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L15 - Integrated Motion on Ethernet/IP
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1. T i i U1 110111 LE Gil iie erat Kinetix 5500 Servo Drive System hee ag tae Tce el 1585J M8CEIM x Ethemet shielded Cable 1585 M8CBM OM3 0 3 m 1 0 ft Ethernet cable for drive to drive connections PanelView Pius Display Terminal ma 1734 AENTR POINT VO i j EtherNet IP Adapter Add Your Drive Hardware In this section you add the following drive hardware to the I O configuration Drive03 PowerFlex 527 Note Drive01 and Drive02 Kinetix 5500s have already been pre configured for you 1 Right click on the Ethernet network icon and select New Module Hr Logical Model 0 Configuration 8 1769 Bus fg 0 1769 L36ERM Integ_Motion_K5500_ B 1 1769 1016F A Digital_Inputs H 2 1769 0B16 B Digital_ Outputs B 3 1769 IF4xOF2 4 Analog_IO Ctrl y Properties Alt Enter f Controller Orc vide The Select Module Type window opens 24 of 142 In the search box type 527 and watch as the list repopulates Select the catalog number PowerFlex 527 STO CIP Safety 7 a Select Module Type a M Allen Bradley M Communication A Cognex Corporation M Controller M Endress Hauser M Digital M FANUC Corporation M DFI to EtherNet IP M FANUC Robotics America or BRAS Wa nae S afe owerFlex 527 AC Drive CIP Motion Safe Torque Off CIP Safety Allen Bradley Drive Motion Se Ada to Favorites 25 of 142 TIP The PF527 has em
2. z d 192 168 1 26 PowerFlex 527 PowerFlex 527 Close 192 168 1 8 1734 4ENTR EtherNet IP Adapter 1734 4ENTR Ethernet Adapter 192 168 1 9 1732E IBBMBSOER 24 DC In M8 1732E IBBMSSOER 24 DC In M6 Help Refresh Set Project Path Clear Project Path Path AB_ETHIP 14192 168 1 12 Path in Project AB_ETHIP 14192 168 1 12 If the path is not already set in the controller click Set Project Path Note f your control hardware is different than recommended or if you have any questions about the hardware consult with your lab instructor Open the door on the front of the processor to reveal the Secure Digital card and the operation mode switch Verify that the switch is in the REM remote position Ensure that the Kinetix 5500 and PowerFlex 527 drives are each powered up Click the Download button in the Who Active window The Download window opens Click the Download button to send the program to the controller When downloading completes place the controller into Run Mode Method 1 Logix Designer x A Done downloading Change controller mode back to Remote Run l Click Yes Method 2 12 of 142 Rem P Go icfemProo A and seleRun Mode Logix Designer x A Change controller mode to Remote Run Click Yes 10 Verify that your controller is communicating OK indicator should be solid green LINK1 indicator should be flashing green indicatin
3. Shunt Regulator Resistor Type External Internal External Shunt fone a External Shunt Resistance 3 00C External Shunt Power External Shunt Pulse Power External Shunt External Shunt Resistance External Shunt Power External Shunt Pulse Power 0 000 Kilowatts Click Apply then OK to close the Module Properties window for Drive03 Configure Axis Properties In this section you will configure the following Axis AxisO3 PowerFlex 527 and associated induction motor Note Axis01 and Axis02 on the left has already been pre configured for you 1 From the Motion Groups gt MotionGroup folder in the Controller Organizer right click on AxisQ3 and select Properties 32 of 142 E E Motion Groups 3 MotionGroup ARID AxisO1 3 AxisO2 f E Ungroupe Goto Module E E Add On Instr B AlarmHist H A CIP_Face Fault Help H 8 Machines S Data Types Monitor Axis Tag Clear Axis Faults H E User Defii Cut Ctrl D Strings O i Add On C Copy Ctrl C H Predefine F Paste Ctrl V E E Module Ds Delete Del E Trends Th Logical Model Motion Direct Commands 1 0 Configura Manual Tune f 1769 Bus Motion Generator Gago 17 N p 17 Cross Reference Ctrl E EER i aa Ethernet F properties Alt Enter F0 1769 E I 1734 AENTR A Point_IO_Chassis o H E PointIO 4 Slot Chassis fl 2198 H003 ERS Drive01 fl 2198 H003 ERS Drive02 1 PowerFlex 527 5TO
4. Actions to Take Upon Conditions General E Motor Eia Stop Action Current Decel amp Disable 7 Parameters Motor Feedback Motor Overload Action lt none gt x Scaling vete Ovaka Aoi beo Ti nverter Overload Action knone gt Polarity Autotune Shutdown Action Disable 7 B Load Backlash A Compliance DANGER Modifying Exception ction settings may require programmatically stopping or i Friction eee disabling the axis to protect Migereresna la op personnel machine and property Velocity Loop Refer to user manual for additional Acceleration Loop information Torque Cunent Loop Planner Bus Regulator Thermal Overload Factory Limit StopDrive Homing StopDrive Bus Undervoltage Factory Limit Drive Parameters Bus Undervoltage User Limit Pamias Lit Status Control Module Overtemperature Factory Limit StopDrive Faults amp Alarms Control Module Overtemperature User Limit StopDrive nn Converter AC Power Loss StopDrive x Manual Tune Cancel amp pply Help 9 Disconnect the Ethernet cable between that runs between the drives 71 of 142 Notice that after a few moments AxisO1 ControlSyncFault and Axis0O1 ModuleConnFault tags both register a value of 1 Note Both faults indicate a loss of communications Name za a Value Force Mask Style H AxisO1
5. At this point you will configure the machine to operate by specifying the Operating Points 11 Prior to executing the User Defined Cam ponder the following questions e How does the Feed Rate differ compared to the original results e How does the Product Cut Length compare to the original design e What difference do you expect to see in the Torque Reference 12 Download the program to the controller at 192 168 1 12 1 Click Who Active button 2 Select controller from the Ethernet driver 3 Click Download button 4 On pop up dialog window click the Download button Path AB_ETHIP 1 192 168 1 12 2 V Autobrowse Refresh gt Workstation BASEIMA T1BGVSY ss Linx Gateways Ethernet gt gs AB_ETHIP 1 Ethernet N ATOM T S226ERM 1769 DERM L 4i 192 168 1 2 1783 BMSO6TA Stratix 5700 1783 BMSO6TA Stratix 5700 5 192 168 1 24 2198 H003 ERS 2198 H003 ERS Update Frmware 3i 192 168 1 25 2198 H003 ERS 2198 H003 ERS 192 168 1 8 1734 AENTR EtherNet IP Adapter 1734 AENTR Ethernet Adapter F Cose os nat po OO 6 en gO ce go gt OOP Ee a ed ee ad oe 13 Once the program is downloaded set the controller to Run Mode 14 The ANALOG INPUT 0 rotary knob defines the machine Feed Rate and the range is from 0 to 200 cm s As a starting point set the rotary knob to 5 0 which equates to half speed AAD OFA 15 16 17 18 19 20 21 22 23 Make sure t
6. j Run Stop Errors Log Logging Stopped Periodic 1 ms Capture fi J ort Machine_Performance Friday May 09 2014 Po eaa ANS Dz AcuaPoston 100 a a ma 3 AXIS_02 VelocityFineCommand 400 a 1 40 07 PM Make Up Move Knife Speed Matches Feed Rate Torque Spike ae i 1 40 05 PM 1 40 06 1 40 07 1 40 09 1 40 10 1 40 11 PM Lat j sit td La M r j There are several items to observe that include Area of the Cut Region and the Make Up Move e At the center of the Cut Region the Rotary Knife Velocity Command and Actual Velocity equal the machine Feed Rate 107 of 142 1 40 11 PM 2 472 98 0 4 0 4 2 0 Compare the Knife Velocity cm s 2T to the speed of the Conveyor by looking in the configurable _speed_cm_per_second variable rung 8 The torque spikes at the beginning and end of the Cut Region 24 Now let s observe how the Feed Rate affects the performance Return to Step 10 and modify the Feed Rate by setting the ANALOG INPUT 0 to a different setting such as 2 0 and repeat the process to see the change 108 of 142 Designing a Basic Cam Table Now we will create a Cam profile using Microsoft Excel and then adding it to the ControlLogix Controller 1 For this section of the lab you will need to take the controller Offline to edit a Cam profile Do that now From the Start menu in Windows run Microsoft Excel 20
7. Figure 5 Rotary Knife Cam Profile Review Code and Execute a Cam Profile 1 Open file Desktop Lab Files PCAM Rotary Knife Lab PCAM_RotaryKnife_Begin ACD 2 Download the program to the controller at 192 168 1 12 1 Click Who Active button 2 Select controller from the Ethernet driver 3 Click Download button 4 On pop up dialog window click the Download button Path AB_ETHIP 1 192 168 1 12 v s 1 A Workstation BASEIMA T1BGVSY es Linx Gateways Ethernet gt AB_ETHIP 1 Ethernet OR 9 192 168 1 12 1769 L36ERM LOGIXS336ERM 1769 L36ERM A LOGIXS336ERM ii 192 168 1 2 1783 BMSO6TA Stratix 5700 1783 BMSO6TA Stratix 5700 f 192 168 1 24 2198 HO003 ERS 2198 H003 ERS f 192 168 1 25 2198 H003 ERS 2198 H003 ERS J 192 168 1 8 1734 AENTR EtherNet IP Adapter 1734 AENTR Ethernet Adapter fwd pm de 4 Pa ak eee a Pou nage Ca ary a 200 na pe PI PP aat oadet P o a pM OP an pasm PI DEPE DE 3 Once the program is downloaded set the controller to Run Mode 4 Open file Desktop Lab Files PCAM Rotary Knife Lab PCAM_RotaryKnife mer by double clicking it to run the lab HMI 5 On the Replace Local System Directory dialog press the Yes button to continue 103 of 142 6 Click Application Settings FactoryTalk iew ME Station Current application PCAM_RotaryKnife_mer Load Application Run Application Application Settings F3 F1 F2 Delete Log Files Ter
8. Trends oof Machine Performance lt 5 6 VO Configuration 1769 Bus Click Run to start collecting data in the trend On the HMI press the Start button to ready the system for motion The Machine State should transition from Stopped to Idle 106 of 142 Machine Status Machine Control o eorom MSEE t Sa _ Safe Speed State STOPPED State IDLE 19 Press the Start button again to start executing the motion application code The Rotary Knife is reoriented to the beginning of the Cut Region the axes are homed the Conveyor is started and the Rotary Knife begins cutting the Product 20 Now go back to the Trend screen Once the Rotary Knife has run several cycles you can stop collecting data by pressing the Stop button 21 Press the Stop button on the HMI to stop motion 22 Let s review the signals monitored by the trend AXIS_01 ActualPosition Corresponds to the Master Axis Product cm The distance between cuts should equal the Cut Length AXIS_02 ActualPosition Corresponds to the orientation of the Rotary Knife rev AXIS_02 ActualVelocity Corresponds to the angular velocity rev s AXIS_02 VelocityFineCommand Corresponds to the command velocity AXIS_02 TorqueReference Corresponds to the torque applied to the Rotary Knife Rated and it is desirable to minimize the torque level 23 Now review the trend to see the performance of the machine Trend Machine_Performance E gi 10 x
9. 1170 98 oe A 5 1 812 8 AXIS_02 ActualPosition 100 013 110 AXIS_02 ActualVelocity 110 ee ae m AXIS_02 VelocityFineCommand 470 Sie 14 AXIS_02 TorqueReference 106 71 E 1 10 106 71 1 08 1 70 71 19 1 42 34 PM 1 42 35 1 42 40 PM Last es S There are several items to observer that includes e Area of the Cut Region and the Make Up Move At the center of the Cut Region the Rotary Knife Velocity Command amp Actual Velocity equals the machine Feed Rate e Compare the Knife Velocity cm s 2T to the speed of the Conveyor by looking in the configurable speed _cm_per_ second variable rung 8 e The previous torque spikes at the beginning and end of the Cut Region are not present 24 Why does the User Defined Cam Table that has a shorter Cut Length and produces more Products per second require less torque This example illustrates the importance of the Cam Design In this specially chosen example a Cut Length was chosen that allows the boundary conditions between the Cut Region and the Make Up Move to match The graph shown below shows the Default Cam Table Cam1 and the User Defined Cam Table Cam2 By observing the Cam Profiles velocity command in red the designer can observe the severe step response in the velocity command This step response is what causes the large torque spikes 113 of 142 z Ja s F ajaja FA v sjal s 8 3 ala as amp E
10. A a 16 00 4 MASTER CommandAcceleration 150 00 00 MASTER CommandPosition 5 3 00 r T Te even eee ees eee 2 25 18PM 2 25 19 2 25 20 2 25 21 2 25 22 2 25 23 PM Lea Laa a 12 Let s calculate the total time of the Slave s move and compare it to the values captured in the trend We asked the Slave to move 5 position units at 3 times the Master s speed The Master is running at 1 position units sec Notice how Units per MasterUnit is like a gear ratio So solving for total time of the move we have 5 position units 3 position units sec 1 667 sec 13 Click on the trend at the start and end of the Slave s move Note the time of each Then calculate the difference in time Is it approximately 1 667 seconds 14 Here it is in this example 2 25 20 760 2 25 19 080 1 680 seconds 2 25 19 080 PM 2 25 20 760 PM 94 of 142 15 Note the velocity of the move by clicking in the middle of the green velocity curve Is it 3 rev sec or 3 times the Master s speed of 1 rev sec Yes it is Wow moves with a built in gear ratio Nice 2 25 19 880 PM 20 00 16 00 12 00 8 00 4 00 0 00 2 25 18 180 PM 2 25 23 180 PM 16 Let s try another MAM with MDSC in Units per MasterUnits 17 Change the Master jog speed in the MAJ instruction on rung 3 to a value of 2 Motion Axis Jog WAJ Motion Axis Jog Axis MASTER Ga Motion Control MASTER Ctrl MI MAJ 2 DN
11. In this lab we will introduce you to the CompactLogix with Integrated Motion on EtherNet IP product family by performing the following Creating a project by utilizing the Drives amp Motion Accelerator Toolkit Learn about the core concepts and benefits of Integrated Motion on EtherNet IP Configure your motion hardware including controller and drives Note Much of the information and detailed steps provided in this lab can also be found in the C P Motion Configuration and Startup User Manual MOTION UM003 EN P available via Literature Library More information about the programming techniques used here can be found in the publication Drives and Motion Accelerator Toolkit Quick Start IASIMP QS019 EN P available via Literature Library Open the Application File 1 Return to Logix Designer 2 From the Tool Bar menu choose the Open icon fJ Logix Designer Intro_CIP_K5500_Complete 1769 L36ERM 21 1 File Edit View Search Logic Communications Tools Window Help alalu JAA a aa E 7 The Open window appears You do not need to save changes to your existing file 3 Browse to the folder Lab Files on the desktop and open file Integ_Motion_K5500_PF527 Base ACD When you open the logic file the Controller Organizer appears on the left side of the Studio 5000 window The Drives amp Motion Accelerator Toolkit is a modular programming structure that was used to create this sample log
12. Add a Motion Coordinated Linear Move MCLM and a Motion Coordinated Circular Move MCCM 10 From the Controller Organizer navigate to the routine Main Task gt P02_Application gt R10_ApplicationCode and open it This routine contains our application specific code and will be used throughout this lab Tasks ee MainTask gg PO1_Machine 28 P02_Application fi Program Tags ff ROO_Main E RO1_PowerUP H RO2_Monitor H RO3_Control EH RO4_Reset B SUP EEG a Ey P03_Module_XY CoordMotion S E Unscheduled Programs Phases 11 Add a MCLM instruction by 1 Go to rung 3 2 Place your curser here 3 Select Motion Coordinated instruction tab 4 Select the MCLM instruction 78 of 142 H tot tal Q MORMI MCCM MCCD MCT MCTP MCSD MDCC MCSR 3 b j Motion State Maticg TE P PE PE AE Mineo n Config Motion Coordinated ASCII String ASCII Conversion CLM E abcd Motion Coordinated Linear Move Coordinate System a Mannan Contra COORDINATED LINEAR MOVE Move Type D Position Move to point 0 4 Equal Source A QI Motion Coordinated Linear Move XY_CoordSys_Ctri CSI MCLM 1 ER Inst_Error L Source B Motion Coordinated Linear Move XY_CoordSys_Ctrl CSLMCLM 1 IP XY_CoordSys MovePendingQueuveFullStatus MOV i Move Source 10 Dest RunSEQ 0 0 omrnanrnnrnrrrrmrrrdrmrara Dm D mm D s 12 Enter instruction data as shown in the picture to the right It is important that you
13. Using Multiplexing to Optimize Performance In this section you will use a project that has many axes and Is near its utilization limits You will see how to optimize performance for different axes and scan times to reduce the burden on the controller and get more processing power for the same cost 1 Open file Desktop Lab Files Multiplexing Lab Multiplexing Begin ACD 2 Locate the Motion Group MG in the Controller Organizer and select Properties H E Motion d See New Axis gt wr New Coordinate System He Monitor Group Tag Ys Fault Help is ar M ie Cut Ctrl x t Copy Ctrl C Sun i Delete Del Add Or Le Ala Motion Direct Commands it CIF i Ma Cross Reference Ctrl E H E Data T Print i Use C str Properties Alt Enter s p wO Ad Predefined 3 The dialog box will appear and you should select the Attribute tab 138 of 142 z Motion Group Properties MG aH Attribute Jag 4 Select the Ellipsis button shown below to access the Axis Schedule Panel amp Motion Group Properties MG E oj x Non Major Fault 7 5 Within the Axis Schedule Panel you can adjust which axes fall into each of the Update Schedules as well as view the estimated utilization of some key metrics In the screen shown the Base Update Rate is 2 0ms 139 of 142 6 Alternate 1 Alternate 2 3 0 ms 20 0 ms Estimated Utilization Motion Actu
14. while those with a solid outline indicate a emai P STOPPED Disabled J CLEARING was am m an end state Depending on your current machine state use the following commands to transition between states ABORTED Press Clear Faults ABORTED gt CLEARING gt STOPPED STOPPED Press Start STOPPED gt RESETTING gt IDLE gt STARTING gt RUNNING RUNNING Press Stop RUNNING gt STOPPING gt STOPPED Note The machine is placed into the ABORTED state whenever a drive fault condition and or a state transition error has been detected The machine is also placed into the ABORTED state on Power Up or during first scan i e Program to Run Mode of the controller Refer to the Alarm History faceplate to determine the cause for the ABORTED condition Faceplate Operation Machine Control Program AUTOMATIC mode refers to the automatic function or automatic sequencing for the machine Operator MANUAL mode allows for some manual operations like enable disable move jog home etc The machine status indicators provide a summation view of all the devices for the entire machine The Program Operator selector button lets you toggle between the two modes The Clear Faults button attempts to clear faults on all devices The condition that caused the fault must be corrected before the clear is successful Run the Machine Follow these steps to start and stop the motion system in Prog
15. 4 Installation X 25 5 Fosaa amp Validation equirements 3 Mitigation Design amp Verification For more information on any of these areas please visit another session during this event focused on Safety Lifecycle Management or consult with your local Rockwell Automation or distributor resources Safe Torque Off STO One of the most visible and common hazards on machines comes from moving parts Since many of these parts are moving because of motors attached to them let s focus on ways to make those motors safe At the most basic level there is only one safety control function that can be performed with a motor removal of torque producing power This was done traditionally with Lock Out Tag Out LOTO to remove all sources of power from a machine More recently control power has been left on and motor power was removed through a variety of means Over the last decade communication channels between field devices and controllers have evolved to include safe connections The protocol used by Rockwell Automation is based on the CIP Safety standard from ODVA This standard is designed and certified for transport of data with high integrity This design includes sending the data over standard networks in specialized packets to remove the chances for data corruption This is accomplished by using basic safety principles including Duality Diversity and Diagnostics 126 of 142 normal data gt Duality 7 7 _inverted data gt D
16. 5 Click the to expand the tag to view the data structure 6 Take a moment to scroll through and examine the AXIS_CIP_DRIVE axis structure The tags are sorted alphabetically rather than by logical groupings This can be switched by pressing the button in the Name header If the logical groupings sort is used instead the next few steps will have a different screen image AXIS_CIP_DRIVE axis structure is significantly different than that of an AXIS_SERVO_DRIVE which is used for SERCOS based servo drives Some of the tags match and have an analogous function other tags were added to the AXIS_CIP_DRIVE axis structure For comparison purposes AXIS_SERVO_DRIVE axis structure contains 207 tags while AX S_C P_DRIVE contains 463 tags 7 Locate the Axis01 AxisFault tag Name zaf Value Force Mask Style Data Type AAi wee AXIS_CIP_DRIVE 16 0000_0000 Hex DINT sis01 PhysicalAxisFault of Decimal BOOL AxisO1 ModuleF ault o Decimal BOOL Axis01 Config ault D ecimal BOOL Axis01 GroupFault Decimal BOOL Axis01 MotionF aul Decimal BOOL AxisO1 GuardF ault Decimal BOOL TET Decimal BOOL Decimal Notice the basic fault type bits are listed under the AxisFault word when any fault condition is detected the associated fault type bit is set 8 Locate the AxisO1 ModuleFaults tag this i
17. CIP Safety Drive03 The Axis Properties window opens 2 Notice on the General page that the PowerFlex 527 drive module you added in the previous section is assigned to this axis 33 of 142 Axis Properties AxisO3 Categories General H Motor kn Model Axis Configuration gt Analyzer Feedback Configuration Motor Feedback Motor Feedback Re z aes Application Type Basic Hookup Tests Loop Response Medium gt Polarity Autotune Assigned Group 3 Load Backlash Motion Group MotionGroup Se New Group Compliance Update Period 3 0 Position Loop Velocity Loop Associated Module Torque Current Loop Baas Module Drive03 7 Homing Module Type PowerFlex 527 STO CIP Safety ao Acti l Er TRTE Power Structure 25C 2P5 Drive Parameters b Parameter List Axis Number fi Status 7 Faults amp Alarms Tag Axis State Safety State Manual Tune Cancel Apply Help Do not close the Axis Properties window until instructed to do so 34 of 142 There are thr amp xis Configurationtions for the PowerFlex 527 drive Frequency Control Position hadpelocity Loop The Aoplication Tvoe and Loop Response are used to confiaure the axis to optimize the Autotune results Use the description and table to determine the most appropriate configuration for your typical machine There are five differapplication Types Integrated Motion drives Custom Ad
18. Connection Motion only Power Structure lt none gt Status Creating Cancel Help 1 Type DriveO3 in the Name field 2 Select Private Network and set the Ethernet address to 192 168 1 26 3 Click OK TIP The PF527 IP address can be configured from the HIM of the drive OR you can use DHCP to assign an IP address On the HIM navigate to Settings gt Network gt Static to change the static IP address or Settings gt Network gt DHCP to setup DHCP 5 If the Select Module Type window is still open press Close The drive that you just added should now appear under the Ethernet network in your I O configuration 6 To complete the drive configuration right click on Drive03 and select Properties 27 of 142 3 Trends New Module Logical Model i Discover Modules 1 0 Configuration 5 8 1769 Bus ben Falo 1769 L36ERM Integ_Motion_ S EERE B 1 1769 IQ16F A Digital_Inputs Copy Ctrl c J 2 1769 0816 8 Digital_Outputs Paste Ctr gt D 3 1769 IF4X0F2 A Analog I0 Delete Del E aa Ethernet F 1769 L36ERM Integ_Motion_K55I Cross Reference Ctrl E El J 1734 4ENTR A Point_IO_Chassis H E PointIO 4 Slot Chassis Properties Alt Enter filly 2198 HO03 ERS Drive01 fly 2198 HO03 ERS Drive02 Print on fowerFlex 527 STO CIP Safety DriveD3 peo t Controller Organizer Tin Logical Organizer The Module Properties window opens b A Search Results 7 From the General
19. Friction i Velocity Feedforward Observer IV Acceleration Feedfonvard Position Loop Velocity Loop IY Torque Low Pass Filter Acceleration Loop Torque Current Lo Planner Motor with Load e C Uncoupled Motor e Homing Actions Travel i 400 0 e evs Drive Parameters Lirnit Parameter List Speed 25 0 e revs s Status Torque 100 0 Rated Faults amp Alarms T q i b Direction Forward Uni directional e M Measure Inertia using Tune Profile Manual Tune Perform Tune une Status Success oop Parameters Tuned Name fem tuned unt PositionLoopBandwidth 1 852124 18 530634 Hz PositionintegratorBand 0 0 00 Hz YelocityLoopBandwidth 74 08496 74 122536 Advanced Compensation Load Parameters Tuned pee o Units MaximumAcceleration 10381 242 3028 4631 MaximumDeceleration 10381 242 3278 5566 rev Systeminertia 0 012868189 0 04236162 Accept Tuned Values e DANGER Starting tuning procedure with controller in Program or Run Mode causes axis motion OK Cancel Apply Help If your Tune Status does not display Success please refer to the Common Faults Encountered While Tuning section in a few pages If you have any questions please consult with your lab instructor 7 Take time to scroll through the Loop Parameters Tuned and Load Parameter Tuned lists Loop Parameters Tuned name O fenn Ture iis P
20. IP Power and performance oriented nature of the Integrated Motion solution Ease of motion system setup utilizing the Drives amp Motion Accelerator Toolkit You will see how easy it is to create an Integrated Motion Solution by doing the following Creating and configuring motion axes using Logix Designer Learning basic motion direct commands Utilizing the Drives amp Motion Accelerator Toolkit to speed programming of your motion application Learning some basic troubleshooting techniques Being introduced to the advanced diagnostic tools available in the controller Learn advanced motion topics such as camming tuning and coordinated motion During this lab you will be able to understand how Logix Designer can help you reduce the number of hardware and software components as well as the flexibility associated with information data access in the control system Tools amp prerequisites For this hands on lab we have provided you with the following materials that will allow you to complete the labs in this workbook 6 of 142 Software Logix Designer v24 00 FactoryTalk View ME Station v7 00 RSLinx Classic v3 61 Hardware Computer with Windows 7 operating system CompactLogix 1769 L836ERM Demo DEMO CMXL361 Kinetix 5500 3 axis Demo w PowerFlex 527 O9P096G Ethernet Patch Cables 3 x RJ45 to RJ45 2m length 2x RJ45 to RJ45 1m length Required Files Integ Motion _K5500_
21. PF527_Complete ACD Integ Motion _K5500 PF527_ Base ACD Integ_Motion_K5500_PF527_ViewME MER Network Setup Note This is the recommended configuration for the lab however due to the variable nature of EtherNet IP topologies many other configurations will work Ethernet Switch Port 1 to Computer Ethernet Switch Port2 to Processor Port 1 Processor Port 2 to POINT I O Port 2 To Kinetix 5500 Drive 02 4 POINT I O Port 1 Port 2 Kinetix 5500 Drive 02 To Kinetix 5500 Drive 01 5 Port 1 Port 2 Kinetix 5500 Drive 01 Port 1 To PF527 Drive 03 Port 2 CompactLogix Processor 192 168 1 12 POINT I O Ethernet Adapter 192 168 1 8 7 of 142 ArmorBlock Input 192 168 1 9 not Module used ArmorBlock Output 192 168 1 10 not Module used Kinetix 5500 Drive01 192 168 1 24 Kinetix 5500 Drived2 192 168 1 25 PowerFlex 527 Drive03 192 168 1 26 Ethernet Cable Routing Ethernet IP Addresses For the remainder of the basic lab m Drive01 and Axis01 will refer to the Kinetix 5500 drive on the left side of the demo case m Drive02 and Axis02 will refer to the Kinetix 5500 on the right side of the demo case m Drive03 and Axis03 will refer to the PowerFlex 527 AC drive to the left of the Kinetix 5500s 8 of 142 About the CompactLogix Demo ETAP Controller unused in 1769 L36ERM Power 1769 Chassis Point I O this lab Processor Supply Based I O on Ethernet IP Ethernet Switch Circuit Breaker I
22. Primary wd s x2 V Enable Coordinate System Auto Tag Update Cancel Apply Help i 7 Select the Units tab and enter inch for Coordination Units 9S Coordinate System Properties XY_CoordSys 3 fos General Geometry Units Offsets Dynamics Motion Planner Tag Coordination Units inch 1 0 1 1 0 Tal 1 In this lab the specified Units for the axes and Coordination Units are the same so the Conversion Ratio Units shown will be inch inch and the ratio will be 1 1 The option to fill in a Conversion Ratio is more useful when we are dealing with different units For example if the axes units were in Degrees then the Conversion Ratio Units column would display Degrees Inch 8 Select the Dynamics tab and enter the data into each field as detailed in the screen shot below 77 of 142 I gt Coordinate System Properties XY_CoordSys General Geometry Units Offsets Dynamics Motion Planner Tag Vector Maxmum Speed Maximum Acceleration Maximum Deceleration Maximum Accel Jerk 50 of Max Accel Time Calculate Maamum Decel Jerk 50 of Max Dece Time l Calculate j Note Each axis has its own Dynamics defined during individual axis configuration but so does the Coordinate System It has its own Vector Max Speed Accel and Decel and Accel amp Decel Jerk as defined here 9 Click OK to save your changes and close the dialog window
23. The Alarm History faceplate provides a summary of current and past alarms for all the configured devices or drives configured in the application The faceplate receives fault information directly from each of the device modules and applies a timestamp based on the order in which it was received 67 of 142 12 21 2010 10 46 02 AM Axis 01 Control Syne Fault 12 21 2010 10 46 02 AM Axis 01 Drive Fault 12 21 2010 10 45 56 AM Axis 02 Control Sync Fault 12 21 2010 10 45 56 AM Axis 02 Drive Fault The Alarm History faceplate can be an effective diagnostic tool for troubleshooting helping machine operators pinpoint root causes quickly When you are done with the Alarm History faceplate close it by pressing the Close button on the bottom of the screen Equipment Status Faceplate The Equipment Status faceplate lets you quickly load and configure a summary display of preconfigured status and diagnostic displays faceplates The Equipment Status faceplate works in conjunction with individual device faceplates and provides a single summary display of all the devices that may be configured for an application 68 of 142 Equipment Status X Device State Value 1 Value 2 Value 3 Value 4 Axis 01 _ Kanol EJ Axis 02 aA Axis 03 You can configure up to nine device faceplates to run with the Equipment Status screen and each device faceplate can be launched directly from it 13 When you are done with the Equipment Status faceplate close it by pre
24. an Integrated Motion System Estimated Time 20 Minutes 00 17 Open the Application Pilessexsiia tutes uceatencteleseastite lee esl evar uewlaee cee et vedt nea 17 Hardware and Network Considerations ccccccsseeseeeeeeecceaeeeeeeeeeeeeeaeeeseeeeeeeesaaeaaceeeeeeeessaaaeeeeeeeeesaaaaaees 22 Add YOur DFVe IANO WANG xsius artidratesaseatneties cat a lv Sad hainaasesSeataiad E 24 Gomigube AXIS Propers mermere eda haart da cas iced a ee Sod late ea ae ade 32 Save and Download Your Motion Project ccccccccsseeeceeeceeeseeeeecaeeeeeeesseeuseeeeeeseseeeeeseaeeeeeessaaeeeeeesseaseeees 43 Lab 2 Axis Commissioning Hookup Test and Autotune Estimated Time 10 Minutes c00 46 PIS AHOOKUD FOSIS vertents tunutesiinesd nc ews aces meuinadistanteatasiteacatiaton ahha busspattiuusisteahiten dott tannntleninasate 46 PS AUO I a sacha inc te tte Sida ancecieshea cabs wach chen ince aces estimates E Sea neeemermes 49 Common Faults Encountered While Tuning cccccceeccceccseseeceeecaeeeeceeeceeueeeeeeeeaeeeeesseeseeeessaaeeeeeessaaseees 53 Lab 3 Using Motion Direct Commands Estimated Time 10 Minutes cccccseeeeeeeeeeeeeeeeeeeeeeeeeeeees 55 Jogging an Axis Using Motion Direct COMMANAS cccceccceeceseeseeeeceeeeeeeeeesaeeeeeesaeaeeeeeessaaeeeeesssaeeeeeesas 55 Varying the Speed of the Axis Using a Motion Direct Command cccecceeceeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeaaaeee
25. between the Master and Slave axes with a MDAC instruction 92 of 142 w z ER Bi js 2 e Set your MAM units for speed accel decel and jerk to Units per Master Units e Select a Lock Position of the Master that will trigger the Slave to move e Select a Lock Direction of the Master the direction that along with the Lock Position will trigger the Slave to move Rung 6 contains our move instruction Notice that we have the condition that the MDAC instruction needs to be IP in process before we can execute the move otherwise the move instruction would error MAM 2 MDSC in Units per MasterUnit Gear Ratio between Master and Slave Motion Instructions Move On Off Motion Axis Move MASTER_Ctri MLMDACIO IP HMI_ON 2 MAM Motion Axis Move EN Axis SLAVE Ga Motion Control SLAVE_Ctrl MI MAM 2 DN gt Move Type 0 Position MAM_MDSC_unitpermasterunittPOS 5 0 P Speed MAM_MDSC_unitpermasterunitSPD 3 06 PC Speed Units Units per MasterUnit Accel Rate Accel Units Units per MasterUnit2 Decel Rate 100 Decel Units Units per MasterUnit2 Profile Trapezoidal Accel Jerk 10000 Decel Jerk 10000 Jerk Units Units per MasterUnit3 Merge Disabled Merge Speed Programmed Lock Position 5 Lock Direction Position Forward Only Event Distance 0 Calculated Data 0 A A Motion Axis Mowe SLAVE _Ctri MI MAM 2 ER Inst_Error The MAM instruction will execute an absolute move from position 0 to position 5 5revs wit
26. control a portion of the machine Following the demonstration you will move into the formal lab where you will learn how to construct this solution with 10 of 142 detailed step by step directions Along the way the lab will highlight concepts important to Integrated Motion on Ethernet IP Let s begin Launch Studio 5000 and Open Application Files 1 Launch Studio 5000 double click on the Studio 5000 desktop icon 2 SC Ces Le 2 From the Open column choose the Existing Project icon Rockwell Software Studio 5000 Create Open xplore New Project Help rom Import Sample Project Release Notes rom Sample Project From Upload About Recent Projects The Open Project window appears 3 Browse to the folder Lab Files on the desktop and open Integ_Motion_K5500_PF527_Complete ACD Logix Designer opens 4 Select Who Active from the Communications menu The Who Active window appears 5 Drill down through the AB_ETHIP 1 driver and select the device at 192 168 1 12 the CompactLogix processor 11 of 142 gt amp Who Active i iol xj JV Autobrowse Workstation WIN7 M x Linx Gateways Ethernet E gs AB_ETHIP 1 Ethernet Upload 192 168 1 10 1732E OBSM85R 24 DC Out M8 1732E OB8M8SR 24 DC Out M8 i 192 168 1 12 1769 L36ERM LOGIX5336ERM 1769 L36ERM A LOGIX5336ERM Download 192 168 1 24 2198 HO03 ERS 2198 HO03 ERS H 192 168 1 25 2198 H003 ERS 2198 H003 ERS Update Firmware
27. faults from the Startup screen or if in Operator mode from the Axis CTRL display The Alarm History screen logs fault information from all of the devices When you are finished reconnect the Ethernet cable to the drive Note The drive will automatically recover from a Control Sync Fault but the machine is still faulted Therefore a Clear Faults command on the machine will be needed once the Ethernet cable has been reconnected It may take up to a minute to recover Press Clear Faults Press Program Operator until Operator is displayed and then again until Program is displayed This is required because we had Operator control of the axis above while we were jogging it manually 7 Press Start Press the button Axis01 x gt y A Axis Axis f N Status CTRL AxisO1 Device Name Equipment Status Equip Name revs Position Units revs s Velocity Units Percent Rated Current Units Value 4 Units From the Configuration screen you can enter display names and units as required for your application Some of the labels are used on the Equipment Status faceplate 65 of 142 9 Press the button Trend Axis 01 Configuration ao Y Sale RM J E GD sius cin lt p Next Pen Pause 0 1 27 55 PM 1 33 55 PM Ld Position EE current The Trend screen lets you view your current feedback actual velocity and actual position trends of your axis The Trend Configuration button is only visible on the Tre
28. hazard e avoid a hazard e recognize the consequence ren A O NEO Labels may be located on or inside the drive to alert people that dangerous voltage may be present Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures gt P Integrated Motion on Ethernet IP Contents Boyu Do a e a E E E E E 6 POU AIS WAU vossen ere Rer SN PEER EE ENA A A EE AE EAA S EAE ERER 6 Tools amp proreguisieSssssitrseidisinni onni naia aa aee a ra Eaa da n ei ieaiaia ina at niaii ain 6 NetWOrK SEUD iat oeni a eE a r eoii a a ai Menaiciadtnuse 7 About the CompactLogix D MO cccccccsseeeseccceeeceeeeeeeceeeeeeeeaeeeseeeeeeessaeeeeeeeeeeeesseaaseseeeeeessaaaaeueeeeeeessuaaaeees 9 About the Kinetix 5500 and PF527 3 Axis Demo ccccccceceeeeeeeeeeeeeeeeaaeeeeeeeeeeeeeaaaaaeeeeeeeeessaaaseeeeeeeeeeaaas 10 Demonstration Estimated Time 15 minutes cccccccssseeceecceeeseeeeeceeeseeeeesaeseeeeseeeeueeeeessaeaeeeeessaageeeeeeaas 10 Launch Studio 5000 and Open Application Files cccccccccccccsssseeeeeeaeeseeeeeseeeeeeeeeeeeeeeeeeesseeeeeeeeseegeeeeeeeas 11 Open and Aun the TIMI Ap piC AHO Mia teccaccctessswacdnicesunadonsessacuieeadonineeconsdautamerdeceacaqeeumaienianeecsgiautanaruesecneeceaevess 13 lai ANG StOp Tie MaACHING aean E EEE EEE EEE A AS 14 3 of 142 GIP Motion Axis Faceplate Mantai COW esnin ey lee ee eae lve ie cee ete 15 Lab 1 Basic Configuration of
29. methods of compensating for a mechanical resonance include a costly redesign of the mechanics or a quick software modification that programmatically compensates for the resonance This procedure focuses on the programmatic approach to compensate for the mechanical resonance by setting the Torque Notch Filter For complex mechanics it may also be necessary to decrease the Torque Low Pass Filter or decrease the servo loop gains 1 Perform the following move sequence by using Motion Direct Commands to excite the resonance 1 Enable the drive with an MSO instruction 2 Slowly jog the axis with a MAJ or MAM instruction 3 Stop the axis with a MAS instruction A Disable the drive with an MSF instruction 2 Determine if an audible high frequency resonance exists in your motion application e If an audible high frequency resonance is not present during the move sequence skip the remaining steps and tuning is complete e If an audible high frequency resonance is present during the move sequence use a FFT Fast Fourier Transform smart phone or tablet application to identify the dominant resonant frequencies When the Adaptive Tuning Features become available there will be features internal to the drive to identify mechanical resonances 3 Ifa resonance is below the 1 2TrDrive Model Time Constant Hz i e Load Observer Bandwidth and a low pitch growling sound is present then an instability is present and the servo loop gains must be
30. nductionMotorStatorResistance Motion Axis Parameters Associated Page MilimeterRey 88 0 ots RS 1000000 0 Motion Counts revs 100 0 Motor Rated oO ho Sensorless Vector 8 0 imps RMS 200 0 none Direct Coupled Rotary 1 S666666 revs s 2 is Cancel Help Notice you can access all the parameters associated with each category page Take time to scroll through the various parameters Each Parameter Group list may contain more attributes than the associated category page In some instances attributes listed on the Parameter Group list are not displayed on the associated category page Also the parameters shown are dependent on the motor control configuration of the axis 10 Navigate to the Tag page 42 of 142 Axis Properties AxisO3 Categories General Motor Model Name fAxis03 n Analyzer Scaling Hookup Tests Polarity Planner Frequency Control l Actions Drive Parameters Description a Type Base oo Status Scope eal Integ_Motion_K5500_PF527_Base Faults amp Alarms External Read Write Be ag Access Axis State Safety State Manual Tune Cancel Notice that Data Type for an Integrated Motion on EtherNet IP based drive is AXIS_CIP_DRIVE This new data type was added in RSLogix 5000 v18 to support CIP Motion based drives 11 Click OK to close the Axis Properties window Save and Download Your Motion Project After co
31. port on those drives can be used for load feedback of the primary axis if the axis has a Feedback Configuration of Load or Dual Axis 2 is for a Feedback Only or half axis Typically a Feedback Only axis will act as a master reference for electronic gearing applications 11 Navigate to the Power tab and verify the following Bus Regulator Action Shunt Regulator Shunt Regulator Resistor Type Internal 30 of 142 CE Module Properties Local PowerFlex 527 STO CIP Safety 1 1 Dj x General Connection Time Sync Module Info Internet Protocol Port Configuration Network Associated Axes Power Jia gt Power Structure 25C Y 2P5 Advanced 1P 110 2 54 O 4kWw PWM Frequency fa khz Regenerative Power Limit 100 000 Regulator Rated Bus Regulator Action Shunt Regulator Shunt Regulator Resistor Type External Internal External Shunt lt none gt External Shunt Resistance External Shunt Power 0 2000 Kilowatts External Shunt Pulse Power 0 000 Kilowatts Status Offline Cancel Apply Help 12 Verify that External Shunt shows lt none gt even though it is grayed out Do this by clicking the External radio button then clicking the Internal radio button 31 of 142 Shunt Regulator Resistor Type External Internal External Shunt y External Shunt Resistance Ohms External Shunt Power Kilowatts External Shunt Pulse Power 0 000 Kilowatts
32. the applications Depending on the version of Studio 5000 this may be the configuration when an axis is created The general rule of thumb constrains the Velocity Loop Bandwidth Load Observer Bandwidth 4 Position Loop Bandwidth Velocity Loop Bandwidth 4 Load Observer Integrator Bandwidth Velocity Loop Integrator Bandwidth Position Loop Integrator Bandwidth 0 Torque Low Pass Filter Bandwidth 5 Load Observer Bandwidth Load Ratio 0 and the Load Observer Bandwidth 1 2 t Drive Model Time Constant In the included ACD file Axis_01 has appropriately been configured Steps 2 6 are shown to illustrate the appropriate setup procedure in the event the axis was not configured After understanding the desired 116 of 142 configuration you will be asked to appropriately configure Axis 02 Finally the program is executed to illustrate the performance of the tuning strategy 1 Open file Desktop Lab Files Tuning Techniques Lab Tuning_Begin ACD 2 Right click on Axis_01 and select Properties 3 Motion Groups Sg MG o a 01 i AxIs_02 3 Choose the Autotune category and verify the Application Type is set to Basic Loop Response to Medium and Load Coupling to Compliant Make any necessary changes and click Apply Axis Properties AXIS_01 10l x Categories PERT une Control Loop by Measuring Load Characteristics General Motor Application i Perform
33. to maximize the production rate without exceeding a specified torque which can cause excessive wear The exact design objectives are not specified for the lab While operating the machine note the machine performance based on the Feed Rate and Cam Design Overview of How to Control the Machine with a Basic Cam Design For the machine described in Figure 1 there are several methods to control the axes in order to cut the Product at a specific length Each approach has pros and cons in regards to the ease of use and the achievable Feed Rate In this lab we are going to develop a Basic Cam Profile to coordinate motion between the Conveyor and Rotary Knife This approach will provide good machine performance and minimize the design complexity for a typical engineer Conveyor Control This axis is defined as the Master Axis to control the machine The machines Feed Rate is controlled by the speed of Motor 1 The exact relationship based on the circumference of a spindle is defined as E Feed Rate Feed Rate S 21 spindle 2A Tepinate Equation 1 Relationship between Motor 1 Speed to Feed Rate In this application the Axis controlling the Conveyor is scaled based on the length of Product that has run through the machine Rotary Knife Control When controlling the example machine the obtainable Feed Rate is dictated by the methodology used to control the Rotary Knife When using a Basic Cam Design to control the Rotary Knife the m
34. window Lastly notice that the Kinetix 5500 drive on the left is displaying a fault message on the display and the Module status indicator should be flashing red Reconnect the Ethernet cable Verify that after a few moments AxisO1 ControlSyncFault and Axis0O1 ModuleConnFault tags both returned to a value of 0 and the drive is now displaying STOPPPED again It may take up to a minute for the drive to reconnect to the controller Each time the drive is connected to a controller it is reinitialized 73 of 142 APPENDIX Optional The following appendices are OPTIONAL and provides some examples of more advanced motion topics Even the most experienced motion control engineers occasionally struggle with complex applications The following appendices will cover advanced topics such as finding an optimal tradeoff between response and stability when tuning CAM instructions drive multiplexing and more Come along and learn practical solutions to getting that machine really flying The motion advanced topics lab consists of a variety of labs that will introduce you to motion examples and programming features The intent of the labs is to expand your knowledge of detailed motion topics by providing a simplified example of use and function of advanced concepts Each lab should take approximately 20 30 minutes to complete Choose the labs topics that most interest you so you can complete them in the allotted session time The PF527 is NO
35. 00 PF527 demo is fully powered up 6 Click the Download button in the Who Active window The Download window opens If the followina window pops up to Update Firmv aracelick Xx Condition The revision of the offline project and at least one module s firmware are not compatible The project may not execute correctly without updating all incompatible module s firmware Controller Controller Name Integ_Motion_K5500_PF527_Complete Controller Type 1769 L36ERM A LOGIX5336ERM Comm Path AB_ETHIP 14192 168 1 12 Serial Number 40584521 Firmware Revision 24 01 Security No Protection Offline Project Controller Name Integ_Motion_K5500_PF527_Base Controller Type 1769 L36ERM CompactLogix 5370 Controller File ab Files Integ_Motion_K5500_PF52 _Basefdr ACD Serial Number 40584540 Firmware Revision 24 Security No Protection A Before downloading to this controller you should A Update any incompatible module s firmware Select File 7 Click the Download button to send the program to the controller 44 of 142 8 When downloading completes place the controller back into Run Mode Method 1 x A Done downloading Change controller mode back to Remote Run _ Click Yes Method 2 Rem P Go icem Pros W and sele un Mode x A Change controller mode to Remote Run Click Yes 9 Verify that your controller is communicating OK indicator should be solid gr
36. 0416 79908 0 122555016 4 0 05393541 0 11 7683439 5 0 065703754 0 113968037 6 0 077100558 0 111147962 7 0 088215354 0 109054002 8 0 099120754 0 10 7574689 9 0 109878223 0 106637596 10 0 120541982 0 106198729 11 0 131161855 0 106236643 12 0 141 78552 0 10674966 13 0 152460486 0 10775545 14 0 163236031 0 109292844 15 0 174165315 0 111426276 16 0 185307943 0 114253883 17 0 196733331 0 117921439 18 0 208525475 0 122646376 19 0 220790112 0 128760708 20 0 233666183 0 13679221 21 0 247345404 0 147630547 8 Now we need to update the Cam Table to include the Make Up Move This time the Product Cut Length will be 70cm Thus the Master Axis goes to 70 enter this value into cell A24 The Rotary Knife rotates to 1 enter this value into cell B24 Ay B 24 70 1 9 Copy columns A and B from row 2 to 24 as shown 10 Highlight any data in the Cam2 input of the MCCP command on rung 6 and Delete any data Now paste the Excel data into Cam2 input loading the Cam Table into the controller 110 of 142 CALCLE ATE CAM PROFLE Can Frotte 2 re Maton Catoutate Cam Prof e jin riro AXIS O CLMM ay Comte a DN eee f 73 DE Cam Editor Cam 4 AY le sl l lz alala deve Fo ninn am Length Metion Cak atf Carn Protie ANTS 02 OMEP ER ki Err Motion Cakadate Cam gt Cam frotte ANOS 02 CYMEMCCIOON toy i Eaa iT T Fa RY rt reas ae _ Mrne 7 Source W a Cet Runta 0e
37. 10 with a blank spreadsheet In cells E1 E2 and E3 enter the configuration variables including units as Feed Rate cm s Knife Radius cm and Sample Rate s Load the initial values in cells F1 F2 F3 as 10cm s 15cm and 0 1s E E 1 feed rate cm s 10 Lee knife radius cm 15 3 sample rate s 0 10 In cells A1 B1 and C1 label the system dependent variables including units as Master Axis cm 6 rev and w rev s A B a 1 Master Axis cm 6 rev w rev s In cells A2 B2 and C2 load the initial values 0 0 and F 1 2 3 14 COS 2 3 14 B2 3 14 4 F 2 You can use copy paste for the formula This is the Rotary Knife inverse kinematics equations Cell C2 should show the calculated value of 0 150063088 Now copy the following equations into the following cells A3 Master Axis A2 F 1 F 3 B3 0 B2 C2 F 3 and C3 w F 1 2 3 14 COS 2 3 14 B3 3 14 4 F 2 Make sure to copy the preceding equal sign as part of the formula Highlight row 3 as shown and place the cursor in the bottom right corner of the selected cells to drag amp fill downward until the angle reaches approximately 0 25 row 23 Grab here to drag 0 0 0 150069088 and fill 3 1 0 015006909 0137729691 l This completes the Cam Table for the Cut Region 1 Master Axis cm rev w revs 109 of 142 A B c Master Axis cm rev w revs 0 0 0 150069088 1 0 015006909 0 137729691 2 0 028779878 0 129000304 3 0
38. 11 7683439 0 113968037 0 111147962 0 109054002 0 107574689 0 106637596 0 106198729 0 106236643 0 10674966 0 10775545 0 109292844 0 111426276 0 114253883 0 117921439 0 122646376 0 128760708 0 13679221 0 147630547 0 3 5 0 25 0 2 0 15 E a 8 rev w revs 0 05 4 1 6 i A K 16 21 Master Axis cm Figure 3 Cut Regions Cam Profile O As the Knife exits the Cut Region a Make Up Move reorients the knife to appropriately cut the Product This means the Knife is reoriented to 1 rev when the Master Axis reaches the Cut Length The Make Up Move impacts the obtainable performance and design complexity In this lab a linear Make Up Move shown below is used to illustrate the design procedure ca 21 71 T21 171 Master Axis cm Figure 4 Rotary Knife Linear Make Up Move The final step is to create one Cam Table from the Cut Region and the Make Up Move This Cam Table is graphed in Figure 5 and is loaded into Studio 5000 to control the machine 102 of 142 8 1 Master Axis em Sfrev 0 0 1 0 015006909 4 2 0 020779078 3 0 041679908 4 0 05393541 7 5 0 065703754 0 077100558 7 0 088215 7394 10 Y 0099120754 11 y 0 1098 78723 12 10 0 120541982 11 0 131161855 0141785572 13 iL 157460S86 iL 163735031 17 15 1 1 78165315 18 16 185307943 19 17 196733331 20 18 0 208525475 0 l r 21 19 022079017 0 50 100 150 200 22 20 0722666182 3 0 247345404 Master Axis cm
39. 168 1 12 IP address is selected as shown below Click OK 88 of 142 Edit ShortCuts Backplane lt No Devices gt Sf integ Motion K5500 PF527 Complet 192 168 1 12 17 Node USB CIP Port 1734 AENTRjB EtherNet Adapter 192 168 1 8 1732E IB8MBSOER 24 DC In M8 192 168 1 9 1732E OB8M8SR 24 DC Out M8 192 168 1 10 e PowerFlex 527 192 168 1 26 2198 H003 ERS 192 168 1 25 2198 H003 ERS 1 192 168 1 24 9 Click the Close button 10 On the FactoryTalk View ME Station dialog press the Run Application button 11 On the HMI press the Clear Faults button to reset the system Machine Status Machine Control E FAULTED Power Up Program start Clear C Ready Faults __ Safe Speed State ABORTED Stop Offline IQ Zoom In No Forces Q oom oe No Edits Controller Organizer Alt 0 Errors Alt 1 Controller Alt 2 13 In the Watch window use the pull down for Current Routine and select Master Slave Pos Vel 89 of 142 B23 Curent Routine HA Curent Routine Quick Watch Master_Slave_Pos_Vel A Errors LE Search Results 47 Wa gt Ladder Diagram 14 On the HMI push the Enable Home button to enable and home the axes Notice the values in the watch window Enable Home Watch Master_Slave_Pos_Vel Master_Slave_Pos_Vel Name Scope Value Force Mask MASTER ActualPostion Controler 0 o o __ MASTERCommandPos
40. 1_SensaGuard_InputOkK Sts_Zone1_InputsOK T rs Falling Edge Reset ISO 13849 1 stipulates that instruction reset functions must occur on falling edge signals To comply with this requirement the One Shot Falling OSF instruction is used immediately preceding the Output Enable rung The OSF instruction Output Bit tag is used as the reset bit for the following rung Cmd_Zone1_SafetyReset lt AENTR_1 1 1 Pt06Data SF One Shot Falling Storage Bit Virk_Zone1_OSF_SB Output Bit v rk_Zone1_SatetyReset_OSF_OB Output Enable Rung This rung provides the operator action required to reset or enable the safety zone output The operator action is a LO to HI to LO of Safety Reset latches the ouput enable until either a demand is placed on a safety input there is a input channel or output channel fault or a feedback fault on the output circuit The Inputs OK will go LO in the event of a demand on any safety input s or fault on any safety input channel s within the zone The CombinedOutputStatus will go LO if any output channel on the Zone Module faults The FP feedback fault present drops out the ouput enable in the event of a feedback fault so that reset or enable cannot occur without operator action Virk_Zone1_SafetyReset_OSF_OB Sts_Zone1_InputsOK AENTR_1 2 CombinedOutputStatus Zone1_Contactor FP Cmd_Zone1_OutputEnable c e PPO ISI Cmd_Zone1_OutputEnable In the Outputs routine from Zone 1 there are tw
41. 35 AM 8 50 40 AM XY_Trend Wednesday April 02 2014 T TO T T Y_AXIS ActualPosition 9 ae 35 Your trend should look like the one pictured here J Trend XY_Trend acs hE Stopes E Log Logging Periodic 10 ms Capture of 8 51 12 AM 8 51 17 AM XY_Trend Wednesday April 02 2014 8 51 17 AM E R aS aeee g of This concludes this lab 85 of 142 Appendix B Master Driven Speed Control MDAC Lab RSLogix 5000 V20 introduced a feature called Master Driven Speed Control MDSC The concept of this feature is to create a motion driven speed control system where the slave s position is based on the master s position To define the relationship between the master and slave axes two new instructions have been created e The MDAC Motion Master Driven Axis Control single axis e The MDCC Motion Master Driven Coordinated Control coordinated axes The slave s speed can be directly proportional to the master s speed like a gear ratio Or the slave s speed can be in master units like a single entry position cam This MDSC feature is now an option in the MAJ MAM MCLM MCCM and the MATC motion instructions The MDAC has two pull down menus for Motion Type and Master Reference Motion Type allows you to filter the type of moves that will use the MDSC feature And the Master Reference allows you to select either Command or Actual Position Motion Instructions MDAC Motion Ma
42. 74122536 keina if velocity Feedforward Advanced Compensation SE Filsservae OE ones eet 5 Load Parameters Tuned l Acceleration Feechonvar Position Loop Jee fomen Tuned units Velocity Loop Z Torque Low Pass Filter MaximumAcceleration 10381 242 3028 4631 Acceleration Loop MaximumDeceleration 10381 242 3278 5566 LTorquedCurent Lo M Measure Inertia using Tune Profile Systeminertia 0 012868189 0 04236162 1 v Planner Motor withLoad e Uncoupled Motor e Acsenk EE Homing i Actions Travel Aba 400 0 evs 3 Drive Parameters Lirnit Parameter List Speed 25 0 e revs s Status T d 100 0 Rated Faults amp Alarms x pie ssi b Direction Forward Uni directional Manual Tune OK Cancel Apply Help 9 Click OK to close the Axis Properties window Compliance 10 Save your project You may be prompted to upload the tags from the controller either selection will work 11 IMPORTANT You MUST Perform this step for the PF527 Using what you learned in this section execute a Calculate Tune on the PowerFlex 527 Axis03 52 of 142 TIP You ll need to navigate tMbtor gt Analyzer gt Calculate Mecialn of the Axis03 te Axis Properties awisos OOO O O OOO Categories General Analyze Motor to Determine Motor Model Dynamic Motor Test Static Motor Test Calculate Model Scaling Start Hookup Tests Polarity Planner Frequency Control ressing
43. Coordinate System tag under the motion group Note The maximum number of axes that can be associated with one Coordinate System is limited to three axes Right click on the Motion Group MG and select New Coordinate System 5 6 Motion Groups i gt New Axis gt New Coordinate Sys G Unc 03 Add O Monitor Group Tag 9 Data Ty Fault Help 3E Trends Enter XY_CoordSys for the name Verify the Data Type COORDINATE_SYSTEM is automatically set and the Scope is controller scoped Click Create when done New Tag Ea Name XY_CoordSys Description Type Alias For Data Type COORDINATE_SYSTEM Scope f CIP_XY_CoordMotion A ci Read Write v Style Constant Open COORDINATE_SYSTEM Configuration Let s configure our newly created coordinate system Double click on XY_CoordSys under the motion group to open the configuration dialog window 76 of 142 H E Motion Groups Sg MG dh X_AXIS QD Y_AXIS mea XY CoordSys Ungrouped Axes 6 Assign Coordinate X1 to X_AXIS and X2 to Y_AXIS Also verify that the Enable Coordinate System Auto Tag Update check box is checked We are going to use these values in our trend later so we want them continually updated D Coordinate System Properties XY_CoordSys Motion Group MG T Type Cartesian v Dimension 2 Transform Dimension 0 Coordinate Axis Name Coordination Mode o x xas
44. ERS Kinetix 5500 84 195 528 Volt Safe Torque Off Drive Allen Bradley Drive Motion 2198 H025 ERS2 Kinetix 5500 84 195 528 Volt CIP Safe Torque Off Dr Allen Bradley Drive Motion S m MNANILIINAArME Pren AP GEO 4A tO ee N A O ce Le TE mene nee EE m oe P ee ee oan nee T hs mon gt 35 of 384 Module Types Found Add to Favorites Il Close on Create Create Close Help Z 4 Click the Create button The New Module dialog box appears 5 Configure the new drive 1 Type the drive Name UM_CIP_Drive 2 Set Ethernet Address 192 168 1 88 3 Under Module Definition click Change The Module Definition dialog box appears 4 From the Connection pull down menu choose the Connection mode Motion and Safety 129 of 142 EN New Module x General Connection Safety Time Sync Module Info Internet Protocol Port Configuration Network Associated Axes Poa gt Type 2198 H008 ERS2 Kinetix 5500 2 54 195 528 Volt CIP Safe Torque Off Drive vendor Allen Bradley Parent EN3TR_Drives Ethernet Address Name UM_CIP_Drive Private Network 192 168 1 55 Description C IP Address i i Module Definition Change Safety Network 3C70_04FD_3AE3 Kiber 3C70_04FD_3AE3 st Revision 2 1 Electronic Keying Compatible Module 5 12 2014 6 15 04 547 PM Connection Motion and Satety 2198 HO08 ERS2 Power Structure m Revision 2 v 1 Electronic K
45. Forward Only Event Distance 0 Calculated Data Motion Axis Move SLAVE_Ctrl ML MAM 3 ER Inst_Error Close any open Trends Open the trend called position MAMS3 Click Run to start collecting data in the trend Press the Enable Home button on the HMI to enable the drives and set both axes to position 0 Again you will have less than 5 seconds to complete step 8 once you complete step 7 This is because after 5 seconds the Master axis will have passed the 5 revs position where the Slave move is to be triggered Press the MDSC button on the HMI You should see the MDAC instruction go IP in process Press the MAM 3 button on the HMI After the Slave axis right motor move completes click the Stop buiton in the trend Press the Stop button on the HMI to stop the Master axis Use the scroll back in time buttons until you see the Slave s move in the trend Click on the right edge of the green velocity curve Verify that the Active Value Bar shows that the Master s position at the end of the Slave s move is 10 5revs lock position 5revs master units 10 97 of 142 Investigate the trend until you are convinced that the Slave moved 1 position unit in the time it took the Master to move 5 position units position MAM3 Thursday May 01 2014 2 27 06 PM 0 00 2 27 01 PM 2 27 02 2 27 04 2 27 05 2 27 07 2 27 09 PM 13 Let s try another MAM with MDSC in MasterUnits 14 Change the Position to 25 in the MAM
46. L15 Integrated Motion on Ethernet IP For Classroom Use Only LISTEN THINK SOLVE Rockwell Allen Bradley Rockwell Software Automation Important User Information This documentation whether illustrative printed online or electronic hereinafter Documentation is intended for use only as a learning aid when using Rockwell Automation approved demonstration hardware software and firmware The Documentation should only be used as a learning tool by qualified professionals The variety of uses for the hardware software and firmware hereinafter Products described in this Documentation mandates that those responsible for the application and use of those Products must satisfy themselves that all necessary steps have been taken to ensure that each application and actual use meets all performance and safety requirements including any applicable laws regulations codes and standards in addition to any applicable technical documents In no event will Rockwell Automation Inc or any of its affiliate or subsidiary companies hereinafter Rockwell Automation be responsible or liable for any indirect or consequential damages resulting from the use or application of the Products described in this Documentation Rockwell Automation does not assume responsibility or liability for damages of any kind based on the alleged use of or reliance on this Documentation No patent liability is assumed by Rockwell Aut
47. MAJ instruction will move an axis at a constant speed until you tell it to stop 8 Click Execute Once the Execute button has been pressed the axis will immediately begin to move 9 The axis should be rotating at 2 revs s Though this soeed can be monitored in the controller you can verify this visually Varying the Speed of the Axis Using a Motion Direct Command 1 Select the Motion Change Dynamics MCD instruction 57 of 142 KJ Motion Direct Commands AxisO3 1 Commands Re MSO Re MSF fe MASD Re MASR Re MDO Ro MDF Re MDS wll MAFR Motion Move hen MAS Ro MAH oly MAJ a Axis State Running Axis Fault No Faults Start Inhibited Not Inhibited Motion Group Shutdown Axis Ss label e Change Acceldek NOS Change Deceldek No o lt Speed Units Units per sec DANGER Executing motion command with controller in Program or Run Mode may cause axis motion Safety State Unknown No Motion Connecti Execute Help Set Change Speed to Yes and enter a Speed of 70 The MCD instruction will selectively change the speed acceleration rate or deceleration rate of a move and or jog profile in process Click Execute You should see a clear increase in the rotational speed of the axis Remember we initially had configured the axis to jog at 2 revs s Now it s rotating at five times that speed and without having to write an application program e
48. ModuleF aults 16 0000 0041 Hex Decimal ay 4xis01 ModuleSyncF ault 0 Decimal i m AxisO1 TimerE ventF ault o Decimal AxisO1 Module ardwareF ault 0 Decimal Avis ModuleConnFautt O O O Decimal Asis01 ConnFormatFault 0 Decimal 4xis01 LocalModeF ault 0 Decimal Data Type DINT BOOL BOOL BOOL BOOL BOOL BOOL BOOL Control Sync Fault Several consecutive updates from the controller have been lost Module Connection Fault Communication with the controller has been lost 10 From the Motion Groups gt MotionGroup folder in the Controller Organizer select Axis01 2198 HO003 ERS DriveO1 AD Axis 1 192 168 1 24 Type AXIS_CIP_DRIVE Description Axis Fault ModuleF aut Module Faults ControlSyncFaut ModuleConnF autt Group Fault No Faults Motion Fault No Faults Initialization Fault No Faults Attribute Error No Faults Guard Fault No Faults Start Inhibited Not Inhibited Motor Catalog VPL 41001 M P Notice that both module faults are displayed in the quick view pane 11 From the Motion Groups gt MotionGroup folder in the Controller Organizer right click on Axis01 and selected Properties The Axis Properties window pops up 12 Navigate to the Faults amp Alarms page 72 of 142 13 14 15 16 Categories Faults and Alarms Log General E Motor Date Time amp Source Condition Action End State Model 12 11 2014 10 31 13 677 Faults Cleared Fault Log Rese
49. PIMA PD T TO E Og FOO E T a a ns _ 10 Set the controller to Run Mode 11 Open file Desktop Lab Files Tuning Techniques Lab Tuning mer by double clicking it to run the lab HMI 12 On the Replace Local System Directory dialog press the Yes button to continue 13 Click Application Settings FactoryTalk iew ME Station Current application Tuning mer Load Application Run Application Application Settings F3 Delete Log Files Terminal Settings Before Running 14 Select Device Shortcuts and hit the Enter button 119 of 142 Application Settings Backplane lt No Devices gt 17 Node USB CIP Port 1734 AENTRJB EtherNet Adapter 192 168 1 8 1732E IB8M8SOER 24 DC In M8 192 168 1 9 1732E OB8M8SR 24 DC Out M8 192 168 1 10 PowerFlex 527 192 168 1 26 2198 H003 ERS 192 168 1 25 2198 H003 ERS 1 192 168 1 24 Click the Close button 16 On the FactoryTalk View ME Station dialog press the Run Application button 17 On the HMI press the Clear Faults button to reset the system 120 of 142 Machine Status Machine Control L FAULTED Power Up Program Clear C Ready Faults C_ Safe Speed State ABORTED o swp 18 From the Controller Organizer navigate to the routine Main Task gt P02_Application gt R1 O ApplicationCode and open it ies Tasks 3 MainTask C8 P01_Machine a P02_Application Program Tags Ep ROO_Main 3 RO1_PowerUP B R02_Monito
50. Profile 21 Download the program to the controller at 192 168 1 12 1 Click Who Active button 2 Select controller from the Ethernet driver 3 Click Download button 4 On pop up dialog window click the Download button Path AB_ETHIP 1 192 168 1 12 v s 3 E Workstation BASEIMA T1BGVSY 4 ja Linx Gateways Ethernet gt ae AB_ETHIP 1 Ethernet 192 168 1 12 1769 L36ERM LOGIXS336ERM 1769 L36ERM A LOGD ij 192 168 1 2 1783 BMSO6TA Stratix 5700 1783 BMSO6TA Stratix 5700 192 168 1 24 2198 H003 ERS 2198 H003 ERS f 192 168 1 25 2198 H003 ERS 2198 H003 ERS 3 192 168 1 8 1734 AENTR EtherNet IP Adapter 1734 AENTR Ethernet Adapter et ox 4 oa P te ek el a f e b p el T Tt oe cme oF OP gee POI OO Dt nn net net dO PO OO OOD th ell 22 Once the program is downloaded set the controller to Run Mode 23 Open file Desktop Lab Files Coordinated Motion Lab CIP_XY_CoordMotion_Begin mer by double clicking it to run the lab HMI 24 Click Yes button on the Replace Local System Directory dialog 82 of 142 25 Click Application Settings Current application CIP_XY_CoordMotion_Begin mer Load Application Run Application Application Settings F3 Delete Log Files Before Running F5 Terminal Settings 26 Select Device Shortcuts and hit the Enter button Application Settings Device Shortcuts d 27 Verify that the controller at 192 168 1 12 IP a
51. S Direction 0 Kenai MASTER Ctrl Data JogSpdf2 206 IP Speed Units Units per sec 18 Change the Slave position to 10 in the MAM on rung 6 Leave the speed at 3 Motion Axis Move MAM Motion Axis Move EN Axis SLAVE Motion Control SLAWE Ctrl Mil MAM 2 DN S Move Type ER P Speed 3 0 PC ams Speed Units Units per MasterUnit v aa 19 Click Run in position _MAM2 to restart the trend 20 Press the Enable Home button on the HMI 95 of 142 21 22 23 24 20 26 27 Press the MDSC button on the HMI Press the MAM 2 button on the HMI After the Slave s move completes click the Stop button in the trend Press the Stop button on the HMI to stop the Master axis Again verify that the Slave s motion started when the Master s position was 5 Also check that the starting Slave s position was 0 and the final position is 10 Click in the middle of the Slave velocity curve green and verify that the value is 6 00 So our gear ratio for speed is 3 2 rev sec or 6 revs sec Now let s verify the total time of the Slave s move So solving for total time of the move we have 10 position units 6 position units sec 1 667 sec Click on the trend at the start and end of the Slave s move Note the time of each Then calculate the difference in time Is it approximately 1 667 seconds Execute and Verify a MAM in MDSC mode using MasterUnits We jus
52. Safety Safety only Motion only 8 Click OK to close the New Module dialog box Your 2198 H008 ERS2 servo drive appears in the Controller Organizer under the Ethernet controller in the I O Configuration folder E 610 Configuration 1756 Backplane 1756 410 ff 0 1756 L735 STO_Multiplex 2 1 1756 L75P STO_Multiplex Partner 2 1756 EN3TR EN3TR_Drives Eg Ethernet ffl 2198 HO03 ERS2 Drive _01 fil 2198 HO03 ERS2 Drive_02 ffl 2198 HO03 ERS2 Drive_03 il 2198 HO03 ERS2 Drive _04 ffl 2198 HO03 ERS2 Drive _05 fl 2198 HO03 ERS2 Drive_06 fl 2198 HO03 ERS2 Drive_07 tl 2198 HO03 ERS2 Drive_08 ff 2198 HO03 ERS2 Drive_09 4 2198 H003 ERS2 Drive_10 fl 2198 HOO3 ERS Drive_11 JME 198 HO08 ERS2 UM_CIP Drive n 1756 EN3TR EN3TR_Drives 3 1756 EN3TR EN3TR_Safety 9 Right click the drive you just created in the Controller Organizer and choose Properties The Module Properties dialog box appears 10 Click the Safety tab 132 of 142 EN Module Properties EN3TR_Drives 2198 H008 ERS2 2 1 General Connection Safety Time Sync Module Info Internet Protocol Port Configuration Network Associated Axes Po KIK Connection Requested Packet Connection Reaction Max Observed Type Interval S i Time Limit ms Network Delay ms TEN Advanced Configuration Ownership Reset Ownership Configuration Signature The connection between the owner and th
53. Start calculates motor parameters H Actions tart test when ready Drive Parameters Parameter List Status Faults amp Alarms Tag Motor Stator Resistance 1 49 Ohms Motor Stator Leakage Reactance 44 9 Ohms Test State Ready Model Parameters Current Test Results Motor Rotor Leakage Reactance 44 9 Ohms Motor Flux Current 0 066 Amps Rated Slip Speed 19 55 RPM Axis State Stopped Safety State Unknown No Motion Connection Manual Tune Cancel Use the Motor Analvzer tool to identifv the model for motors that have the data source set to Nameplate Datasheet For all other motor data source confiaurations this test is not applicable The Motor Analyzer dialog box applies for PowerFlex drives and supports Induction and Permanent Motor types The Motor Analvzer dialoa box contains a number of tests that can be executed each contained within separate tabs on the Motor Analvzer dialoa box Each of the tests is similar in that thev each consist of a Start a Stoo an Information and an Accent Test Result control Test Results disolav an output of test execution 12 Saveyour project Common Faults Encountered While Tuning In this section we will review some of the more common faults that are encountered during an Autotune 1 Autotune Travel Limit Speed or Torque set to zero x Enter non zero valeus for Travel Limit Speed and Torque before A executing tuning procedure Check to make sure that
54. State Safety State Manual Ture Cancel Help For the beta early version of the PF527 in this lab only Frequency Control has been tested At release there will be an encoder card available for closed loop Velocity and Position control for the PF 527 Incremental A quad B with Z channel z channel marker pulse encoder support 4 Navigate to the Motor page 36 of 142 gt Axis Properties AxisO3 Categories General Motor Device Specification Motor u Model Data Source Nameplate Datasheet Parameters Analyzer Scaling Hookup Tests Polarity Planner Frequency Control Nameplate Datasheet Phase to Phase parameters Actions Drive Parameters Rated Power 0 025 kw Pole Count Parameter List Rated Voltage 230 0 Volts RMS Rated Frequency Hertz Status Baie amp Alani Rated Speed 1600 0 RPM Tag Rated Current fo 22 Amps AMS atalog Number Change Catalog Motor Overload Limit fi 00 0 Rated Axis State Safety State Manual Tune Cancel Help 1 For the Data Source select Nameplate Datasheet 2 For Motor Type select Rotary Induction 3 Enter the following motor data Rated Power 0 025 kW Rated Voltage 230 Volts RMS Rated Speed 1600 RPM Rated Current 0 22 Amps Pole Count 4 Rated Frequency 60 Hz Motor Overload Limit 100 Rated Data Source options for K5500 and PF527 Nameplate Datasheet Mo
55. T used in these advanced motion topics 74 of 142 Appendix A Logix Coordinated Motion In this lab we will create a coordinate system in the Motion Group and demonstrate the Logix Coordinated Motion instructions The multi axis coordinated motion instructions are used to perform linear and circular moves in single and multidimensional spaces A Cartesian coordinate system in Logix can include one two or three axis Single Axis Cartesian System 2 Axis Cartesian System 3 Axis Cartesian System Three Dimensional Point in Space Let s look at an example of a two axis Cartesian system application Most motion applications require multiple motion moves to be executed in succession A gluing machine is a typical example The simulated gluing machine will apply a glue bead following the tool path shown below Glue Machine This application can be accomplished with the following e 3 MCLM Instructions e 2 MCCM Instructions e A simple ladder based state machine Creating the Coordinate System 1 Open file Desktop Lab Files Coordinated Motion Lab CIP_XY_CoordMotion_Begin ACD 2 Inthe Controller Organizer note that under the Motion Group MG two CIP Drive Axes have been created and configured 75 of 142 5 Motion Groups 9 23 MG Ll X_AXIS MD Y_AXIS E Ungrouped Axes At this point we could program basic motion instructions such as MAJ MAM MAG etc To program coordinated motion however we need to create a
56. Tune DANGER Starting tuning Model Type Basic a A procedure with controller in Analyzer iss Start stop Program or Run Mode causes Motor Feedback R P y Medium axis motion z esponse Sealing Tune Status Ready Hookup Tests Load ade Compliant Loop Parameters Tuned Coupling Palit _ foe ferme Tuned onda 7 iin TUE PositionLoopBandwidth 1852124 m i Pa sition Integrator B a nd width E PositionintegratorBand a sy ie Velocity Integrator Bandwidth xi ompliance 7 Friction i A FEE Advanced Compensation Load Parameters Tuned Observer F Acceleration Feedfonvard Position Loop Name Velocity Loop Vv 7 orgue Low Pass Filter MaximumAcceleration 9317 798 TB Acceleration Loop MaximunDeceleration 9317798 rev Torque Current Lo M Measure Inertia using Tune Profile Systeminertia 0 013809751 v Planner Motor withLoad C Uncoupled Motor e Reset melys f Homing ccept fiurne UES Actions Travel 500 i w Drive Parameters Limit Parameter List Speed Boo 8 e rev s H Status Torque 100 0 Rated Faults amp Alarms z i 5 i gt Direction Forward Uni directional e Manual Tune Cancel Help Note If the following window appears click yes unless you are specifically modifying one of the dependent attributes and do not want to reconfigure all of the tuning parameters Always reconfirm the tuning parameters if this box appears Logix Designer xi You have change
57. ain objectives include e Controlling the Knife s Linear Velocity within the Cut Region to match the machines Feed Rate e Reorienting the Rotary Knife during the Make Up Move to appropriately cut the Product In this lab a 2 segment Cam Profile is used to control the orientation of the Rotary Knife based on the Master Axis A 2 segment 100 of 142 Cam Profile simply refers to a single Cam Profile that consists of two parts which are referenced as the Cut Region and the Make Up Move While the Knife Blade is in the Cut Region the inverse kinematics that are equations that describes the Knifes linear velocity relative to the angular velocity are used to maintain a constant linear velocity parallel to the Conveyor As the Knife Blade exits the Cut Region the Make Up Move reorients the Knife to cut the Product at the specific Cut Length In order for the Knife Velocity to equal the Feed Rate through the Cut Region the Cam Profile must account for the Knifes Kinematics illustrated below cos 2m6 n 4 7 2mw Tp 2TUW gt Figure 2 Rotary Knife Kinematics This may sound complicated but it is fairly straight forward It is well understood that the linear velocity of the Knife Blade is equal to 2T where is the radius of the knife cm and the angular velocity rev s Thus by geometric identities the Knife Velocity is equal to 2T COS 2T10 T1 4 where 8 is the angular orientation revs The zero angular orientation is shown in Figure 2 a
58. al Utilization Motion Logix Controller 40 3 Logix Controller Task I O Cycle 93 4 Task I O Cycle Connection I O Cycle 59 1 Communications 41 8 Ethernet Media 6 1 cence Imagine that you just discovered that Axis _01 and Axis 02 require a faster update rate to keep up with a very demanding application Try setting the Base Update Rate to 1 0ms and see what happens to the system estimated utilization You may have noticed warning symbols indicating that task overlaps may occur or that too much Logix processing is being spent on Motion Planning This would impact other tasks within the controller For this application let s look at a few other axes though Axis _03 through Axis_07 are servo applications that can be run at a slower rate than our high performance application and Axis_08 through Axis_11 are simply running conveyors and don t need to update fast at all Try to optimize the Update Rates and group schedules to maintain tight control over Axis_01 and Axis_02 without jeopardizing any of the key utilization metrics An example configuration is shown below 140 of 142 Ge Axis Schedule Panel Update Period and Schedule Base 1 0 ms in 0 5 increments Axis 02 Estimated Utilization Motion Logix Controller Task I O Cycle Connection I O Cycle Communications Ethernet Media IAB Info 28 7 Vo 61 8 64 1 21 5 3 1 lol x Alternate 1 Alternate 2 3 0
59. avel se Drive Parameters Limit Parameter List Speed revs s Le Status Rated Torque Faults amp Alarms nc Ree gt Direction Forward Uni directional Manual Tune Cancel Apply Help Set the Application Type to Tracking the Travel Limit to 400 revs and the Speed to 25 revs s Tune Status should display Ready Click Apply and press start to initiate the Autotune Once the Start button has been pressed the axis will immediately begin to move The Autotune window opens Logix Designer Autotune xi Test State Executing ait for command to complete after axis motion for errors if command fails You should hear the servo enable for as long as it takes to reach the configured speed and then decelerate This is a very quick process usually less than one second When the Autotune completes the Test State will change from Executing to Success cc x Test State Success est complete stop e Click OK 50 of 142 6 Your Tune Status should display Success gt Axis Properties AxisO2Z Categories General Peet une Control Loop by Measuring Load Characteristics Motor Model ries Tracking oo Analyzer L i Motor Feedback TSE Medium Load Roia Coupling Rigid ns Response Scaling Hookup Tests Polarity Customize Gains to Tune Load Position Integrator Bandwidth F SES IV Velocity Integrator Bandwidth Compliance
60. ay consists of a tree of folders that contain all of the information about the programs and data in the current controller project The default main folders in this tree are Controller Project Name Contains the controller scoped tags controller fault handler and the power up handler Tasks Tasks are shown in this folder Each task contains its own programs with routines and program scoped tags The routines can be ladder diagrams sequential function chart function block diagram and or structured text Motion Groups Underneath the Motion Groups folder you will find one group of axes which contains individual axes as well as coordinate systems In addition you will find Ungrouped Axes which are axes that have yet to be assigned to any particular group You can assign these axes to the motion group via the Axis Assignment tab of the Motion Group Properties window Add On Instructions Add On Instructions are instructions that you define or they can be provided to you by someone else Once defined in the project they are similar to the built in instructions already in the Logix controllers An Add On Instruction allows you to encapsulate your most commonly used logic as sets of instructions They are useful for commonly used instructions in your projects and to promote consistency across the projects Trends Trends are shown in this folder Data Types Shows predefined and user defined data types User defined data is
61. bedded dual EtherNet IP and Intearated Safetv all included The only option card required for the PF527 is an encoder card When in the I O tree with a safetv controller the Safety tab is available to configure your safety connection See below N Module Properties EN2TR PowerFlex 527 STO CIP Safety 1 1 General Connection Safety Time Sync Module Info Internet Protocol Port Configuration Network Associated Axes Po4 gt Connection Requested Packet Connection Reaction Max Observed E Type Interval RPI ms Time Limit ms Network Delay ms Sieve oao o _Advanced _ Safety Output 20 0 Configuration Ownership Reset Uwnership Configuration Signature d03a_ecd 9 20 50 4M Status Offline Cancel See the Advanced Safety Lab in the Appendix for more information about Integrated Network Safety 3 Click Create The New Module window will appear 4 On the General tab 26 of 142 DE New Module J E x General Connection Time Syne Module Info Internet Protocol Port Configuration Network Associated Axes Power Di_4 gt Type PowerFlex 527 STO CIP Safety PowerFlex 527 AC Drive CIP Motion Safe Torq vendor Allen Bradley Parent Local Ethernet Address Name Drived3 Private Network 192 168 1 26 Description a C IP Address Z C Host Name Change Electronic Keying Compatible Module Module Definition Revision Oa
62. created in this folder V O Configuration Contains the information about the hardware configuration of this controller project It holds a hierarchy of modules with which the controller is configured to communicate 19 of 142 4 Select Controller Properties from the Edit menu The Controller Properties window opens 6 Controller Properties Integ_Motion K5500 PF527_ Base Integ_Motion_K5500_PF527_Base 5 Select the General Tab Notice that the controller type has been selected for you already With the 1769 L36ERM CompactLogix controller that we are using in this hardware setup the slot and chassis type cannot be changed by the user Note f your controller hardware is different than specified please consult with your lab instructor to make the appropriate changes 6 Select the Date Time tab 20 of 142 amp Controller Properties Integ_Motion_K5500_PF527_Base i iol x Nonvolatile Memory Memory Internet Protocol Port Configuration Network Security Alarm Log General Major Faults Minor Faults Date Time Advanced SFCExecution Project i The Date and Time displayed here is Controller local time not workstation local time Use these fields to configure Time attnbutes of the Controller Set Date lime and Zore tram Workstatior A U Time Synchronize ER A DANGER If time synchronization is M Enable Time Synchronization disabled online active axes in any controller in
63. cription Uses Performance Levels to define the risk of random dangerous failure for simple devices including electromechanical components and machine systems Uses Safety Integrity Levels to define the risk of random dangerous failure for complex electronic devices such as Programmable Automation Controllers and machine systems Defines the expected behavior for various safety functions that can be performed by variable frequency drives and servo drives Uses Safety Integrity Levels to define the risk of random dangerous failure for any scale of electronic control system from small machines to very complex processes Kinetix 5500 Hardwired PLd SILCL 2 Check SILCL 2 Kinetix 5500 Networked PLe SILCL 3 Check SILCL 3 Certification to these standards implies that the drive can be used as a subsystem in a safety function up to the limit shown in the table These certifications alone do not guarantee that the drive is implemented in the proper way There are many aspects of the Machine Safety Lifecycle that are not covered in this tutorial that influence the overall Performance Level or Safety Integrity Level of a machine including the e Risk Assessment e Functional Requirements e Mitigation Design amp Verification e Installation amp Validation e Change Management amp Improvements 125 of 142 amp Guidelines 5 Manage Change 1 Risk amp Improve y Assessment a
64. culates the position velocity regulator gains 1 Ifthe Properties window is not open right click on Axis02 and select Properties The Axis Properties window opens 2 Navigate to the Autotune page 49 of 142 Axis Properties AxisO2 Categories al tune Control Loop by Measuring Load Characteristics pi General E Motor Application Perform Tune DANGER Starting tuning Model Type Tracking nd A procedure with controller in Analyzer is Start Stop Program or Run Mode causes Motor Feedback Aectoree Medium axis motion Sealing i Tune Status Hookup Tests SE Rigid Loop Parameters Tuned Plat ede name O enen Tune unt Ee ih hye BONETO LUNE PositionLoopBandwidth 1652124 Hz E Load Position Integrator Bandwidth PosttionintegratorBand 00 se E p Pa i Velocity Integrator Bandwidth velocityLoopBandwidth 74 06496 Hz zi Compliance Ez Friction iV Velocity Feedtonvard Advanced Compensation a F Load Parameters Tuned Le v Acce PTA ior rey fe Wart x eee tox seen cece Jeane enen Tuned unt _ Velocity Loop Z Torque Low Pass Filter MaximumAcceleration 10381 242 rev MaximumDeceleration 10381 242 ss rew Acceleration Loop Systeminertia 0 012868189 W x Torque Current Lo V Measure Inertia using Tune Profile Planner Motor withLoad e Uncoupled Motor e Accept Tuned Values E Homing Actions Tr
65. d a parameter which affects other attributes Do you want to automatically update all dependent attributes Refer to Help For a list of dependent attributes 4 Choose the Load gt Observer category and verify the Load Observer Configuration is set to Load Observer with Velocity Estimate Make any necessary changes and click Apply 117 of 142 Axis Properties AXIS 01 10l x Categories General ri E Motor Model Configuration Load Observer with Velocity Estimate Parameters Analyzer Bandwidth 296 33984 Hertz fem Motor Feedback Scaling Hookup Tests Polarity Autotune Load Backlash Compliance Friction Integrator Bandwidth 0 0 Hertz Position Loop Velocity Loop H Acceleration Loop Make note of the Load Observer Bandwidth value 5 Choose the Load category verify the Load Ratio is set to 0 Make any necessary changes and click Apply Axis Properties AXIS 01 E lol x Categories Characteristics of Motor Load General a A ie onal Load Inertia Mass Analyzer Load Coupling Compliant sed MEREN MV Use Load Ratio Scaling Hookup Tests Polarity Motor Inertia 0 000011 Kg m 2 Autotune iS Total Inertia Backlash Compliance Friction Inertia Mass Compensation eee Systeri nenia 0013809751 Rated Rev s 2 mee aks System Acceleration 7241 2603 R A 5 Velocity Loop i ev s 2 100 Rated Acceleration Loop Torque Current L
66. ddress is selected as shown below Click OK 83 of 142 Edit ShortCuts Backplane lt No Devices gt _ 17 Node USB CIP Port 1734 AENTRJB EtherNet Adapter 192 168 1 8 1732EB8M8SOER 24 DC In M8 192 168 1 9 1732E OB8M8SR 24 DC Out M8 192 168 1 10 PowerFlex 527 192 168 1 26 2198 H003 ERS 192 168 1 25 2198 H003 ERS 1 192 168 1 24 28 Click the Close button Application Settings Device Shortcuts 29 Click Run Application button on the FactoryTalk View ME Station dialog 30 On the HMI press the Clear Faults button to reset the system 84 of 142 Machine Status Machine Control E FAULTED Power Up Program Clear _ Ready Faults _ Safe Speed State ABORTED Stop 31 Now press the Start button to ready the system for motion The Machine State should transition from Stopped to Idle Machine Status Machine Control C _ Ready _ Safe Speed State STOPPED Stop State IDLE 32 Press the Start button again to start executing the motion application code Both motors in the demo box should now be rotating per the program motion instructions 33 From the Controller Organizer expand the Trends folder and open the trend XY_ Plot by double clicking 5 6 Trends Lh XY Plot C 5 6 YO Configuration f 1769 Bus 34 Click Run to begin trending the X and Y axes Al Trend XY_Trend fs foe Logging Stopped Periodic 10 ms Capture C of 8 50
67. decreased before continuing with the following steps 4 Ifa resonance is above the 1 2mDrive Model Time Constant Hz and a high pitch sound is present then a mechanical resonance is present and you must set the Torque Notch Filter Frequency to the identified audible frequency 123 of 142 Axis Properties AXIS_01 E Ioj xj Categories Compliance Compensation General a El Motor Model Torque Low Pass Filter Bandwidth Analyzer Torque Notch Filter Frequency Motor Feedback A ie Torque Lag Filter Gain Scaling Hookup Tests Torque Lag Filter Bandwidth 0 0 Hertz Polarity Autotune Load ees m Backlash Compliance Friction Observer Pasition Loop Velocity Loop Acceleration Loop Torque Current Lo Planner Homing Actions Drive Parameters Parameter List Status Faults amp Alarms r b Manual Tune Cancel Help In 95 of the application utilizing the default tuning gains and setting the Torque Notch Filter Frequency will provide adequate performance In the remainder of the applications it may necessary to compensate for more complicated mechanics multiple resonant frequencies or reduce the tracking error These situations are beyond the scope of this lab You may discuss these situations with the lab instructor or consult you technical specialist as the situation arises This concludes this lab Appendix E Network CIP Safety The goal of this s
68. e 2198 Hxxx ERS2 drive is based on the following e Servo drive catalog number must be 2198 Hxxx ERS2 networked Servo drive safety network number e GuardLogix slot number e GuardLogix safety network number e Path from the GuardLogix controller to the 2198 Hxxx ERS2 drive e Configuration signature If any differences are detected the connection between the GuardLogix controller and the 2198 Hxxx ERS2 drive is lost and the yellow yield icon appears in the controller project tree after you download the program 11 Click Advanced button The Advanced Connection Reaction Time Limit Configuration dialog box appears Advanced Connection Reaction Time Limit Configuration Input Requested Packet Interval RPI ho ms 6 500 Timeout Multiplier 2a 1 4 Network Delay Multiplier 200 H 10 600 Connection Reaction Time Limit 40 1 mg M Output Requested Packet Interval RPI 20 ms Safety Task Period Timeout Multiplier 2 1 4 Network Delay Multiplier 200 10 600 Connection Reaction Time Limit 60 0 ms Cancel Help 133 of 142 Analyze each safety channel to determine the appropriate settings The smallest Inout RPI allowed is 6ms Selecting small RPI values consumes network bandwidth and can cause nuisance trips because other devices cannot get access to the network 12 Click OK to close the Advanced Connection Reaction Time Limit Configuration dialog box For more informat
69. e_ fly 2198 HOO3 ERS2 Drive 1 2198 HO03 ERS2 Drive Launch RSNetwors Sla 2198 HOO3 ERS Drive _ f 1756 EN3TR EN3TR_Dr E 3 1756 EN3TR EN3STR_Safety o B Ethernet S J 1734 AENTR BAENTR_ Print gt PrintTO 3 Sint Chas The Select Module Type dialog appears ma Paste Ctrl V Crass Reference Ctrl E Audit Network Properties Alt Enter 128 of 142 3 By using the filters check Motion and Allen Bradley and select your 2198 H008 ERS2 servo drive i Catalog Module Discovery Favorites Enfer Search Text for Module Type Clear Filters Module Type Category Filters ar MDI to EtherNet IP Allen Bradley Motion J Cognex Corporation Motor Overload O Endress Hauser MotorO verload O FANUC CORPORATION hd aber barker ECL CARI Daksis Ammen Hide Filters 2 Module Type endor Filters Joonan Catalog Number 2198 H003 ER 2 Kinetis 5500 14 195 528 Volt CIP Safe Torque Off Dr Allen Bradley Drive Motion Safet 2198 H008 ERS Kinetix 5500 2 54 195 528 Volt Safe Torque Off Drive Allen Bradley Drive Motion 2198 HO008 ERS2 Kinetix 5500 2 54 196 528 Volt CIP Safe Torque Off Allen Bradley Drive Motion Safet 2198 HO15 ERS Kinetix 5500 64 195 528 Volt Safe Torque Off Drive Allen Bradley Drive Motion 2198 HO15 ERS2 Kinetix 5500 64 195 528 Volt CIP Safe Torque Off Dr Allen Bradley Drive Motion Safet 2198 H025
70. eak performance However there are Basic Cam Designs that can be incorporated into the program that are quite useful This lab focuses on the Basic Cam Designs that requires an understanding of motion control but does not require a motion control expert Based on the labs time constraints if you struggle to fully grasp the in depth discussion continue to progress through the content The lab is structured to allow you to complete the lab and observe the results without fully understanding the in depth discussion 99 of 142 Overview of the Example Machine The purpose of the example machine shown in Figure 1 is to cut Product at the specific Cut Length The topology of the machine includes two axes of motion The first axis controls a Conveyor referenced as the Master Axis that carries Product at a constant speed The second axis controls a Rotary Knife that cuts the Product in the middle of the Cut Region at the Bottom Dead Center at the specific Cut Length Master Axis Wo Motor 2 Rotary Knife Feed Rate J Cut Region w n Motor 1 Conveyor Knifes Velocity Cut Length Figure 1 Machine Topology The radius of the Conveyors spindles are 5cm and Rotary Knife blade is 15cm The Product Cut Length is 200cm It can be assumed that the load torque of the Rotary Knife is much greater than the torque generated during the cutting operation Thus the torque is primarily dependent on the Cam Profile and the Feed Rate The goal is
71. ection is to provide an overview of Networked Safety for servo drives enabled by CIP Safety During this section you will Learn about the basic safety standards applied to servo drives and variable frequency drives Examine the difference between various methods for Safe Torque Off STO See how to configure a Kinetix 5500 drive with Networked Safety Review and write ladder logic that could be used to execute STO in a Kinetix 5500 drive Safety Basics Variable frequency drives servo drives and motors in general are covered by a variety of safety standards These standards fit into legal frameworks in different ways depending on the region Some of the standards are written around components such as a drive and others are written around the entire machine The drives made by Rockwell Automation that support Functional Safety are all certified by an independent third party T V Rheinland to the following product standards 124 of 142 Standard ISO 13849 1 IEC 60261 IEC 61800 5 2 IEC 61508 Title Safety of Machinery Safetyrelated Parts of Control Systems Part 1 General principles for design Safety of Machinery Functional safety of safetyrelated electrical electronic and programmable electronic control systems Adjustable speed electrical power drive systems Part 5 2 Safety Requirements Functional Functional safety of electrical electronic programm able electronic safety related systems Des
72. eeeeeeees 92 Execute and Verify a MAM in MDSC mode using MasterUnits ccc ccccccceeeeeeeeeeeeeeeeeeeeaeeeeeeeeaeeeeeeeenas 96 Appendix C PCAM Rotary Knife Application Lab cccccccsesccccceeeecccesececceeseeeceaeeeceeusceeseaseeesseseeessaaeees 99 Overview of the Example Machine cccceccccccceeccseeseeeeeeeeeeeaeeeseceeeeeseseeeeeeeeeeeessseeaseceeeeessaaeaeeeeeeeeseaaas 100 Review Code and Execute a Cam Profile cccccceccccccceccceeeseeeeeeeeeeaaeesceeeeeeeeeaaeeeeeeeseeeeeaeaceeeeeseseesaaaeees 103 Designing a Basic Cam Table ccccccccccseeseceeeeseeseeeeeeseeeeeeeseeeeeeeeeeseeeeeeesseaeeeeeessaaeeeeesseaeeeeesssegeeeeeeeas 109 Appendix D T nmg Techniques Labisse a a a a a a 114 Configuring the Default Tuning Configuration en0annnennennneesennnnnosrnnnnnssnnrneosrnrnrnnrnnrrensnnrrresnnnrrensenenee 116 Identify and Compensate for Mechanical Resonances cccccsseeeeeeecaeeeeeeeecseeseceeesaeeeeeeeesseaeeeeessaaaeeeees 123 Appendix E Network CIP Safety ssecss e cs2ssecancscaveunscetsenevas teeess airida aiai 124 Configure a Network Safety Drive ccccccccccccsssseceeccaeeeeceeeceeesececeseeaeceeseeeaeeeseseaaueeeesseaaeeeeessaageeeessaaaaes 128 Wie Prog an OC OO ria a a a a A e E N 134 Appendix F Multiplexing Introduction Using Multiplexing to Optimize Performance AB INIO eve reer ener ae ene eee Ceara 5 of 142 Before you begin Prereq
73. een LINK indicator should be flashing green indicating network activity LINK2 indicator should be flashing green indicating network activity 10 Verify that the K5500 drives are ready Module light should be solid green Network light should be solid green Port status indicators may be flashing green indicating network traffic The Kinetix 5500 and PF527 drives should both display STOPPED in all capital letters at the top of their displays If any of the above steps did not work as described please consult your lab instructor Note With the PF527 Beta units the LEDs are not behaving properly This issue has already been fixed If your drive says STOPPED you are successfully connected 45 of 142 11 Open the Controller Properties Edit Menu and navigate to the Date Time tab Controller Properties Integ_Motion_K5500_PF527_ Base s Df x Nonvolatile Memory Memory Intemet Protocol Port Configuration Network Security Alarm Log General Major Faults Minor Faults Date Time Advanced SFCExecution Project i The Date and Time displayed here ts Controller local time not workstation local time Use these fields to configure Time attributes of the Controller Set Date Time and Zone from Workstation Date and Time 9 15 2014 10 12 35 PM Change Date and Time e Time Zone UTC 00 00 vie F Adjust for Daylight Saving 01 00 Time Synchronize J DANGER I
74. ess 57 Stop the Axis Using a Motion Direct Command cecccccccseeeceeecaeeeeeeecaeeseeeeesaeeeeeeeeeeeeeeeessaaeeeesesaaeeeees 58 Lab 4 Adding an HMI Estimated Time 15 Minutes ccccccecccccecceseeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeesseeeeeeeeeas 60 Switch to the AMI APOC AON nuiir mors erect a aka a TE a ettoamuhateuieurs 60 Face Dlate Opera ON enen T trees Seeeess a en eee eS 61 Lab 5 Troubleshooting Techniques Estimated Time 10 Minutes cccccseeccecseeeeeeeeeeeeseeeeeeeseeeeeeeas 69 Diagnostic Capabilities of Logix Designer cccecsccccccsessecececeeeeeeeeccaeueeeeeeaeseeeessaaaeeeeesssageeeesssaageeeeesaas 69 APPENDIX 7 Ophonal tases ails teats ecard cea chaste Seb cece canse a des 74 Appendix Logix Coordinated MOuOM xcxtwti cies Nn N 75 Creating ine Coordinate Syste Mirne eon e sl cele eacde eeu eels 75 Add a Motion Coordinated Linear Move MCLM and a Motion Coordinated Circular Move MCCM 78 Execute the Coordinated Motion Profile ccccccssccceeccceeeesseeceeeeeeeeeeeseeeeeeeeeseeeasaeeeeeeesssaaagseeeseeessanaaaaaes 82 Appendix B Master Driven Speed Control MDAC Lab cccceecccceeceseeeeeeseaeeeeeeeesaeeeeeeeesaaaeeeeesaaaeeeees 86 Execute the MAM Instruction in Classic Mode ccccccccsssssseeeeeeeeeeeeeseeeeeeeeeeeaeaceeeeeeesseaaaseeeeeeeesnaaaaasaes 86 Execute and Verify a MAM in MDSC mode using Units per MasterUniit ee cccceeeeeeeeeeeeeee
75. eying Compatible Module Connection Motion and Safety Power Structure Motion and Safety Motion only IY Verify Power Rating on Ca Safety onl Cancel Help Note When Safety appears in the Connection mode networked safety is implied 6 Click OK on the Module Definition dialog 7 The Safety Network Number SNN field populates automatically when the Connection mode includes a networked Motion and Safety or Safety Only connection Safety Network 3C70_04FD_3AE3 parade 3C70_04FD_3A4E3 ere 5 12 2014 6 15 04 547 PM For a detailed explanation of the safety network number refer to the GuardLogix Controller Systems Safety Reference Manual publication 1756 RMO099 130 of 142 Connection Mode Motion only Motion and Safety Safety only Controller Needed ControlLogix 1756L7x GuardLogix 1756L7xS or CompactLogix 5370 GuardLogix 1756 L7xS GuardLogix 1756 L7xS Description Drive Cat No 2198 Hxxx ERS Only hardwired safe torque off connections are possible N A N A 131 of 142 Description Drive Cat No 2198 Hxxx ERS2 Motion is managed by this controller Safety is managed by another controller that has a Safety only connection to the drive Motion and Safety are managed by this controller Safety is managed by this controller Motion is managed by another controller that has a Motion only connection to the drive Motion and
76. f time synchronization is disabled online active axes in any controller in this chassis or any other ls the system time master synchronized device may experience z unexpected motion Safety controllers may 2 ls a synchronized time slave fault if no other time master exists in the Duplicate CST master detected local chassis O CST Mastership disabled O No CST master Advanced V Enable Time Synchronization App lu Click the Set Date Time and Zone from Workstation to set the current date and time Click OK 12 Save your project again and continue on to Lab 2 You may be prompted to upload the tags from the controller either selection will work Lab 2 Axis Commissioning Hookup Test and Autotune Estimated Time 10 Minutes This lab is built on the project file from Lab 1 In this lab we will introduce you to the process of commissioning a servo axis by performing the following Axis properties Hookup Tests Axis properties Autotune Review common commissioning errors that may occur during an Autotune Axis Hookup Tests In this section of the lab you will use Logix Designer to access the Axis Properties to run the Motor and Feedback Hookup Test The Motor and Feedback test applies motion to the motor allowing the user to verify the power and feedback connections between the drive and motor This test also establishes the forward or positive direction of axis motion 46 of 142 1 You s
77. g network activity LINK2 indicator should be flashing green indicating network activity 11 Verify that the Kinetix 5500 drives are ready Module light 7 should be solid green Network light 8 should be solid green Port status indicators 4 and 5 may be flashing green indicating network traffic Note With the PF527 Beta units the LEDs are not behaving properly This issue has already been fixed If your drive says STOPPED you are successfully connected 12 The Kinetix 5500 and PF527 drives should read STOPPED in all capital letters across their display screen lt may take up to one minute for the drives to reach these states If any of the above steps did not work as described please consult your lab instructor Open and Run the HMI Application 1 Minimize Logix Designer so that the HMI screen on the desktop can be seen 2 Click Start The Lab on the warning screen of the HMI to load the Startup screen 3 The Startup screen should initially be displayed 13 of 142 Toggles the machine between Program AUTO and Operator MANUAL modes Indicators provide Machine Status Machine Control info about the a ae overall machine E ok Program Esen gt status C Ready C SafeSpeed State STOPPED Stop Launches the axis Axis01 Indicates the current While in Program When visible clears Faceplate screens gt state of the machine mode the Start and any faults detected by p
78. gt Machine Status Machine Control info about the TEAT a overall machine i ok Program Start status gt C Ready C SafeSpeed State STOPPED Stop Launches the axis Axis01 Indicates the current While in Program When visible clears Faceplate screens gt state of the machine mode the Start and any faults detected by provides status info Refer to the state Stop function controls the machine Axis02 di th hi and allows manual lagram e machine control E ee Exits the runtime aunches the Launches the Alarm History window and closes ce R ae Equipment Status the application screen logs fault info screen displays key axis values Launches the State Diagram screen provides an overview of the state machine includes a current amp previous state State Alarm Equipment Exit Diagram History Status The Startup screen provides Machine Status and Control plus it allows navigation to all other screens Take a moment to familiarize yourself with the Startup screen before moving on to the next section It may look a little different depending on the status of the machine 4 While in Program mode the Machine operates based on the following state diagram 60 of 142 ee ee See nk f GED EN ss RESETTING Enabled PARTIAN STARTING oo RUNNING nees ma Se ih hy ABORTING CLEAR ABORTED The states with a dashed outline indicate a transitional state
79. h a speed of 3 0 Units per MasterUnit The Master on the left will be jogging at 1 unit sec 1rev sec The MAM will execute when the rung goes from false to true and the Master passes the Lock Position of 5 and will execute in a Lock Direction of Position Forward Only Close any open Trends Open the trend called position MAM2 Click Run to start collecting data in the trend Press the Enable Home button on the HMI to enable the drives and set both axes to position 0 You will have less than 5 seconds to complete step 7 once you complete step 6 This is because after 5 seconds the Master axis will have passed the 5 revs position where the Slave move is to be triggered Press the MDSC button on the HMI You should see the MDAC instruction on rung 2 go IP in process 93 of 142 7 Press the MAM 2 button on the HMI 8 After the Slave axis right motor move completes click the Stop button in the trend 9 Press the Stop button on the HMI to stop the Master axis 10 Use the scroll back in time buttons until you see the Slave s move in the trend 11 Click on the left edge of the green velocity curve Verify that the Active Value Bar shows that the Slave s motion started when the Master s position was 5 Verify that the starting Slave s position was 0 E SLAVE CommandPosition 20 00 position_MAM2 Wednesday April 30 2014 20 00 0 03 SLAVE ey Re 00 Te 100 00 SSeS CommandAcceleration 0 00 0 00 ne N ho tn h
80. he POINT I O 1734 IB8 input INO is set to the right 1 to load the User Defined Cam Table Cam Profile 2 Manually align the white strip on the load disk of the right hand motor Knife AXIS_02 to face toward you This represents the knife blade and where the product is cut We want to monitor the machine performance in a trend Under Trends in the Controller Organizer double click on the trend Machine_Performance to open it Trends fe Machine Performance deems 5 6 VO Configuration gt 1769 Bus Click Run to start collecting data in the trend On the HMI press the Start button to ready the system for motion The Machine State should transition from Stopped to Idle Machine Status Machine Control provam SR sae __ Stop _ Safe Speed State STOPPED State IDLE Press the Start button again to start executing the motion application code The Rotary Knife is reoriented to the beginning of the Cut Region the axes are homed the Conveyor is started and the Rotary Knife begins cutting the Product Now go back to the Trend screen Once the Rotary Knife has run several cycles you can stop collecting data by pressing the Stop button Press the Stop button on the HMI to stop motion The machine performance is shown below 112 of 142 Run Stop Errors Log Logging Stopped Periodic 1 ms Capture fi 4 of 1 TT aXxIS_01 ActualPosition 1 812 80 Machine_Performance Friday May 09 2014 1 42 40 PM
81. he three input devices are in this routine The E Stop code is shown here There is extensive commentary in the rung descriptions that helps explain each portion of the code 134 of 142 DCS Dual Channel Input Stop DES Zone1_EStop O1 gt Safety Function EMERGENCY STOP Input Type EQUIVALENT ACTIVE HIGH FP Discrepancy Time Msec 500 Restart Type AUTOMATIC Cold Start Type AUTOMATIC Channel 4 Zone1_EStop_4 lt AENTR_1 1 1 Pt00Data 0 Channel B Zone1_EStop_B lt AENTR_1 1 1 Pt01 Data 0 Input Status AENTR_1 1 CombinedinputStatus 0 Reset Cmd_Zone1_FaulttReset lt AENTR_1 1 1 Pt06Data 0 Zone1_EStop 01 Sts_Zone1_EStop_InputOK ee Review the Logic routine These three rungs monitor the status of the inputs restart functionality and setting of the Output Enable bit This logic is quite simple functionally Immediate removal of power however there are more complex functions that can be developed as well Safety Input Interlock Rung This rung includes 3 safety device input interlocks with tag names Sts_ZoneName_DeviceName _InputOK through Sts_ZoneName_DeviceNamesd_InputOK that energize the Sts_ZoneName_InputsOK OTE instruction These interlocks tags can be driven by the individual safety device input logic routines provided in this toolkit The Sts_ZoneName_InputsOK tag is then included in the Output Enable Rung which drives the ROUT instruction Sts_Zone1_EStop_InputOK Sts_Zone1_LightCurtain_InputOK Sts_Zone
82. hould be Online with your controller 2 Before running the Motor and Feedback Hookup Test verify that the K5500 drives are ready Check the drive status Module light should be solid green Network light should be solid green Port status indicators may be flashing green indicating network traffic The Kinetix 5500 and PF527 drives should both display STOPPED in all capital letters at the top of their displays 3 Right click on AxisO2 and select Properties The Axis Properties window opens 4 Navigate to the Hookup Tests page Categories General Test Motor and Feedback Device Wiring Motor Model Motor and Feedback Motor Feedback Marker Motor Feedback Seen Test Distance 1 0 e revs Scaling Raa cel Start DANGER Starting test with controller in Polarity Program or Run Mode initiates axis motion Autotune E Load Test State Ready Backlash Compliance ressing Start initiates motion Friction atch motion direction during test Position Loop Velocity Loop Acceleration Loop Current Test Results T fC tL Faye ENSSAT AT Motor Feedback Polarity Normal H Planner Homing Actions Motor Polarity Normal Drive Parameters Parameter List Motion Polarity Normal Status Faults amp Alarms Accept Test Results Tag Manual Tune Cancel Help Enter a Test Distance of 7 0 revs This will provide enough axis travel to detect a mar
83. iagnostics gt Diversity Safety Message Producer to Consumer VO to Controller Controller to Controller Data Section Time Stamp Section Time Coordination Message a Consumer to Producer ck Consumer Time 7 CR 1 C Byte Value Syte 2 Seamless communication in the past was nearly impossible because no single network was able to integrate safety and standard control systems while also enabling the seamless transport of data across multiple plant floor physical networks That changed with the Common Industrial Protocol CIP an application protocol for industrial networking that is independent of the physical network The CIP protocol provides a set of common services for control configuration collection and sharing across all of the CIP networks DeviceNet ControlNet and EtherNet IP CIP Safety also helps eliminate the need to install expensive and difficult to maintain gateways between each network Before the development of safety networks engineers often had to use smaller systems or minimize their performance requirements since it was difficult to hard wire interlocks and relay based safety logic into a complete automation system Now engineers can integrate their devices on common physical network segments and allow safety and standard information to flow between devices and controllers The latest generation of Safe Torque Off drives includes the ability to safely remove torque using the network connecti
84. ic file The sets of tools included with the Drives and Motion Accelerator Toolkit provide pre configured example logic that can be customized to meet the needs of motion applications a quick start to programming your drives and motion system 17 of 142 Controller Organizer Controller Tags 9 Controller Fault Handler 2S Power Up Handler F 2 ites Et ra MainTask E POO_Machine E E PO1_Application H E poz_AxisO1 a EB Pos_Axisoz 05 Unscheduled Programs Phases S Motion Groups Be MotionGroup RED AxisO1 AD AxisO2 a Ungrouped Axes 7 Add On Instructions 5 AlarmHistory_AOT H 8 CIP_Faceplate_AOI B A MachineSTATE_AOT 5 6 Data Types a User Defined ar Strings EET Add On Defined 8 Predefined E E Module Defined lf Logical Model 3 83 1 0 Configuration E 1769 Bus a o 1769 L36ERM Integ_Motion_K5500_PF52 s 1 1769 IQ16F 4 Digital_Inputs 2 1769 081678 Digital_Outputs ow f 3 1769 IF4x0F2 A Analog_IO s Ethernet fa 1769 L36ERM Integ_Motion_K5500_PF527_6 n J 1734 4ENTR A Point_IO_Chassis o BE PointIO 4 Slot Chassis i j 0 1734 A4ENTR A Point_IO_Chassis i 1 1734 IB8 Point_Digital_Inputs J 2 1734 OB8 C Point_Digital_ Output j 3 1734 8CFGDLX C Point_DLX fl 2198 H003 ERS DriveOl f Controller Organizer fy Logical Organizer 18 of 142 The Controller Organizer is a graphical representation of the contents of your controller project This displ
85. iguration is to set it equal to 1 2 tr Drive Model Time Constant The Drive Model Time Constant is an internal drive parameter associated with the type of drive motor and feedback device Torque Notch Filter is a filter that passes most frequency signals unaltered but attenuates signals within a specific range of frequencies Notch filters typically have a relatively narrow and deep attenuation band Maximum attenuation is achieved at the notch filter frequency The notch filter in Kinetix 5500 6000 6200 and 6500 drives is second order with an attenuation of approximately 40 dB at the notch frequency The notch filter is effective in resonance control when the resonant frequency is higher than the control loop bandwidth The notch filter works by significantly reducing the amount of energy in the drive output that can excite high frequency resonances It can be used even when resonant frequencies are relatively close to the control loop bandwidth That is because the phase lag introduced by the notch filter is localized around the notch frequency For the notch filter to be effective the Notch Filter Frequency must be set close to the mechanical resonant frequency As a general rule of thumb the Notch Filter Frequency should not be less than 300Hz Configuring the Default Tuning Configuration In this portion of the lab the axis will be configured to the Default Tuning Configuration which will work without modification for approximately 80 of
86. in the previous lab section to execute a Calculate tune 5 Click Execute 6 You should see an indication that the command was executed in the Errors window and hear the PF 527 drive fan turn on Linking routine RO2 Monitor of program PO3_Axis03 Linking routine RO3S Control of program PO3_Axis03 Linking routine RO4 Reset _Abort of program PO3 AxisO3 Linking routine R1O EnableDisable FaultClear of program PO3_Axis03 Linking routine Rll OperatorMode of program PO3 Axis03 Finalizing download Reading ChangeLog Complete 0 error s O warning s Motion Direct Commands AxisO3 1 M50 16 0000 No Error You should also notice that the display shows the drive status as Running 7 Select the Motion Axis Jog MAJ instruction 56 of 142 EJ Motion Direct Commands Axis03 1 Commands otion Axis Jog Re MSO Paes faxs03 0 Re MSF Re MASD Label a Re MASR oS S Re MDO A Re MDF a_i J wie 5 E poton Mk Decel Rate H E Motion Move Decel Unts Unitspersecs2 m MAS R MAH Accel Jerk MAJ Decel Jerk eR MAM MAG Merge i Re MCD Qe MEP x A DANGER Executing motion command with controller in Program or Run Mode may cause axis motion Axis State Running Safety State Unknown No Motion Connecti Axis Fault No Faults Start Inhibited Not Inhibited Motion Group Shutdown Help Enter in a Speed value of 2 The
87. ion about the Advanced Connection Reaction Time Limit Configuration refer to the GuardLogix 5570 Controllers User Manual publication 1756 UM022 13 Click OK to close the Module Properties dialog box Write Program Code Let s examine the ladder logic associated with using networked Safe Torque Off drives hardwired Safe Torque Off drives and contactors There are two zones in this example e Zone 1 has five network Safe Torque Off drives and one motor that is safeguarded with redundant contactors This zone will utilize Stop Category 0 and coast to a stop upon a safety demand e Zone 2 has five network Safe Torque Off drives and one drive that is used in a hardwired configuration This zone will utilize Stop Category 1 and ramp to stop upon a safety demand removing power after a configurable time Each zone has the same inputs including an Emergency Stop a Light Curtain and a SensaGuard door monitor Each zone is represented as a program with routines for Input Logic and Output The code in the Safety Task is based on ladder logic from the Safety Accelerator Toolkit and the standard task is based on the Drives and Motion Accelerator Toolkit Zone 1 1 From the Safety Task in the Controller Organizer expand the Zone1 program H E SafetyTask El 3 zonet 4 I Parameters and Local Tags B MainRoutine Inputs Logic Outputs ONEZ E Unscheduled Programs Phases E Motion Groups 2 Review the Inputs routine T
88. isO1 but at approximately half soeed The program in Logix 14 of 142 Designer is gearing Axis02 to AxisO1 at a 2 1 Master Slave gear ratio while AxisO3 jogs ata constant speed using a Motion Drive Start instruction 4 Press Stop The motion system stops CIP Motion Axis Faceplate Manual Control Axis01 1 Press the Fault gt N JE button from t amp d artupscreen to launch the faceplate Axis 01 Axis Axis Status CTRL C lt Help Configuration CI Module Fault CI Config Fault CI Group Fault CI Motion Fault CI Guard Fault Ci init Fault CI APR Fault Trend ical Axis Fault CI Axis Alar Operator MANUAL Control Bus Ready C Drive Enable C Axis Shutdown C Axis Inhibit CI Power Stuct En Axis Homed Safe Off OK Axis Status The CIP Motion Axis faceplate provides axis status information fault information and trending data Axis Press tho button Axis 01 A PEG m Q The faceplate also includes the ability to manually control the axis s RA Operator Enabled Enabled Home Axis Homed F Saag Position 0 77 units Jog Fwd Jog Spd 0o00 units Jog Rev 15 of 142 This picture shows the drive enabled however your screen may differ when you first load the faceplate From the Axis CTRL display you have the ability to enable disable home move jog and clear an axis fault lf Program is currently displayed press the Program Operator button until Ope
89. ityLoopOutput 00 A ean O00 S Load 0 0 dGain o0 Backlash E SS ee Compliance AccelerationFeedback Aidh o0 Position Loop TorqueReference lt fidh o0 Velocity Loop TorqueReterenceFitered 1 AforBandwidth O0 Torque Current Loop T eneterence ntes Afosiive Oo pae m Amiviegstve oo Homing V CurrentFeedback lt focityLowPassFiterBandwidth 00 Actions TorquelowPassFiterBandwidth 00 Drive Parameters Systeminertia g Parameter List l OutputFrequency A obese K Clown o Faults amp Alarms Li A0 ae Z oa 0 0 I Motorcepacty SCO InverterCapacity 0 0 gt gt Axis State Safety State Manual Tune Cancel Apply Help 9 Navigate to the Parameter List page 41 of 142 Axis Properties AxisO3 i 5 x Categories General E Motor Parameter Group ActuatorDiameter ActuatorDiameterUnit ActuatorLead Planner Frequency Control Actions Drive Parameters Parameter List ActuatorLeadUnit ActuatorType Average Velocity Timebase BreakFrequency reak Voltage onversionConstant urrent YectorLimit requencyContralMethod ductionMotorFluxCurrent aa r oO nverterOverloadAction LoadType MaximumAcceleration Axis State Manual tune Safety State Frequency Control tions i nductionMotorRatedFrequency ductionMotorRatedSlipSpeed ductionMotorRotorLeakageReactance ductionMotorStatorLeakageReactance
90. just configured could be used as well 62 of 142 Axis 2 Press button Axis 01 a i o H y a Axis LA be Status C C Axis Fault EE Bus Ready Operator Enabled Enabled Home Axis Homed Position 0 77 units Jog Fwd Jog Spd 0o00 units Jog Rev From the Axis CTRL display you have the ability to enable disable home move jog and clear an axis fault Note Some of the numbers shown are both indicators and keypad input buttons For example the Jog Spd indicator displays the actual speed feedback of the drive not the desired jog speed However by clicking the indicator you launch the keypad input object where you can enter the desired jog speed These inputs will only work when the axis is in Operator mode and the drive is Enabled Dual Purpose Controls a 4 Enter desired jog speed 0 10000 Position 0 24 units JogSpd 100 units Actual speed feedback from drive 63 of 142 If a fault condition exists the icon flashes yellow The Fault display determines the fault information from the drive and displays the fault type code and description If there is no active fault the display shows the last fault condition recorded To easily generate the fault shown on the screenshot remove the Ethernet cable from its port on one of the drives Press a button 64 of 142 The Help screen displays the fault descriptions and actions Press the arrows to switch between screens You can clear
91. ker Test State should display Ready The Hookup Tests make the axis move even when the controller is in program mode 5 Press Start to conduct the test Once the Start button has been pressed the axis will immediately begin to move 6 The Motor and Feedback Test window opens 47 of 142 Logix Designer Motor and Feedback Test You will hear the servo enable and you should observe Axis02 move approximately one revolution in T the CW direction When the motor has completed one revolution and the drive has received the encoder signals correctly the Test State will change from Executing to Passed Logix Designer Motor and Feedback Test l x Test State Passed est complete Stop Help Click OK Click Yes if the axis moved in the forward or positive CW direction Logix Designer xi A Did the axis move in the forward direction ves J n om Click Accept Test Results to update save the Motor and Feedback Polarities 48 of 142 sl est Motor and Feedback Device Wiring Motor Feedback Test Distance 1 0 Start Stop Compliance Friction Position Loop Velocity Loop _ Acceleration Loop Torque Current Loop Drive Parameters i Parameter List 10 Proceed to the Axis Autotune section of the lab Axis Autotune In this section of the lab we will tune Axis02 The Autotune measures the system inertia acceleration deceleration rates as well as cal
92. locity PI control loop which is nested within an outer position PI control loop are illustrated below Position Feed Command Forwards 7 Accel Filters Torque Loop Torque Scalar Da 7AA T 7 eS i le w P Position 7 Loop Velocity Loop Torque Estimate Velocity Estimate Torque Load The multi loop PI control structure is common among servo drives There are slight differences between drive families based on the implementation and specific units which are not covered as part of this lab This lab will focus on the details pertaining to the Load Observer and Torque Notch Filter N PAS TTN Load Observer Velocity Feedback Filter Position Feedback Load Observer The load observer feature is part of the control loop inside the drive that estimates the mechanical load on the motor and compensates for it thereby forcing the motor to behave as if it is unloaded and relatively easy to control As a result the load observer automatically compensates for disturbances and load dynamics such as inertia torque changes compliance backlash and resonances that are within the velocity loop bandwidth The load observer acts on the acceleration signal within the control loops and monitors the Acceleration Reference and the Actual Position feedback The load observer models an ideal unloaded motor and generates a load Torque Estimate in torque units that represe
93. ls synchronizing time for devices connected in a network The sole system time master is referred to as the Grandmaster and is determined by a Strict arbitration process By default the Grandmaster is both PTP Coordinated System Time CST master and typically will be a viable communication module or processor The settings on the Advanced window Date Time tab can allow the processor to win the arbitration over the other processors and or communication modules connected to it The EtherNet port on the backplane is also 1756 IB16ISOE 1756 OB16ISOE The following example illustrates the Grandmaster Master Slave relationship for a ControlLogix chassis and it s connected I O the same would hold true for eligible CompactLogix controllers Note In systems with multiple processors all controllers need to have time synchronization enabled if they are to use CST PTP time The System Time timestamp is a 64 bit LINT value that represents the number of nanoseconds or microseconds starting from January 1 1970 at 12 00 am 7 Click OK to close the Controller Properties window Hardware and Network Considerations Before we continue on with the lab let s discuss some of the hardware and network options that are available with Integrated Motion on EtherNet IP Network Topology Integrated Motion on EtherNet IP allows for multiple network topologies providing the flexibility necessary to meet even the most de
94. manding applications Listed below are 3 of the more popular network topologies Note These diagrams were sourced from the CompactLogix 5370 Controllers User Manual 1769 UM021 EN P More network topologies are shown in the CIP Motion Popular Configuration Drawings IASIMP QR019 EN P available via the Rockwell Automation Literature Library Device Level Ring with Integrated Motion 22 of 142 CompactLogix Controller Programming Network os ps ile CompactLogix 5370 Controller Gil Fil VMTN CORE s ANMI LE F 1734 AENTR POINT 1 0 EtherNet IP Adapter gz Kinetix 5500 Servo Drive System H a Tins pE a 1585J M8CBJM x Ethernet shielded Cable 585J MECBJM O0M3 0 3 m 1 0 ft Ethemet cable for drive to Grive connections Linear with Integrated Motion CompactLogm Controller Programming Network i i I ili L pil CompactLogix 5370 Controller Logix Designer Application s 3 Lag J lia m z Siu tie _ _ sia EiT Beti E Kinetix 5500 Servo Drive System Aad aiea eain kaia Th 1585 MaCBiM OM3 0 3 m 1 0 ft Ethernet cable 15851 M CBIM x for drive to drive connections Ethernet shiekled Cable aes 1734 AENTR POINT V 0 PanelView Plus EtherNet IP Adapter gz H Star with Integrated Motion 23 of 142 CompactLogm Controller Programming Network CompactLogmx 5370 Controller s
95. minal Settings Before Running 7 Select Device Shortcuts and hit the Enter button Application Settings Device Shortcuts 8 Verify that the controller at 192 168 1 12 IP address is selected as shown below Click OK 104 of 142 10 11 12 Edit ShortCuts Backplane lt No Devices gt Sf integ Motion K5500 PF527 Complet 192 168 1 12 17 Node USB CIP Port 1734 AENTR B EtherNet Adapter 192 168 1 8 1732E IB8M8S0ER 24 DC In M8 192 168 1 9 1732E 0B8M8SR 24 DC Out M8 192 168 1 10 PowerFlex 527 192 168 1 26 2198 H003 ERS 192 168 1 25 2198 HO03 ERS 1 192 168 1 24 Click the Close button On the FactoryTalk View ME Station dialog press the Run Application button On the HMI press the Clear Faults button to reset the system Machine Status Machine Control Eg FAULTED Power Up Program Clear C_ Ready Faults __ Safe Speed State ABORTED o swp From the Controller Organizer navigate to the routine Main Task gt P02_Application gt R10_ApplicationCode and open it Tasks Ga MainTask a 8 P01_Machine aS P02_Application A Program Tags of ROO_Main E RO1_PowerUP RO2_Monitor H RO3_Control i H R04_Reset f B ES PEE A e P03_Module_XYCoordMotion E Unscheduled Programs Phases Let s review the application code Rung 1 Orient Rotary Knife to the beginning of the Cut Region a 1 8 rev move relative to home Rung 2 Home the Conve
96. mpleting the Logix configuration you must download your project to the CompactLogix controller 1 Click the Verify Controller button ey on the Logix Designer toolbar The system verifies your Logix controller program and displays error warnings if any in the status window 2 Select Save As from the File menu and save your program using a name of your choosing 3 Select Who Active from the Communications menu The Who Active window opens up 4 Drill down through the AB_ETHIP 1 driver to find the processor at 192 168 1 12 43 of 142 Who Active JV Autobrowse Refresh Workstation WIN7 VM zx Linx Gateways Ethernet G AB_ETHIP 1 Ethernet Upload E 192 168 1 10 1732E OBS8M8S5R 24 DC Out M8 1732E OB8M8SR 24 DC Out M8 G i 192 168 1 12 1769 L36ERM LOGIXS336ERM 1769 L36ERM A LOGIXS336ERM Download H 192 168 1 24 2198 HO03 ERS 2198 HO03 ERS l H 192 168 1 25 2198 HO03 ERS 2198 H003 ERS Update Firmware ba 192 168 1 26 PowerFlex 527 PowerFlex 527 Close 192 168 1 8 1734 AENTR EtherNet IP Adapter 1734 AENTR Ethernet Adapter Chose 192 165 1 9 1732E IBBMBSOER 24 DC In M8 1732E IBBMBSOER 24 DC In MS Help L set Project Path Clear Project Path Path AB_ETHIP 14192 168 1 12 Path in Project AB_ETHIP 14192 168 1 12 Click Set Project Path 5 Verify that the operation mode switch on your controller is in the REM remote position Ensure that the Kinetix 55
97. ms Actual Utilization Motion Logix Controller Task I O Cycle Cancel Apply Help This section is not a comprehensive view of system sizing however It is recommended to attend any labs that are offered for Integrated Architecture Builder for a more information on network and controller sizing That program includes a sizing tool using the same algorithms and allows for complex system design including HMI tags I O devices and other communications An example of the results screen for the sizing tool in Integrated Architecture Builder is shown below Connections vO 112 Logic Hmi 10 Remana M Memory Used 288KB Avaiable 80MB serores EMO Communication Modules Comm1 connected to network EtherNet IP001 Motion Packets per Second PPS 0 LO Packets per Second PPS 1 867 HMI Packets per Second PPS 127 This concludes this lab Periodic Task Scan Time 00 msec CIP Motion input Cycle Utilization Drive to Controller Periodic Task Rung Capacity Ra Output Cycle Utilization Controler to Drive g Continuous Task Scan Time REET Motion Task I O Cycle Utiization Logix Controller Utiization Connection Memory Details Logix System Minimum Time Sice zizaon ME oton Capacty Used 00 CIP Connections M VO Capacity Used 63 TCP Connections SSRI HMI Capacity Used 4 0 CIP Motion Pos Axes M I 141 of 142 www rockwellautomation com Power Control and Informatio
98. n Solutions Headquarters ericas Rockwell Au ion 1 uth Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 l l es aaa R A oira Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 JERRY ERB AO 663 tea TON NG nl a Euro au perge Sil Anomarion 10 14 Core Cesare 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 142 of 142
99. n feedback will unwind or rollover once per motor revolution 6 If a popup window appears click Yes to automatically update all dependent attributes Logix Designer Ei You have changed a parameter which affects other attributes Do you want to automatically update all dependent attributes Refer to Help for a list of dependent attributes 7 Navigate to the Frequency Control page and select Sensorless Vector and click Apply 38 of 142 Axis Properties AxisO3 Categories General Frequency Control Motor Model Frequency Control Method Basic Yolts Hertz PE n Analyzer Basic olts Hertz Basic Volts Hertz Scaling Hookup Tests Polarity Planner Frequency Control Actions Drive Parameters Parameter List Status Faults amp Alarms Tag Axis State Manual Tune Control Method Basic Volts Hertz Fan Pump Volts Hertz Sensorless Vector Sensorless Vector Economy Limits Fan Pump VYolts Hertz Vols RMS Maximum Frequency Hertz Volts RMS Break Frequency Hertz Volts RMS Volts RMS Maximum Voltage Break Voltage Start Boost Run Boost revs s Velocity Limit Positive 53 333332 Velocity Limit Negative 53 333332 revs s Safety State Cancel Apply Help Description Volts Hertz control is a basic control method providing a variable frequency drive for applications like fan and pump It provides fair speed and starting to
100. n this routine on the rung rung 2 that energizes the Output Enable bit The addition of the TOF instruction gives the standard task time to execute stopping instructions to put the axes into a disabled state at a Known position before the torque is removed This is essential for vertical loads and many other coordinated applications Virk_Zone_SatetyReset_OSF_OB Sts_Zone_InputsOK AENTR_2 2 CombinedOutputStatus Zone_Contactor FP i TOF Timer Off Delay Timer Wrk_Zone_Timer_StopCat1 Preset 5000 Accum 0 Cmd_Zone_OutputEnable Vrk_Zone_Timer_StopCat1 DN Cmd_Zone_OutputEnable 9 Open up routine MainTask gt P02_Zone2 gt RO3_Control and examine rung 3 Since these drives are only rated for Stop Category 0 the programmer should plan to execute code in the Standard Task to bring the drives to a stop and disable them before the torque is removed This ensures that any mechanical brakes can be set before holding torque disappears Machine Commands Machine Cmd STOP ONS 0 6 ONS LL LL Fill File Source 0 Dest RunSE o 4 Length Fill File Source 0 Dest ResetSEQ O Length 4 Zone2 Sts_Zone_InputsOK i Move Source 1 Dest StopSEQ 0 0 The addition of the Zone2 Sts_Zone_InputsOK tag provides a Stop command to the application This will stop the running sequence and reset sequence and initiate the stopping sequence By doing this you can prog
101. nE Slave Position Slave Position ji N Small Step Change inthe Velocity as CECE TELE CEE E TERETE REECE CERT E RRC R RRR RRE 7 E Large Step Change Ps m inthe Velocity g G E es G Master G G 02 If it is necessary to achieve this level of performance for arbitrary Cut Lengths then Advanced Cam Designs are necessary that match the boundary conditions This concludes this lab Appendix D Tuning Techniques Lab In this lab a tuning procedure is presented that provides a solution that compensates for unknown mechanics produces high performance results and does not require expertise in tuning It has been observed that this procedure produces satisfactory results for nearly 95 of the applications our customers encounter There are two parts to the procedure The first part leverages the load observer which is a feature internal to the drive The load observer estimates the torque required to move the mechanical load in real time and adds the result to the torque command This automatically compensates for a wide range of unknown mechanics The second part compensates for problematic mechanics which can arbitrarily limit the performance This mechanical limitation is often referred to as a mechanical resonance By identifying the resonance the Torque Notch Filter can be configured to compensate for the limitation Currently the identification and setting of the Torque Notch Filter is a manual operati
102. nd screen 10 Press the button Axis01 x REARS O E Position Max A Position Min O w Velocity Max O velocityMin 4 Current Max O Current min The Trend Configuration screen lets you adjust the trend scales Axis 11 Preso a s button Axis01 x 2HBRE En CI Move C1 Gearing Jog C Gearing Lock CI Homing CIPCAM C Stopping CIPCAM Lock CI Accel CIPCAM Pending CI Decel CITCAM CI TCAM Pending CO Master Offset Move Coordinated Motion b The Axis Status display lets you view general motion axis and drive status 66 of 142 12 Press the gt button to see more status indicator When you are done with the Axis Faceplate close it by pressing the X in the top right corner State Diagram Faceplate The State Diagram faceplate provides a graphical representation of the state machine The green indicates the current state while the gray indicates the previous machine state cette aii RESETTING p me gt i START see ee i eee ee eee at ae eS ee man Ei NE a at RESET J J i sa m amam nnn 8 A eo oo oe oe clear V STOPPED a CLEARING ief ABORTED Sn oe oe oe we m we we ww on The State Diagram faceplate provides a quick reference for machine operators summarizing the relationship between machine states When you are done with the State Diagram faceplate close it by pressing the X in the top right corner Alarm History Faceplate
103. nd the orientation ranges from 0 1 In this case 0 orientation was not chosen to be Bottom Dead Center BDC where the Knife Blade cuts the Product Rather it is chosen to be 45 from BDC which corresponds to the tr 4 phase shift in the geometric identity This offset is chosen to simplify the creation of the Cam Table in Excel and avoid a roll over condition In order for the Knife s Velocity to match the Feed Rate through the Cut Region the angular velocity must be equal to the inverse kinematics shown in Equation 2 If you struggle to follow the geometry that computes the linear velocity continue to progress through the lab content or you can ask the lab instructor for more details rev _ Feed Rate za 7 rk em 2ncos 20 7 Equation 2 Rotary Knife Inverse Kinematic Once the objective of the Cam Design is understood the Cam Table is created which includes the Cutting Region and Make Up Move In this lab for simplicity the Cam Table is created using Excel to clearly illustrate the design process that includes e Labeling the configuration variables including units and loading the system parameters This includes the Feed Rate cm s Knife Radius cm and a Sample Rate s Note the Sample Rate dictates the number of points included in the Cam Table for the cutting region In Studio 5000 arbitrarily increasing the number of Cam Points may not increase the performance In fact at a certain point increasing the number of poin
104. nductive Proximity Power Switch sensor Armara O Hardwired Inputs and Plug unused in this lab on Ethernet IP unused in this lab and Outputs Use the image provided to locate these items on the demo and verify the lab setup Verify the demo power switch labeled 120 220V is on Verify the circuit breaker is on 9 of 142 About the Kinetix 5500 and PF527 3 Axis Demo 24V Power Drive03 and Supply Motor DriveO1 Drive02 Drive Power Switch Registration Sensor Output unused in this lab Power Switch Motor for Motorfor Safe Torque Circuit Drive 01 Drive 02 Off Breaker Use the image provided above to locate these items on the demo and verify the lab setup Verify that the demo power switch is on Verify that the circuit breaker is on Verify that the switch labeled K5500 DRIVE POWER is on Verify that the switch labeled PF525 DRIVE POWER is on Replaced with a PF527 Verify that the red mushroom button labeled SAFE OFF is pulled out Demonstration Estimated Time 15 minutes Before starting the formal lab let s begin with a brief demonstration showing the end result of the lab During the demonstration you will be able to control a complete 3 axis solution via an HMI The demonstration will also allow you to independently control each axis simulating what a real machine operator might need to do to clear a jam or manually
105. nstruction to enable the axis again Execute an MAS to stop the axis and a MSF instruction to disable the axis when you are finished MDS Motion Drive Start Instruction supports the Kinetix 6500 5500 drive in Torque Mode or the PowerFlex drive in Torque Mode or Velocity Mode Once either drive is put in Direct Control mode the following motion instructions are not allowed MSO MRP MAH MAPC MATC MCT MAG When the drive is in Direct Torque Mode the drive is controlled with a TorqueOffset When the drive is in Direct Velocity Mode the drive is controlled by the RampRate and other velocity attributes associated only with the PowerFlex drive 59 of 142 Lab 4 Adding an HMI Estimated Time 15 Minutes The following lab previews the Drives and Motion Accelerator Toolkit FactoryTalk View ME file to control your motion application There are several preconfigured HMI screens that were designed specifically for drives and motion applications including Standard preconfigured auto manual control templates Predefined axis status templates Preconfigured fault diagnostic templates Switch to the HMI Application 1 Minimize Logix Designer so that the HMI screen on the desktop can be seen 2 If the warning screen is displayed click Start The Lab to load the Startup screen 3 The Startup screen should initially be displayed Toggles the machine between Program AUTO and Operator MANUAL modes Indicators provide
106. nts any deviation in response of the actual motor and mechanics from the ideal model This deviation shown below represents the reaction torque placed on the motor shaft by the load mechanics It is estimated in real time and compensated by closed loop operation 115 of 142 Acceleration Command b Acceleration Reference Torque Estimate Kjm Feedback Feedback Velocity Position Velocity Estimate o C C ae Load Observer Plant mJ Ka The load observer also generates a Velocity Estimate signal that you can apply to the velocity loop The Velocity Estimate has less delay than the Velocity Feedback signal derived from the actual feedback device It also helps to reduce high frequency output noise caused by load observer s aggressive action on the acceleration reference Together the Load Observer with Velocity Estimate provides the best overall performance when the Axis Configuration is set to Position Loop The Position Loop configuration incorporates most applications Acceleration Estimate Kof The Load Observer has two configurable parameters which are the Load Observer Bandwidth and the Load Observer Integrator Bandwidth For most applications and the purposes of this lab the Load Observer Integrator Bandwidth will remain 0 The primary configuration is the Load Observer Bandwidth lt can be tuned similarly to the Position and Velocity Loop Bandwidths For the tuning procedure presented in this document a satisfactory conf
107. o Planner Homing Actions Drive Parameters Parameter List Status Faults amp Alarms Y gt Manual Tune Cancel Active Load Compensation Torque Offset o o Rated 6 Confirm the appropriate tuning parameters are loaded in the Axis Properties Click Load Compliance and confirm the Low Pass Filter Frequency 5 Load Observer Bandwidth Click Velocity Loop and confirm the Velocity Loop Bandwidth Load Observer Bandwidth 4 Click Position Loop and confirm the Position Loop Bandwidth Velocity Loop Bandwidth 4 7 Now follow steps 2 6 again to configure Axis_02 for the default configuration 8 At this point Axis _01 and Axis _02 should be configured with the Default Parameters which provides the necessary performance for most applications 9 Download the program to the controller at 192 168 1 12 1 Click Who Active button 2 Select controller from the Ethernet driver 3 Click Download button 118 of 142 4 On pop up dialog window click the Download button 2s S E Workstation BASEIMA TIBGVSY ss Linx Gateways Ethernet as AB_ETHIP 1 Ethernet i 192 168 1 2 1783 BMSO6TA Stratix 5700 1783 BMSO6TA Stratix 5700 f 192 168 1 24 2198 H003 ERS 2198 H003 ERS f 192 168 1 25 2198 H003 ERS 2198 H003 ERS gj 192 168 1 8 1734 AENTR EtherNet IP Adapter 1734 AENTR Ethernet Adapter 4 Ex al Te al ae FS AT T eet QD 00 gg QO
108. o VelociyFeedback SSC SipCompensetin o0 OutputFreuency SSC OutpuCurent iD oO y y 00 o S Digitalinputs Analoginputt 00 Analoginpt2 d o0 Safety State T DigitalOutputs 16 0000_0000 T AnalogOutut io Notice you can select Drive Parameters in addition to the parameters included when Auto Tag Update is enabled Selected parameters can now be both read and written every coarse update rate Scroll through the read parameter list and check VelocityReference OutputFrequency OutputCurrent and then click Apply to save your changes 40 of 142 TIP Currently there is a limit of 10 read and 10 write enabled selections per axis Each parameter selected to be transmitted as a cvclic read write attribute will add overhead to the controller and drive data exchanae and thus impact performance You must analvze the trade off of real time drive parameter exchanae on the timina of the axes The available drive parameters also depend pn the motor control method that the axis is confiaured for So while onlv a few show for Freauencv Control Velocity of Position Control exposes many more Ex Axis Properties AxisO3 Efel o x Categories General Drive Parameters to Controller Mapping T aa d l Parameters to be read each cycle Parameters to be written each cycle e Cpe ooo o p a O wei Os re NO ona C Veloctyeror SSC D lt i Paarl 2 as Autotune L Veloc
109. o different examples The first five devices are all Network Safety drives while the last example is a contactor The drives have much simpler code because they handle all of their own diagnostics and can easily report back that information to the controller as shown 135 of 142 Safety Output Rung This Safety Output Logic Example controls the Network Safe Torque Off outputs of a Kinetix 5500 2198 Hxxx ERS2 drive The CROUT instruction is not needed since only a single output is need to be energized and diagnostics are already built into the module to go to safe state in the event of a fault Cmd_Zone_OutputEnable Drive_01 SO SafeTorqueOff Drive_O1 Sl TorqueDisabled Drive_01 Sl ResetRequired Drive_01 SO Reset Drive_O1 SLRunMode Drive_01 Sl ConnectionFauted Drive_O1 SlSafetyFaut Drive_01 SO SafeTorqueOft ir _ Note This could even be combined into a simple Add On Instruction for even more simplicity 5 The last two rungs of the Outputs routine from Zone 1 demonstrate the additional work that needs to be included for contactors The controller must manage all of the diagnostics for the contactors so the CROUT instruction is used to coordinate the timing of the actuation command feedback and module statuses Zone 2 6 From the Safety Task in the Controller Organizer expand the Zone2 program 7 Since the Input routine is similar to Zone1 skip ahead and open the Logic routine 8 There is an important difference i
110. of the axes in the trend 1O x Run Stop Errors ee o T EE E08 0 00 AXIS_02 ActualPosition 1 00 AXIS_02 PositionError 0 00 0 01 AXIS_02 TorqueReference 15 82 19 95 Loaging Stopped Periodic 1 ms Capture fi of 1 Results Tuesday May 13 2014 1 00 1 16 20 PM 1 16 22 1 16 23 La Caa Notice that even with the large inertia i e a load ratio of approximately 32 1 and significant lost motion on Axis_01 the default tuning settings in conjunction with the smooth Cam Profile nicely controls the axes 122 of 142 Identify and Compensate for Mechanical Resonances For the large inertia loads used in this lab a mechanical resonance does not cause a significant problem thus the Torque Notch Filter does not need to be configured In this appendix a general description of mechanical resonance is presented along with a step by step procedure to identify and compensate for the mechanical resonances What are common causes of mechanical resonances Typical causes can include coupling encoders and compliant system What are typical symptoms They include loud pitch noises that are typically a single frequency above 300Hz Why is it important to minimize the mechanical resonances Mechanical resonances are problematic because they cause excessive ware waste power and reduce the performance How do you compensate for a mechanical resonance The two primary
111. og window 79 of 142 Motion Coordinated Linear Move MCLM Motion Coordinated Linear Move EN Coordinate System XY _CoordSys E3 Motion Control X _CoordSys_Ctri CSIMCLM 1 DN gt Move Type 0 ER Position XY_CoordSys_Ctri Data Position 2 Ell gt IP gt X_AXIS Y_AXIS 7 14 Enter the Target Position values X_AXIS 0 0 and Y_AXIS 4 0 for this MCLM move Then click OK Target Position Entry XY_CoordSys XY_CoordSys_Ctrl Data Position 2 Position Tag 15 Add a Motion Coordinated Circular Move MCCM instruction on rung 4 similar process as step 11 16 Enter instruction data for the MCCM as shown in the picture to the right It is important that you select the correct tag for each entry 80 of 142 17 18 Coordinate System XY_CoordSys Motion Control Motion Coordinated Circular Move MCCM Motion Coordinated Circular Move XY_CoordSys_Ctrl CSI MCCM 0 Coordinate System Motion Control Move Type 0 Move Type 0 Position XY_CoordSys_Ctrl Data Position 4 Position X _CoordSys_Ctrl Data Position 4 G X_AXIS Circle Type 1 Y_AXIS 2 Circle Type 1 Via Center Radius Via Center Radius XY_CoordSys_Ctri Data ViaCenterRadius 0 XY_CoordSys_Ctrl Data ViaCenterRadius 0 Direction 0 Direction 0 Speed AR OIAR oe Speed XY_CoordSys_Cirl Data Speed 0 speed Units Gree por eae Accel Rate XY _CoordSys_Ctrl Data Accel 0 ite j 0 06 Speed Units Units per sec ere ca
112. omation with respect to use of information circuits equipment or software described in the Documentation Except as specifically agreed in writing as part of a maintenance or support contract equipment users are responsible for e properly using calibrating operating monitoring and maintaining all Products consistent with all Rockwell Automation or third party provided instructions warnings recommendations and documentation e ensuring that only properly trained personnel use operate and maintain the Products at all times e staying informed of all Product updates and alerts and implementing all updates and fixes and all other factors affecting the Products that are outside of the direct control of Rockwell Automation Reproduction of the contents of the Documentation in whole or in part without written permission of Rockwell Automation is prohibited Throughout this manual we use the following notes to make you aware of safety considerations Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss gt f WUE Identifies information that is critical for successful application and understanding of the product SNL identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you e identify a
113. on In the future this manual operation will automatically be configured in servo and standard drives that support the Adaptive Tuning Features In this lab you will be shown how to appropriately configure the Load Observer and the simple process for identifying and configuring the Torque Notch Filter Frequency to easily tune most mechanical systems The topic of Advanced Tuning Techniques which covers the remaining 5 of applications is not covered as part of this lab Lab Content Includes e Design Procedure Describes how the key features function e Step by Step Procedure Configuring the Default Configuration 114 of 142 e Appendix Step by Step Procedure Identifying and Compensating for a Mechanical Resonance Key Topics Covered e Tuning Strategy for 5x00 amp 6500 Kinetix servo drives e Tuning less Configuration amp Possible Modifications Design Procedure Describe How the Key Features Function In this section a description of the features that are leveraged as part of the tuning procedure are presented A complete understanding of these features are not necessary to execute the tuning procedure but are included for those who have experience designing control algorithms At any point due to time constraints if you struggle to grasp the design continue to progress through the lab or consult the lab instructor for more details The Kinetix servo drives implement an acceleration torque loop which is nested within a ve
114. on with CIP Safety over EtherNet IP That network connection can provide tremendous diagnostics on the same wires that provide the standard control and reduces your wiring to an absolute minimum GuardLogix Safety Standard Control 127 of 142 Safe Torque Off should be used for routine repetitive predictable actions such as clearing a jam or changing tooling Safe Torque Off is not suitable for electrical work of any kind While it removes the ability to create torque there can still be hazardous voltages present on the motor terminals This is why LOTO is still a crucial part of a safety strategy PLC Control amp Diagnostics Safety Relay Configure a Network Safety Drive Follow these steps to see how to configure Kinetix 5500 drives with networked STO 1 Open file Desktop Lab Files Network Safety Lab Network_Safety_Begin ACD 2 From the I O tree right click on the 1756 EN3TR Module EN3TR_Drives and choose New Module 3 10 Configuration 1756 Backplane 1756 410 z fa 0 1756 L735 STO_Multiplex aj 1 1756 L75P STO_Multiplex Partner 5 2 1756 EN3TR EN3TR_Drives ff pa Ethernet New Module fly 2198 HO03 ERS2 Drive Discover Modules fly 2198 HOO3 ERS2 Drive Slp 2198 HOO3 ERS2 Drive amp Cut Ctrl Els 2198 HO03 ERS2 Drive B Copy Ctrl C l 2198 H003 ERS2 Drive a fl 2198 HO03 ERS2 Drive ffl 2198 HO03 ERS2 Drive Delete Del i 2198 HO03 ERS2 Driv
115. on rung 7 Change the Speed to 7 Motion Axis Move Motion Axis Move EN Axis SLAVE Ga Motion Control SLAVE_Ctrl MLMAM 3 DN 0 ER P PC 15 Click Run in position_MAMS to restart the trend 16 Press the Enable Home button on the HMI 17 Press the MDSC button on the HMI 18 Press the MAM 3 button on the HMI 19 After the Slave s move completes click the Stop button in the trend 20 Press the Stop button on the HMI to stop the Master axis 98 of 142 21 What would you expect for the Master distance at the completion of the Slave move Click on the right edge of the green velocity curve Looks like the Slave s motion ended at 25revs when the Master s position was 12revs 5revs lock position 7revs master units 12 This almost seems like a MAPC instruction where the CamProfile array contains only 1 value Nice position_MAM3 Thursday May 01 2014 3 20 54 PM 25 00 eee 0 0 0 00 0 00 20 00 ati 16 00 8 00 4 00 o o 3 20 49 PM 3 20 51 3 20 52 3 20 54 3 20 56 3 20 57 PM 22 Feel free to make other modifications to the values to drive home the operation of the MDSC motion feature in Logix This concludes this lab Appendix C PCAM Rotary Knife Application Lab In this lab we illustrate the process of designing Cams to control the motion of an Example Machine The topic of Cam Design can become complicated when it is necessary to achieve p
116. ositionLoopBandwidth 1 852124 E 530634 PositionintegratorBand YeloctyLoopBandwidth 74 08496 Advanced Compensation Load Parameters Tuned Systeminertia a 122536 Hz Name E MaximumAcceleration 10381 242 3028 4631 MaximumDeceleration 10381 242 3278 5566 Notice which parameters were updated following the Autotune Following the Autotune updated values are indicated with an asterisk 51 of 142 Name Tuned E PositionLoopBandwidth 1 852124 18 530634 PositionintegratorBand 00 00 VelocityLoopBandwidth 74 06496 74 122536 Note The Current and Tuned values are both displayed indicating the before and after Autotune results 8 Click Accept Tuned Values to accept the updated Autotune values Axis Properties AxisO2 Categories General PET une Control Loop by Measuring Load Characteristics E Motor Application Tracking ttt Perform Tune DANGER Starting tuning B E Model Type i A procedure with controller in oo Analyzer Stat Stop Program or Run Mode causes Motor Feedback Loop Medium Response axis motion Scaling Tune Status Success Hookup Tests eee Rigid Loop Parameters Tuned e Pee eorn fea sj Autotune Fustomire ANNET Tune PositionLoopBandwidth 1 852124 18 530634 Hz pi Position Integrator Bandwidth js PositionintegratorBand a a ae Backlash 7 Velocity Integrator Bandwidth YelocityLoopBandwidth 74 08496
117. other example of when to use Tag Mapping Tag mapping should not be abused since putting logic in the Safety Task does not necessarily make it safe but it can be a very helpful tool for appropriate uses 13 Close the dialog box when finished 14 To see how the mapped tag is energized open up the DriveManagerTask gt P11_Axis_11 gt R02_Monitor routine and look at rung 24 The Servo_Axis GuardGateDriveOutputStatus tag is used to reflect back to the Kinetix_ STO _Feedback_Map tag the status of the gate drivers in the servo drive This concludes this lab 137 of 142 Appendix F Multiplexing Introduction The goal of this lab is to provide an overview of Drive Mulitplexing a new feature for an upcoming release of Studio 5000 Multiplexing allows for the controller to execute up to three effective Coarse Update Periods for the Motion Group There is still only one Motion Group with multiplexing but drives can execute at different rates relative to their performance requirements Previously a single high performance axis could require all of the other axis on the controller to operate at the same rate This leads to extended scan times for other logic since the Motion Group has the highest priority in the controller An arrangement like this could also lead to requiring an additional controller to handle some of the high performance motion axes since the low performance axes have to be updated faster than the application requires
118. peed Control Lab MDSC_MAM_Begin ACD Download the program to the controller at 192 168 1 12 1 Click Who Active button 2 Select controller from the Ethernet driver 3 Click Download button 4 On pop up dialog window click the Download button Path AB_ETHIP 1 192 168 1 12 v fas i 3 Who A th J utobrowse Workstation BASEIMA T1BGVSY es Linx Gateways Ethernet gt gs AB_ETHIP 1 Ethernet H 192 168 1 12 1769 L36ERM LOGIXS336ERM 1769 L36ERM A LOGIXS336ERM iij 192 168 1 2 1783 BMSO6TA Stratix 5700 1783 BMSO6TA Stratix 5700 9 192 168 1 24 2198 H003 ERS 2198 H003 ERS f 192 168 1 25 2198 H003 ERS 2198 H003 ERS t 3 192 168 1 8 1734 AENTR EtherNet IP Adapter 1734 AENTR Ethernet Adapter il a age me gf 290 2 pO PIA Pm pcat ected A og GO quate A A D SEs Set the controller to Run Mode Open file Desktop Lab Files Master Driven Speed Control Lab MDSC_MAM mer by double clicking it to run the lab HMI On the Replace Local System Directory dialog press the Yes button to continue 87 of 142 6 Click Application Settings FactoryTalk iew ME Station Current application MDSC_MAM mer Load Application Run Application Application Settings F3 Delete Log Files Terminal Settings Before Running 7 Select Device Shortcuts and hit the Enter button Application Settings Device Shortcuts 8 Verify that the controller at 192
119. r H R03_Control B AUP EG A A P03_Module_XYCoordMotion E 7 Unscheduled Programs Phases 19 Visually review the Application Code Sequencing Upon starting the application the program will Rung 1 Home Axis_01 Rung 2 Home Axis_02 Rung 3 Illustrate how the default Load Observer Bandwidth is determined Rung 4 aun Axis_01 with a smooth indexing profile to minimize backlash on the axis o x 4 Al alel Peme ajaja Position Velocity Acceleration Rung 5 Run Axis_02 the same as Axis_01 20 We want to monitor the machine performance in a trend Under Trends in the Controller Organizer double click on the trend Results to open it 121 of 142 J Trends fee Results 21 Click Run to start collecting data in the trend 22 On the HMI press the Start button to ready the system for motion The Machine State should transition from Stopped to Idle state Machine Status Machine Control m ok Program M sates ERN _ Safe Speed State STOPPED State IDLE 23 Press the Start button again to start executing the motion application code Each axis should start indexing back and forth in a similar motion 24 Now go back to the trend screen Once the axes have ran several cycles press the Stop button to stop collecting data 25 Press the Stop button on the HMI to stop motion 26 Visually review the performance
120. ram mode If the machine is currently in the ABORTED state 61 of 142 Machine Status E FAULTED __ Ready _ SafeSpeed State ABORTED Power Up press Clear Faults Machine Status 3 ok _ Ready Safe Speed State STOPPED After a few moments the machine should transition to the STOPPED state N Press Program Operator button until Program is displayed Program AUTO is now the active control mode 3 Press Start The required axes enable and begin operating according to the Logix Designer program 4 Press Stop The motion system stops 5 Press Program Operator The machine must be stopped before you can switch control modes When in Operator MANUAL mode you can individually control each axis from its corresponding faceplate CIP Motion Axis Faceplate Axis01 1 Press the button from tS artupscreen to launch the faceplate Axis 01 faut gt A JZ d Ga Qe Hele CI Axis Alar Configuration Operator MANUAL Control CI Module Fault Bus Ready Trend C Config Fault C Drive Enable Axis Status CI Group Fault C1 Axis Shutdown CI Motion Fault C Axis Inhibit CI Guard Fault CJ Power Stuct En C init Fault Axis Homed CI APR Fault Safe Off OK The CIP Motion Axis faceplate provides axis status information fault information and trending data The faceplate also includes the ability to manually control the axis These screenshots were done with AxisO1 however AxisO2 that you
121. ram the machine to come to the controlled stop of your desire 136 of 142 10 Most of the Outputs routine remains unchanged There is a difference in the last two rungs from Zone 1 The Feedback parameters for the CROUT instruction are tied to tags mapped from the Standard Task to the Safety Task Open the routine and view this difference in the last two rungs 11 Tag mapping is accomplished from the dialog box that appears after following the menu path Logic gt Map Safety Tags B File Edit view Search Logic Communications Tools Window Help alsm a sje 2 Offline Monitor Tags Edit Tags Produced Tags Map PLC SLC Messages J al knone gt Hd tali heal Ack y Favorites A Add O1 q E Add On Instructior Verify a j Data Types E 7 User Defined NO Forcing con ar Strings SFC Forcing b CR Add On Define Predefined Online Edits a Module Defined 12 Follow the path and view the dialog box x E Standard Tag Name amp Safety Tag Name E F Kinetis_STO_Feedback Map f Kinetis_STO_Feedback_Safety Bea Delete Row e Feedback for purely diagnostic purposes is a common function that uses mapping from the Standard Task to the Safety Task Reset functionality does not necessarily need to be safety rated since many other safeguards are in place to prevent restart when dangerous situations could occur and represents an
122. rator is displayed Operator MANUAL mode is now the active control mode Press the Enabled Disabled button until Enabled is displayed The axis should now be enabled and the Enabled indicator light should now be solid green Press the Jog Move buiton to select between the 2 types of manual control To set to jog speed for example click on the corresponding Jog Spd display box to launch the keypad Position 0 77 units The units for both Jog and Move manual contiteNesend revs sec Note Some of the numbers shown are both indicators and kevoad input buttons For example the Jog Spd indicator displavs the actual soeed feedback of the drive not the desired ioa soeed However by clicking the indicator you launch the keypad input object where you can enter the desired jog speed Dual Purpose Controls z 4 Enter desired jog speed 0 10000 Position 0 24 units JogSpd 1 00 _ units Actual speed feedback from drive Take a few minutes to manually control the axis by executing a Jog command To move the axis press and hold the Jog Fwd or Jog Rev buttons This concludes the demonstration When you are finished manually controlling the axes be sure to Stop and Disable all of the drives Maximize Logix Designer and go offline with the current file by selecting Go Offline from the Communications menu 16 of 142 Lab 1 Basic Configuration of an Integrated Motion System Estimated Time 20 Minutes
123. rovides status info Refer to the state Stop function controls the machine Axis02 di h hi and allows manual lagram the machine control Axis03 Exits the runtime window and closes the application Launches the Launches the Alarm History Equipment Status screen logs fault info screen displays key axis values Launches the State Diagram screen provides an overview of the state machine includes current amp previous state State Alarm Equipment Diagram History Status exit The Startup screen provides Machine Status and Control plus it allows navigation to all other screens Take a moment to familiarize yourself with the Startup screen before moving on to the next section It may look a little different depending on the status of the machine Start and Stop the Machine 1 Ifthe machine is currently in the ABORTED state Machine Status Mi FAULTED Power Up __ Ready _ SafeSpeed State ABORTED press Clear Faults Machine Status ok __ Ready _ SafeSpeed State STOPPED After a few moments the machine should transition to the STOPPED state 2 Press Program Operator button until Program is displayed Program AUTO is now the active control mode 3 Press Start The required axes enable and begin operating according to the Logix Designer program You should see that all three axes begin to rotate If you notice closely you might be able to tell that Axis02 appears to be following Ax
124. rque at a reasonable cost Fan Pump Volts Hertz is based on the Basic Volts Hertz but is specifically tailored for fan pump applications Sensorless Vector is an alternative Velocity Control Method that does not require configuration of a Volts Hertz curve Instead by knowing the Stator Resistance and Leakage Inductance of the motor the drive device can calculate the appropriate Output Voltage required for a given Output Frequency This method provides better low speed Velocity Control behavior than by using the Basic Volts Hertz method Induction Economizer mode consists of the sensorless vector control with an additional energy savings function When steady state speed is achieved the economizer becomes active and automatically adjusts the drive output voltage based on applied load By matching output voltage to applied load the motor efficiency is optimized Reduced load commands a reduction in motor flux current 39 of 142 8 Navigate to the Drive Parameters page ce Anis Properties aiso O O OOOO Categories Drive Parameters to Controller Mapping Parameters to be read each cycle General Motor os Model Analyzer Scaling Parameters to be written each cycle a ed Hookup Tests Polarity Planner Frequency Control Actions oe rive Parameters Parameter List Status Faults amp Alarms Tag Axis State Manual Tune v M m M M VeioctyReterence o
125. s a different tag than AxisO1 ModuleFault 70 of 142 Name zal Value Force Mask Style Data Type Avis 1 ModuleF auts 16 0000_o000 Hex DINT Aris01 ControlSyncFault E Decimal BOOL Decimal OOL 4xis01 ModuleS yncF ault he Axis01 TimerE ventF ault Faults Decimal OOL 44801 ModuleH ardwareF aut as Decimal OOL OOL OOL OOL OOL OOL OOL OOL OOL OOL Decimal OOL Decimal BOOL Hex INT OOL noL Decimal f Axis01 ClockSkewF ault amp xis01 ControlConnF ault 2 T pe 3 a O m 3 a I D Q 3 a o o oo o o o o oa Decimal Decimal Decimal Decimal 4xisO1 ContralSyncAlarm TEA 4xis01 ModuleSyncAlarm Mi E a a A a A a a oO At Trwevenslom Alarms o0L Me a aa es i Bool Axis ClockSkewdlarm 0 Decimal BOOL Notice the fault types are further broken down into individual fault and alarm status bits This is one of the many benefits of the multi discipline integrated controller you don t need to create code to collect motion controller diagnostics in the discrete controller or HMI Let s see how this works by generating a module fault condition The exception actions are used to set how an axis responds to different tvoes of faults The lexception actions are located on the Actions page of the Axis Properties Categories
126. select the correct tag for each entry ay eee ET Linear Move Coordinate System XY_CoordSys MCLM i Motion Coordinated Linear Mowe EN Motion Control Coordinate System XY_CoordSys XY CoordSys Citrl CSI MCLM 1 Motion Control X _CoordSys_Ctri CSI MCLM 1 DN gt Move Type 0 ER Move Type 0 Position XY_CoordSys_Ctrl Data Position 2 EJ Position XY_CoordSys_Ctrl Data Position 2 cons a Speed XY_CoordSys_Ctrl Data Speed 0 AC Speed XY_CoordSys_Ctrl Data Speed 0 a Se ee he eee TN Speed Units Units per sec PC Speed Units Units per sec Accel Rate XY_CoordSys_Ctri Data Accel 0 0 06 Accel Rate XY_CoordSys_Ctrl Data Accel 0 Accel Units Units per sec2 Decel Rate XY_CoordSys_Ctri Data Decel 0 Accel Units Units per sec2 0 0 Decel Units Units per sec2 Decel Rate XY_CoordSys_Ctrl Data Decel 0 Profile Trapezoidal Accel Jerk 100 Decel Units Units per sec2 Decel Jerk 100 Profile Trapezoidal mum iaria Termination T 5 Accel and Decel Jerk 100 OAIT ie i Merge Disabled Jerk Units of Time Merge Speed Programmed i Command Tolerance 0 Termination Type 5 Lock Position 0 Merge Disabled Lock Direction None Merge Speed Programmed Event Distance 0 Calculated Data 0 Command Tolerance and Lock Position 0 for A both Lock Direction None Event Distance and Calculated Data 0 for both 13 After completing the instruction entries click on the ellipsis next to the Position tag to open the dial
127. ssing the X in the top right corner 14 Click Stop to stop the drives Continue on to Lab 5 Lab 5 Troubleshooting Techniques Estimated Time 10 Minutes In this lab you will learn some basic troubleshooting techniques In this lab you will be asked to troubleshoot a Module Connection Fault using Logix Designer Diagnostic Capabilities of Logix Designer First let s look at Logix Designer diagnostic capabilities using the file you saved in the previous lab 1 Maximize Logix Designer You should be Online with the controller 2 From the Controller folder in the Controller Organizer right click on Controller Tags and select Monitor 69 of 142 Tags I Controller Organizer Controller Intro _CIP_K5S500_Base Controller Tagga E3 Controller Faul New Tag Ctrl W eS ta MainTask Edit Tags POO_Machi verify cg PO1_Applic Export Tags 8 PO2_Axis0 OB PO3_Axis0 C Unscheduled Print 3 Verify that you are on the Monitor Tags tab of the Controller Tags window 4 gt f Monitor Tags A Edit Tags 4 Locate the Axis01 Data Type AXIS_CIP_DRIVE tag Force Mask Style A AxisO1 _CIP_ AxisO1_ Ctrl UBT_ServoCtrl AxisO1_FP ae ili teak CIP_Faceplate_A0I Fl Axis01_Module fee keas F UDT_ModuleStatus Most of the diagnostic tags are automatically generated as part of the axis structure when an axis is created in Logix Designer
128. ster Driven Axis Control Motion Instructions MDAC Motion Master Driven Axis Control Ra SLAVE ae lt 0 Slave Axis SLAVE EJ KON Master Axis MASTER G Master Axis MASTER GE HER wan Co eS eee Motion Control MASTER_Ctr MLMDAC O HIP Gastar cies Motion Type Al AC Master Reference Move 3 Jog Actual Time Cam C Master Offset Move Within the motion move instructions 4 new instruction operands have been introduced e Lock Position O Event Distance e Lock Direction O Calculated Data And for instruction unit operands we have introduced new values of Units per MasterUnit Master Units and Seconds For the MAM instruction we have the added feature of programming the move in time time as the master unit You define the end point of the move and the total time of the move In this lab we will cover some of the basic functionality of Motion Drive Speed Control by doing the following e Use the MAM in classic time driven mode with speed accel decel and jerk defined in user units e Use of the MDAC instruction e Use the MAM in MDSC mode with speed accel decel and jerk defined in Units of MasterUnits Execute the MAM Instruction in Classic Mode Here we will show the basic use of the MAM instruction in classic time driven mode with speed accel decel and jerk defined in user units It will give a point of reference for using the MDCS functionality 86 of 142 Open file Desktop Lab Files Master Driven S
129. t No Action No Action Analyzer 42 11 2014 10 31 13 704 No Alarms Alarm Log Reset Alarm Off Motor Feedback 12 11 2014 10 31 21 591 Faults Cleared Connection Reset No Action No Action Scaling 12 11 2014 10 31 43 431 Faults Cleared Fault Reset No Action No Action Hookup Tests 12 11 2014 10 32 16 731 Module Alarm Clock Jitter Alarm Alarm On Polarity Jy 12 1 2014 10 32 16 770 Module Alarm Clock Jitter Alarm Alarm Off Autotune 44014 14 06 06 9 FE NIFA U Daaa Jo Action z Load Backlash Compliance Friction Observer Position Loop Velocity Loop Acceleration Loop Torque Current Loop Planner Homing Actions Drive Parameters Parameter List Status ini Sais Show M Faults M Alarms M Resets Clear Log ag Axis State Faulted Manual Tune Cancel Help Notice both module faults plus additional information Date Time etc are displayed The Faults and Alarms Log was added to RSLogix 5000 v18 to support CIP Motion drives The Faults amp Alarms page displays the current state of both faults and alarms log structures currently in the controller for an axis The display is read only except for the ability to clear logs independently The grid only shows entries when you are online with a controller When online check or uncheck boxes in the Show row to toggle between showing and hiding the specified group of entries Note that only the last 25 faults and alarms are displayed Click Cancel to close the Axis Properties
130. t saw how you can set up the MAM where the speed of the move is geared to the Master How about having the speed of the Slave be in Master Units so the instruction behaves more like a one shot position cam Same steps as the previous section but now the MAM units for speed accel decel and jerk need to be set to Master Units 1 2 To start change the Master jog speed back to 1rev sec on rung 3 Motion Axis Jog MAJ Motion Axis Jog EN gt Axis MASTER a Motion Control MASTER_Ctri MLMAJ 2 _DN Direction 0 ER IP Rung 7 contains our move instruction In this MAM the lock position of the Master is still 5 Here we want to move the Slave 1 position unit 1rev in the time it takes for the Master to go 5 position units revs This will be a slow move 96 of 142 MAM 3 MDSC in Master Units Think Position CAM Move On Off HMI_ON 3 Motion Instructions MASTER_Ctri MI MDAC 0 IP Motion Axis Move MAM Motion Axis Move EN Axis SLAVE f Motion Control SLAVE_Ctri ML MAM 3 DN Move Type 0 Position MAM_MDSC_masteruntPOS 1 06 oe Speed MAM_MDSC_masterunitSPD 506e PC Speed Units Master Units Accel Rate 100 10 11 12 Accel Units Decel Rate Decel Units Profile Accel Jerk Decel Jerk Jerk Units Merge Merge Speed Lock Position Master Units 100 Master Units Trapezoidal 10000 10000 Master Units Disabled Programmed c Lock Direction Position
131. ta ip waco Rat XY dSys_Ctrl Data Decel 0 Accel Rate XY_CoordSys_Ctrl Data Acceljo a ae P 3 Decel Units Units per sec2 Accel Jerk 100 Decel Rate XY_CoordSys_Ctrl Data Decel 0 Decel Jerk 100 Decel Units Units per sec2 Jerk Units of Time Profile Trapezoidal Termination Type 5 Accel and Decel Jerk 100 paid Caen Merge Speed Programmed Jerk Units of Time Command Tolerance 0 i i Lock Positi 0 Termination Type 5 iii r Lock Direction None Merge Disabled Event Distance 0 Calculated Data 0 Merge Speed Programmed Command Tolerance and Lock Position 0 for both Lock Direction None Event Distance and Calculated Data 0 for both Open the Position dialog window for the MCCM instruction MCCM Motion Coordinated Circular Move Coordinate System XY_CoordSys E Motion Control XY _CoordSys_ Ctri CS MCCM 0 DN Move Type 0 Position XY _CoordSys_Ctrl Data Position 4 l A X_AXIS IP Y_AXIS Circle Type 1 AC Enter the Target Position values X_AXIS 4 0 and Y_AXIS 8 0 and the Center Position values X_AXIS 0 0 and Y_AXIS 0 0 for this MCCM move Target Position Entry XY_CoordSys XY_CoordSys_Ctrl Data Position 4 XV_CoordSys aa Postion Tas 81 of 142 XY _CoordSys G XY_CoordSys_Ctri CSI MCCM 0 gt gt EN DN gt ER AC PC 19 Click OK to lock in the values 20 Save your program Execute the Coordinated Motion
132. tab click the Change button Module Definition oon Revision 1 1 Sl Electronic Keying Compatible Module Connection Motion only lt none gt Power Structure 8 Select 25C V 2P5 from the Power Structure drop down menu and click OK TIP The PowerFlex 527 utilizes the same power core as the PowerFlex 525 Simply swap the control cores 28 of 142 I x Revision fi 4 Electronic Keying Compatible Module Connection Motion only lt none gt 7 Power Structure IV Verify Power Rating on Ge 9 Click Yes to confirm module configuration change RSLogix 5000 E i These changes will cause module data types and properties to change A Data will be set to default values unless it can be recovered from the existing module properties verify module properties before Applying changes Change module definition 10 Navigate to the Associated Axes tab 29 of 142 ON Module Properties Local PowerFlex 527 STO CIP Safety 1 1 General Connection Time Sync Module Info Internet Protocol Port Configuration Network Associated Axes Power Di4 gt Axis 1 a New Axis Motor Feedback Device Status Offline Cancel Apply Help In the drop down menu for Axis 1 choose Axis03 TIP Though this drive type does not support auxiliary feedback other CIP Motion drives do In these drives Axis 1 and Axis 2 are both listed The auxiliary feedback
133. the Autotune Travel Limit Speed and Torque are all set to a non zero value 2 Exceeded Travel Limit Tune Status Exceeded Travel Limit 53 of 142 The Autotune Speed might be set too high check the speed and decrease it The Autotune Travel Limit might be set too low check the test distance and increase it 54 of 142 Lab 3 Using Motion Direct Commands Estimated Time 10 Minutes Motion Direct Commands let you issue motion commands without having to write or execute an application program You must be online with your controller to execute a Motion Direct Command Let s see how these work using the project you created in the previous labs Jogging an Axis Using Motion Direct Commands 1 Before running the Motion Direct Commands verify the drives are ready Check the K5500 drive status Module light should be solid green Network light should be solid green Port status indicators may be flashing green indicating network traffic The Kinetix 5500 and PF527 drives should both display STOPPED in all capital letters at the top of their displays Note With the PF527 Beta units the LEDs are not behaving properly This issue has already been fixed If your drive says STOPPED you are successfully connected 2 Right click on AxisO3 and select Motion Direct Commands E Motion Groups B 5 MotionGroup ADD AxisO1 tt AxisO2 Ba Ungroui Goto Module B E Add On Ins 5 AlarmHi Monitor A
134. this chassis or any other synchronized device may experience l unexpected motion Safety controllers may 2 Is a synchronized time slave fault if no other time master exists in the 2 Duplicate CST master detected local chassis O CST Mastership disabled O No CST master Advanced O Is the system time master Verify that the selection box Enable Time Synchronization is checked Controllers that currently support the PF527 include 1756 L7x L7xS and CompactLogix PAC ERM controllers with v24 firmware Enable Time Synchronization ditfers from Make this controller the Coordinated System Time master that was implemented in previous versions of RSLogix 5000 Enable Time Synchronization establishes the module s ability to participate in time synchronization which is a fundamental requirement of CIP Motion CIP Motion doesn t rely on a rigid scheduled network to create determinism Instead CIP Motion delivers the data and timestamp for execution as a part of a standard Ethernet packet This allows motion devices to plan and follow positioning path information according to a pre determined execution plan The controller communication module and all of the motion devices require time synchronization for CIP Motion to function The mechanism that provides time synchronization on EtherNet IP is referred to as CIP Sync CIP Sync is based on the IEEE 1588 Precision Time Protocol PTP standard which detai
135. tion Controler 9 000289 0 i SLAVEActualPosition SLAVE CommandPosition SLAVE Command Velocty le efor Search Results 4 Watch From the Controller Organizer navigate to the routine Main Task gt P0O2_ Application gt R10 ApplicationCode and open it This routine contains our application specific code and will be used throughout this lab Tasks 2 d MainTask PO1_Machine 5S PQ2_Application b A Program Tags Ep ROO_Main H ROL_PowerUP E R02_Monitor 19 cL PO3_Module_ X YCoordMotion fy Unscheduled Programs Phases 16 We will start with executing the MAM in rung 5 This is a very conservative move going from position 0 to 1 at 10 units sec 10 revs sec This is Known as time driven or classic mode 90 of 142 MAM 1 Time Driven classic in Units per second Move On Off Motion Axis Move HMI_ON 1 MAM Motion Axis Move Axis SLAVE Ga Motion Control SLAVE_Ctri MLMAM 1 Move Type 0 Position Speed 10 Speed Units Units per sec Accel Rate Accel Units Units per sec2 Decel Rate 100 Decel Units Units per sec2 Profile Trapezoidal Accel Jerk 1000 Decel Jerk 1000 Jerk Units Units per MasterUnit3 Merge Disabled Merge Speed Programmed Lock Position Lock Direction None Event Distance 0 Calculated Data 0 A Motion Axis Move SLAVE_Ctri MLMAM 1 ER Inst_Error We want to observe the move in a trend Under Trends in the Controller Organi
136. tor parameters are entered directly by the user Optional for those users who have experience with servo motor data and wish to enter their own 3 Party motor parameters Catalog Number For K5500 motors where parameters are acquired from the Motion Database Customers will generally employ an AB motor listed in the Motion Database Motor NV Motor parameters are derived from non volatile memory of a motor mounted smart feedback device equipped with a serial interface Applies to any Hiperface or EnDat based motor which is preprogrammed with Rockwell Automation formatted data 37 of 142 Click Apply to save your changes 5 Navigate to the Scaling page te Axis Properties Awiso3 T Categories General Scaling to Convert Motion from Controller Units to User Defined Units E Motor Le Model Load Type Direct Coupled Rotary Parameters Analyzer Transmission SS Sealing Ratio fF t lt it CR Hookup Tests Polarity Actuator fir Planner Type lt none gt H Frequency Control L Actions Lead 1 0 Millimeter Rev v Drive Parameters Diameter 10 Millimeter z a Parameter List Status Scaling Tag Scaling 1 0 revs s per 1 0 Travel Made Axis State Safety State Manual Tune Cancel Apply Help 1 Enter revs in the Scaling Units box Leave the Scaling set to 1 0 revs per 1 0 Motor Rev 2 Click Apply to save your changes Note Positio
137. ts can decrease the performance due to interpolation errors The rule of thumb is to use eight Cam Points per acceleration ramp E F 1 feed rate cm s 10 2 knife radius cm 15 3 sample rate s 0 10 101 of 142 e Labeling the system dependent variables including units and defining the initial values This includes Master Axis cm 9 rev and w rev s The initial value of cell C2 is computed from Equations 2 with the formula F 1 2 3 14 COS 2 3 14 B2 3 14 4 F 2 A B E 1 Master Axis cm f rev w revs 2 0 0 0 150069088 e The next iteration of the dependent variables are computed as A3 Master Axis A2 F 1 F 3 B3 0 B2 C2 F 3 and C3 w F 1 2 3 14 COS 2 3 14 B3 3 14 4 F 2 Subsequent iterations rows are filled based on the same equations until the orientation of the knife exits the Cut Region In this case the orientation is equal to 90 or 0 25 revs The Cam Profile for the Cut The figure below illustrates the Cam Table for the Cutting Region Region is shown in Figure 3 1 2 3 4 5 6 7 8 A Master Axis cm 0 on non B amp B wh ke B 6 rev 0 0 015006909 0 028779878 0 041679908 0 05393541 0 065703754 0 077100558 0 088215354 0 099120754 0 109878223 0 120541982 0 131161855 0 141 78552 0 152460486 0 163236031 0 174165315 0 185307943 0 196733331 0 208525475 0 220790112 0 233666183 0 247345404 C w revs 0 150069088 0 137729691 0 129000304 0 122555016 0
138. uisite is to be familiar with Logix Designer software and programming When the computer is booted a FactoryTalk View ME Station program will start You will use that Human Machine Interface HMI throughout the lab If you close it at any time you will need to open it again from the C Lab Files directory in order to operate the lab correctly Logix Designer Studio 5000 is a modular framework for engineering collaboration with plug ins for specific engineering tasks For example there will be a core plug in that will be used for developing projects for Logix controllers This plug in is referred to as Logix Designer Logix Designer brings the existing RSLogix 5000 user interface into the Studio 5000 environment which will introduce new shared components These components will bring even more power flexibility and organization to the Logix design environment Studio 5000 will be required for all Logix controllers that are running version 21 firmware or greater About this lab You will be introduced to Logix Designer software environment as the single software tool used by the Rockwell Automation Integrated Motion Solution for configuration programming and troubleshooting as well as the inherent ease with which you can define your motion process This lab exercise demonstrates the following concepts of Integrated Motion on EtherNet IP Time efficient nature of using an Integrated Motion solution Benefits of Integrated Motion on EtherNet
139. vanced tuning user selects Autotune parameters Basic Default tuning parameters Tracking Winding unwinding flying shear and web control applications Point to PointPick amp place packaging and cut to length applications Constant SpeedConveyors line shaft or crank applications Position Position Velocity Velocity x op ae vitega Integrator Velocity Acceleration Bandwidth Bandwidth Bandwidth Bandwidth ee FERO Custom X X Basic X i xX Tracking X X X X X Point to Point X pi X X X Constant Speed X X X X X selected by default When selected Autotune will set the Velocity amp Acceleration Feedforward to 100 There are thr wop Responsetions Low Damping Factor 1 5 Medium Damping Factor 1 0 High Damping Factor 0 8 3 Select Frequency Control from the Axis Configuration drop down 35 of 142 Axis Properties AxisO03 ioj x Categories a General E Motor m ya En Model Axis Configuration Frequency Control Analyzer Feedback Configuration No Feedback w Scaling Hookup Tests Polarity n Planner Frequency Control Assigned Group Actions l t Fide ERANS Motion Group MotionGroup ie New Group Parameter List Update Period 3 0 oo Status Faults amp Alarms Associated Module Module Drivel3 v Module Type PowerFlex 527 STO CIP Safety Power Structure 25C 2P5 Axis Number 1 Axis
140. verything was done on the fly using Motion Direct Commands Stop the Axis Using a Motion Direct Command 1 Select the Motion Axis Stop MAS instruction 58 of 142 G Motion Direct Commands AxisO3 1 Commands otion Axis Stop 5 3 Motion State Axis Axis03 x E nl MSO Re MSF Operand Re MASD Py Re MASR Change Deca Yes Re MDO Decel Rate 5 Re MDF Dece Units g nits per sec Re MDS Change Decel Jerk ves Decelderk 100 5 ca sini Jerk Uruts of Time otion Move Ro MAS Re MAH Re MAJ Re MAM Re MAG Re MON v A DANGER Executing motion command with controller in Program or Run Mode may cause axis motion Axis State Running Safety State Unknown No Motion Connecti Axis Fault No Faults Start Inhibited Not Inhibited Motion Group Shutdown Help Set Change Decel to Yes and enter in a Decel Rate of 5 Units per sec2 or revs s The MAS instruction will initiate a controlled stop of any motion process on the designated axis Click Execute When the axis has slowed to a stop select and execute the Motion Servo Off MSF instruction The MSF instruction disables the specified axis by deactivating both the drive amplifier and the drive control loop Click Execute the PF527 should now show a STOPPED status on the HIM Now use the Motion Drive Start MDS instruction If you have any questions please consult with your lab instructor Note You will NOT have to execute an MSO i
141. xis Tag OE CIP Fa 5 F Fault Hel Ee 5 Machine tae Fy Data Types Clear Axis Faults Oh User De E 7 Cut Ctrl A Strings 4 yO Add on AA Copy Ctrl C G R Predefir 4 Paste Ctrl y H i Module Delete Del 5 Trends So Se Mr Logical Mod Motion Direct Commands a 1 0 Configu Manual Tune i 1769 B Ee fa 0 Motion Generator B 1 Cross Reference Ctrl E B 2 a 3 Print k l sg Eth El as 1176 Properties Alt Enter J 1734 AENTR A Point_IO_Chassis PointIO 4 Slot Chassis i cow A Pn 1PRAAFMTD iA Daint T The Motion Direct Commands window opens 55 of 142 3 Take a moment to look through all the commands available to you by moving the mouse cursor over the instructions 4 Select the Motion Servo On MSO instruction E4 Motion Direct Commands AxisO3 1 Commands m pe Ro MSF Re MASD Ro MASR Re MDO Re MDF Re MDS Leal MAFR 3 Motion Move hel MAS Re MAH Ro MAJ Ro MAM Rp MAG Re MCD Re Mpp Kd D DANGER Executing motion command with controller in Program or Run Mode may cause axis motion Axis State Stopped Safety State Unknown No Motion Connecti Axis Fault No Faults Start Inhibited Not Inhibited Motion Group Shutdown Bente Help The MSO instruction enables the specified axis by activating both the drive amplifier and drive control loop IMPORTANT If the motor spins after only enabling the drive go back to Step 11
142. yor Master Axis AXIS_01 Rung 3 Home the Rotary Knife Slave Axis AXIS_02 105 of 142 13 14 15 16 17 18 Rung 4 Read the Switch POINT I O 1734 IB8 INO on controller demo to determine whether to use the Default 0 or User Defined 1 Cam Table Rung 5 If INO 0 then Load the Default Cam Table Cam Profile 1 Rung 6 If INO 1 then Load User Defined Cam Table Cam Profile 2 Rung 7 Control the Rotary Knife based on the Master Axis and Cam Table MAPC Rung 8 Read the ANALOG INPUT 0 rotary knob on the controller demo and set the Feed Rate Rung 9 Start the Conveyor at the specified Feed Rate which in turn starts the Rotary Knife NOTE In order to modify the Cam Table selection INO or Feed Rate ANALOG INPUT 0 the machine must be brought to a stop and then restarted The ANALOG INPUT 0 rotary knob defines the machine Feed Rate and the range is from 0 to 200 cm s As a starting point set the rotary knob to 5 0 which equates to half speed Make sure the POINT I O 1734 IB8 INO is set to the left 0 to load the default Cam Table Cam Profile 1 Manually align the white strip on the load disk of the right hand motor Knife AXIS_02 to face toward you This represents the knife blade and where the product is cut We want to monitor the machine performance in a trend Under Trends in the Controller Organizer double click on the trend Machine_Performance to open it
143. zer double click on the trend position _MAM1 to open it 5 6 Trends ff position MAMI lt AT position_MAM2 Se position MAM3 Click Run to start collecting data in the trend Run Stor Errors Log Logging Stopped Periodic 10 ms Capture C of 0 On the HMI push the MAM1 button to execute the move We don t need the MDAC instruction for a MAM running in time driven classic mode Note the motion of the right motor in the demo box After the move completes click the Stop button in the trend Use the scroll back in time buttons below the graph until you see the MAM in the trend Your trend should look similar to this 91 of 142 position MAM1 Monday April 28 2014 3 05 51 PM 3 05 52 3 05 53 3 05 52 3 05 53 3 05 53 PM 22 Click on the peak of the velocity curve green triangle and verify that the top speed of 10rev sec was reached in the move Click on the start and end of the position curve blue to verify the start and end positions of 0 and 1 Click in the middle of the acceleration curve red to verify the maximum acceleration of 100rev sec i 100 00 100 00 0 00 0 00 0 00 Execute and Verify a MAM in MDSC mode using Units per MasterUnit Now we will trigger a slave MAM based on a master s position and set the speed as a gear ratio to the master The MAM will be programmed in Units per Master Unit To use the MAM in MDSC Mode we need to Set up the relationship
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