the main crank position and servo motor position Thus for a fixed amount of error the torque generated due to the derivative error term will be zero rate of change is zero This error term is only generated when the amount of error is changing The higher the rate at which the error changes the higher the derivative error term This term is primarily used to stabilize the servo loop It is used to reduce ringing in underdamped responses or to provide fundamental stability to loops that would otherwise be unstable There is a definite comprise between to much D gain and not enough D With too little the system may go unstable or be marginally stable Also excess ringing with a corresponding longer settling time to a step response will occur if the D gain is too low If the derivative gain is too high the system response will be reduced and high frequency oscillations may occur not to the point of instability but to the point where higher current will be drawn and excessive high frequency torque will be applied to the load SYSTEMS Electronics Group 339 HSL WISVCUP User s Manual SECTION 3 TUNING THE SERVO LOOP 3 5 TUNING T
95. ults Normal ONLINE 10 19 2003 10 37AM _ HSL WISVCUP User s Manual SYSTEMS Electronics Group 59 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual 4 6 THE SERVO CUPFEED MENU The Servo Cupfeed menu allows the user to select one of four different Display Set up windows used to modify set up parameters and tune the servo cupfeed motor Prior to making this selection make sure an RS 232 SYSdev cable is connected from the COM port on the computer to the MOTION port on the 4520 motion control board 2 WISYCUP unnamed BM Main Display File Edit View Bodymaker Serov Cupfeed Help Messages 2 Tuning F5 3 Diagnostics 4 Acquire Data Signatures F6 Machine Speed SPM Machine Position 0 24 System Message All Faults Normal ONLINE 10 1 9 2003 10 38AM 4 Once a window menu item is selected the selected window is displayed and the name is changed in the title bar Note In general Read only variables are displayed in blue with a gray background Any variables that can be altered by the user are displayed in black with a white background In most cases a parameter that can be changed will have an associated increment and decrement control The user can either click on the desired parameter and enter in a new value or use the increment or decrement control to change the value by one unit SYSTEMS El
96. vative error term This term is primarily used to stabilize the servo loop It is used to reduce ringing in under damped responses or to provide fundamental stability to loops that would otherwise be unstable There is a definite compromise between to much and not enough D gain With too low the system may be marginally to completely unstable Excess ringing with a corresponding longer settling time to a step response will occur if the D gain is too low If the D gain is too high system response will be reduced and high frequency oscillations may occur This will not cause instability but higher current will be drawn and excessive high frequency torque will be applied to the load Cupfeed Actual Running Error Instantaneous Absolute Error Counts This is the instantaneous absolute magnitude difference between the main crank position and the cupfeed cam position Positive Peak Error Counts This is the maximum positive peak error detected as the cupfeed cam rotates This is updated once every 1 5 seconds while the machine is running Negative Peak Error Counts This is the maximum negative peak error detected as the cupfeed cam rotates This is update once every 1 5 seconds while the machine is running The above diagnostic error data can be used to judge how well the cupfeed cam motor is tuned and how well the cupfeed cam is tracking the main crank ASL WISVCUP User s Manual SYSTEMS Electronics Group 64 SECTIO
97. ween 210 and 211 on the C1 contactor N O contact ASL WISVCUP User s Manual SYSTEMS Electronics Group 93 SECTION 7 TROUBLE SHOOTING Servo Amplifier Motor Test WARNING IN THE SERVO AMPLIFIER TEST MODE THE SERVO MOTOR IS CONTROLLED EXCLUSIVELY BY THE TEST OFFSET POTENTIOMETER ON THE B25A20 AMPLIFIER STAY CLEAR OF THE CUPFEED CAM AND SERVO MOTOR AT ALL TIMES WHILE PERFORMING THIS TEST 26 With the Servo Amplifier Motor Test disabled turn the C1 contactor on close guards 27 Enable the Servo Amplifier Motor Test by performing the following a Select 4 Servo Amplifier Motor Test Mode b Enable Servo Test Mode 1 enable c Are you sure 1 This enables the B25A20 Amplifier The LED on the amplifier should be green 28 The servo motor should run proportional to the Test Offset pot4 on the B25A20 29 The motor is running in an open loop torque mode but should run smoothly either forward or backwards depending on which way the Test Offset pot is turned The motor should also be able to be stopped by nulling out the pot 30 If the motor does not run smoothly jerking or running out of control either something is wrong with the motor stator wiring the motor or the amplifier 31 When done with the test null the Test Offset pot 4 out such that the motor is stopped ASL WISVCUP User s Manual SYSTEMS Electronics Group 94 SECTION 7 TROUBLE SHOOTING 32 Disab
98. will not be executed If the program is currently Offline the user will be prompted to first go Online HSL WISVCUP User s Manual SYSTEMS Electronics Group 40 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE Once selected and the set up program Online with the processor a dialog box will be displayed allowing the user to select the SYSdev file to download Note Only the files with the sdv file extension will be displayed It is important to keep in mind that only a valid M4510 PLC SYSdev file can be downloaded through the set up program Care should be taken when selecting a program to download Once selected a message box is displayed informing the user of the current program revision and checksum of the program loaded in the processor as well as that of the selected program The user must confirm their selection by clicking the Yes command button After the user confirms their choice program download is initiated and the current program download address is displayed When program download is complete the user is prompted to acknowledge Control is passed back to the main program and the set up program remains in an Online edit mode HSL WISVCUP User s Manual SYSTEMS Electronics Group 4 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE HSL WISVCUP User s Manual 4 2 4 DOWNLOAD RESTORE DATA The set up program allows the user to download
99. window Once invoked the set up program will cease communication with the processor and close the Comm port ASL WISVCUP User s Manual SYSTEMS Electronics Group 49 SECTION 4 WISVCUP WINDOWS BASED SET UP PROGRAM REFERENCE 4 5 THE BODYMAKER MENU The Bodymaker menu allows the user to select one of five different Display Set up windows used to modify set up parameters view shift data adjust timing channel set points or receive feedback about the current status of the control system 2 WISYCUP unnamed BM Main Display ioj x File Edit View Bodymaker Serov Cupfeed Help Messages 2 Set up Parameters 3 Machine Timing 4 Shift Data 51 0 States Machine Speed SPM Machine Position o oa System Message All Faults Normal ONLINE 4 0 19 2003 10 36AM 4 Once a window menu item is selected a check mark is placed next to the selected item and the selected window is displayed and the name is changed in the title bar Note Read only variables are displayed in blue with a gray background Any variables that can be altered by the user are displayed in black with a white background In most cases a parameter that can be changed by the user will have associated with it increment and decrement controls The user can either click on the desired parameter to adjust and enter in a new value or use the increment or decrement controls to change the value by 1 unit
100. y power and verify the following 1 2 3 4 5 Green PWR and RUN LEDs on M4510 main processor are on and red FLT LED is off Green PWR and RUN LEDs on S4520 RDC in M4510 slot 01 are both on Green AMP ENB LED is off LED on B25A20 servo amplifier is RED this is normal when the amplifier is disabled which it is until the cupfeed motor is actually running If the above is not as described verify that power is applied to both the M4510 module and the B25A20 amplifier Also verify all cables are connected properly the respective modules Using the set up program verify that the M4510 main processor is loaded with the HSLSCUP application program and that the S4520 in slot 01 is loaded with the SRVCUPR application program See section 4 or 5 for details on using the setup program to verify these programs are loaded SYSTEMS Electronics Group 15 SECTION 2 INSTALLATION

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