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FX Positionining Control Systems

1. Postion controller AC power 5 Er supply gt i H e Outputs the positioning speed and the ith movement quantity in command pulses to the 3 servo amplifier Q e Transfers signals between the programmable i N j controller l Power factor Radio noise e Controls return to the zero point improving AG reactor filter Electromagnetic Line noise i contactor filter Sa a er SE J Powerboard Nearpoint DOG signal e Improves the power factor and cuts noise e Protects the power circuit In some types the limit switch signal is wired to the position controller Main circuit Position controller ae eres NN ea ae aa an ae eee E l Smoothing Regenerative Dynamic l Converter circuit Taie Iweni Si brake 1 I 3 l Positioning AC DC gt DC gt gt DC AC R I command i l control Command He K T x i pulse i Parameter Speed Feedback q I Pulse Deviation Command v current I magnification gt counter 1 l Zero point Current PWM pulse width i L return Electronic gear control modulation control I control I 7 l i Servo amplifier I I l e Rectifies the AC power of the main circuit into the DC power in the l converter and smooths it in the smoothing circu
2. X007 pei KO K17 K100 Ki 0 START Unit No BFM Target No of address 1 transfer points FNC 7 DTA 9 KO K19 K4o000 Ki 27 Unit No BFM Operation No of speed 1 transfer points FNC 79 DTO KO K21 K150 Ki 3 Unit No BFM Target No of address 2 transfer points FNC 79 Bio KO K23 K10000 Ki 0 Unit No BFM Operation No of speed2 transfer points M8000 ENG 79 TO KO K25 K4Mo K1 O RUN monitor Unit No BFM Operation No of commands transfer MO M15 points FNC 78 DERON KO K26 D10 K1 0 Unit No BFM Current No of address transfer points END 433040da eps Fig 4 19 Program example 2 Number Description 1 Set the Target address 1 K100 18 17 Set the Operation speed 1 K40000 20 19 Set the Target address 2 K150 22 21 Set the START command for Two speed positioning 2 O Set the Operation speed 2 K10000 24 23 6 Write operation commands to the FX2n 1PG K4M0 25 Monitor the current address mm D11 D10 27 26 Tab 4 18 Description of program example in fig 4 19 2 4 42 Pa MITSUBISHI ELECTRIC FX2N 10PG positioning Learning to Use the FX Familiy for Positioning Control 4 4 FX2n 10PG positioning The FX2n c and FX3u c PLCs support connection with the FX2n 10PG special function block As described in sectio
3. V NA STL SO 0 M50 X004 ji FNC 156 kso000 K1000 x005 Yooo 2 Waiting for Stop DZRN 1 scan time command Zeroreturn Creep Near point Pulse start speed speed signal output destination number M8029 r SET M10 H Execution completion flag 3 Use this for FX3G and FK3U C PLCs g i M8340 M50 io i RST SO a 1 Yooo Waiting for i Outputting 1 scan time h i Use this tor FX1s and PAN PS i M8147 M50 i A BST So Oo i Y000 Waiting for i Outputting 1 scan time Tms a ea M50 RUN monitor STL so H M51 X004 r yf Ra K500000 100000 Yooo Yo04 0 Waiting for Stop 1 scan time command Designation Output Pulse Rotation c of absolute pulse output direction 2 position frequency destination signal 3 number 2 M8029 fe E T ser mu H 9 2 Execution completion flag me CPt pea RS eS Se Sa es Se RSS ee a ie ee ee Sa SS ji Use this for FX3G and FX3u c PLCs i m8340 msi 5 H tf RST S20 HO SI Y000 Waiting for Outputting 1 scan time i AA aa aaa t Use this for FK1S and FX1N PLCs 1 1 i M8147 M51 H rst s H _ Yo00 Waiting for Outputting 1 scan time Seer ls Sa cea eB kaa AC r NIUE BS SC Tere PNR Sd Sn amelia j M8000 is JH M51 6 RUN monitor vV NYA y y 413040da eps Fig 4 3 Program example 3 To stop the positioning operation be sure to
4. 3 8 3 2 3 Servolockfunction 3 9 3 2 4 Regenerative brake function 3 9 3 2 5 Dynamic brake function 3 10 33 gt DriveiMeChaniSM i c 4 eren IAA Gaeta weet 3 11 3 3 1 Concept of drive system movement quantity 3 11 3 3 2 Setting the target position 3 13 FX Positioning Control Systems V Table of Contents 4 Learning to Use the FX Familiy for Positioning Control Ad KPL positioning o ccsivnsveckss ua ew AAA Kai Gade ws 4 1 4 1 1 Ovemviewofcontrol 4 1 4 1 2 Important memory locations 4 4 4 1 3 ProgramEkamples nsanas 4 5 4 2 Inverter Drive Control 4 21 42 1 Ovemviewofcontrol 4 21 4 2 2 Using the FX2N C FX3U C and FREQROL Inverter 4 22 4 2 3 Programekample 4 26 4 3 FX2N 1PG E positioning 0 tee 4 36 4 3 1 Ovemviewofcontrol 4 36 4 3 2 Important buffer memory locations 4 37 4 3 3 Programerkample 4 38 4 4 FX2N 10PG positioning 0 0 0 eee 4 43
5. Positioning type DDRVA Drive to absolute Number of pulses PLS 100 Frequency Hz 100 000 Tab 4 7 Settings for positioning instruction 5 Click the OK button and then the End button to close the parameters Create the ladder program as shown in fig 4 9 FX Positioning Control Systems 4 15 Learning to Use the FX Familiy for Positioning Control FX PLC positioning Once the ladder program is complete click on Online from the top menu bar in GX Developer and select Write to PLC The following window will appear Write to PLC Connecting interface comt lt gt PLC module PLC Connection Station No Host PLC type FX3U CI File selection Device data Program Common j m Execute Param Piog Select all Cancel all selections Heartless Close 3 Program BA MAIN Related functions Device comment Transfer setup COMMENT Parameter RAI PLC parameter Remote operation Keyword setup Clear PLC memory 4130c0da eps Fig 4 10 Write to PLC window Click the Param Prog button and then click the Execute button The parameters and the created program will be transferred to the PLC To enable the transferred parameters stop the PLC and then restart it Inputs Outputs Zero point signal Pulse train output Near point signal DOG Rotation direction signal Servo ready CLEAR signal Immediate sto
6. 2 2 1 Positioning by AC Servo System Advantages for using an AC servo system With an AC servo system positioning can be performed by many diversified methods Typically a position controller servo amplifier and servo motor are required for positioning with an AC servo system The representative servo system configuration is shown below Servo amplifier ji Servo Commercial Smoothing motor power supply Converter circuit Inverter AC gt DC __s DC gt DC gt AC a K Command a E pulse Speed PLG Feedback an _ Deviation Command J current Positioning counter i Encoder controller Ai Current PWM pulse width Feedback control modulation control pulse The positioning controller The command pulse number The servo motor is equipped with a generates a specified quantity is subtracted by the feedback pulse built in encoder pulse generator of forward rotation or reverse rotation number and the speed command to dedicated to high speed response and pulses at a specified frequency drive the servo motor is made from the suitable for positioning control deviation accumulated pulse number When the accumulated pulse number becomes 0 the servo motor stops 210010da eps Fig 2 1 Block diagram of an AC servo system In the latest AC servo systems conventional weak points have b
7. Tab 4 1 Overview of applicable PLC main units Output terminals for direction can be specified arbitrarily when the FX3U 2HSY ADP is not used Y4 Y5 Y6 and Y7 are used as an example GO The FP RP pulse output method is also available with the FX3U 2HSY ADP The FX3uc can not be connected with the FX3U 2HSY ADP FX Positioning Control Systems 4 1 Learning to Use the FX Familiy for Positioning Control FX PLC positioning Limit switches As with any other positioning system inputs are needed to detect when the workpiece reaches the outer boundary limits in order to prevent damage to the machine For the FX3G and FX3u c programmable logic controller limits are wired to the controller to be used with the DOG search zero return function for reversing the motor s direction of travel in order to hunt for the DOG switch These limits are called the forward rotation limit LSF and the reverse rotation limit LSR Hardware limits are used on the servo amplifier side to stop the motor in worst case scenarios Reverse rotation limit 2 Reverse rotation limit 1 Forward rotation limit 1 Forward rotation limit 2 Servo amplifier side Programmable Programmable Servo amplifier side controller side controller side LSR LSF Servo motor E SSS SSES Reverse rotation lt Forward rotation 141010da eps Fig 4 1 Example of limit switches for the FX3u c PLC Sink vs Source outputs In gener
8. 4 22 G GX iii Perce eked Shee Pee 4 13 GX Developer 4 12 GX IEC Developer 4 12 GX Works2 4 12 H Home position 3 5 J JOG Command 4 12 L Ladder program 4 15 Limit switch 0 0 AA eee 4 2 M Memory addresses FX1S FX1N FX3G FX3U C PLCs 4 4 FK2N TOPG 4 44 FX2N 1PG E 4 37 FX8U 20SSC H Wi wwa 4 65 Index P Position control AI ai kiua 1 9 Positioning example Carrier robot 2 5 Cart travel a reine ecw oii Meee bes 2 4 Constant feed 2 2 Drilling in steel sheet 2 3 Indextabler acta fdmeunes cele ted 2 3 ni IAA katia 2 4 Tapping II EA 2 2 Programming example E500 Series 4 26 FXIN PLGE 5 ht ica ee ese eee 4 5 EXIS REG wie hers feuds oblaasehdi atid 4 5 FX2N 10PG 4 45 FX2N 1PG E 4 38 FX2N 20GM 200 eee eee 4 52 FX3G FX3U C PLC 4 12 FK3U 20SSC H 4 61 FX Positioning Control Systems S SEA AWAUWA 3 9 Setting of target position Absolute method 3 13 Incremental method 3 13 Sink type input 4 2 Sink type output 4 2 Special function block FX2N
9. In order to perform processing on a flat face positioning with high precision is performed by two Fig 2 4 Schematic drawing Drilling in steel sheet 200030da eps 2 2 3 Drilling in steel sheet Description motors X axis feed motor and Y axis feed motor Drilling Y fon unit Y axis Workpiece X Y table X axis feed motor Y axis feed motor 2 2 4 Index table Description The position of the circular table is indexed The index position is set on the outside digital switch or the inside program Shortcut drive is performed depending on the index position A uA SCA y Index table FX Positioning Control Systems Fig 2 5 Schematic drawing Index table 200040da eps Positioning by AC Servo System Examples of AC servo systems 2 2 5 Lifter moving up down Description As negative load is applied on the servo motor in positioning of the lifter in the vertical direction a regenerative option is also used In order to hold the lifter stationary and prevent drop of the lifter by power interruption a servo motor with an electromagnetic brake is used Fig 2 6 Schematic drawing Servo Lifter moving up down amplifier Lifter Regenerative option 200050da eps 2 2 6 Cart travel control Description A servo motor is mounted in the travel cart as the drive source A mechanism such as rack and pinion is adopted to prevent
10. The forward and reverse rotation limit switches must be wired so that they are turned ON by default Normally closed contacts When these limit switches turn OFF due to the workpiece going out of bounds M8343 or M8344 will turn ON and cause the pulse operation to stop 4 18 a MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control X023 M8348 M106 RST M12 o JO Positioning Completes being j the yOG erforme operation Yoo j RST M13 o M105 Joe operation o Is being periormed X030 ENG 152 a H Yooo K2 ae DTBL o command Pulse Table Q output number Saon X023 number yi M JOG M8329 VT Abnormal end X024 M8348 M10 M108 M109 i H it Hf H RST M12 6 Position Position Zero Normal Abnormal ing in ing return ie ji oneei ji f d ratio mpl ositioning positioning c rotation being j ation fn forward in forward RST M13 6 S amp S direction performed flag rotation rotation 3 Y00 direction direction 6 M107 3 X030 2 Positioning operation FNC 152 Y000 K3 5 being performed in forward Stop DTBL Z rotation direction command Pulse Tabie 2 outpu number E d
11. A start command accelerates the motor to a constant speed and moves the work piece to a specified distance Operation speed Start Target position Travel distance IS 411030da eps Zero return The machine movesata specified speed until the DOG input turns ON The work piece then slows to creep speed and stops before the CLEAR signal is output Speed Zero point return Creep speed Zero point DOG input ON Start CLEAR signal 411040da eps Variable speed operation After starting with a specified speed the motor can change its speed depending on com mands from the PLC For the FX1S and FX1N acceleration to different speeds is approximated with the RAMP instruction Speed change Speed change 411050da eps Interrupt 1 speed positioning When an interrupt signal turns ON the workpiece trav els a specific distance at the same speed before decelerat ing to stop Travel distance gt ZA Interrupt input 411060da eps DOG search zero return The machine operates similar to the zero return instruction except for features to hunt for the DOG switch and to use the zero phase signal Origin 411070da eps Tab 4 2 Table operation For programming simplicity position and speed data can be organized in table format for the DRVI DRVA DVIT and PLSV instructions Instructions for FX PLCs 2 FX Positioning Contro
12. Speed 1 H reducer 7 yA 7 1 1 l lt 1 l l Ball screw Ce ee ara eee ae enya ne 1 i 1 EE i i Encoder Taa PLG pulse SS i l y generator AN 1 a eee 4 i When Electro i i i required magnetic i ee ee er Lee ae 1 3 Auxiliary device such as chuck drill and cylinder Personal Hand help Computer programmer Setting display unit e Used to write programs to the position controller allows setting and display of the data Sensor actuator auxiliary device e The actuator moving part drive mechanism is equipped with speed reducer timing belt ball screw and limit switch e Diversified auxiliary devices are also controlled in accordance with positioning e The PLC or the positioning controller also controls auxiliary devices e The auxiliary device operation completed signal is output to the PLC or the position controller 300020da eps Fig 3 1 Components of Postioning Control 2 FX Positioning Control Systems Components of Positioning Control and their Roles Positioning controller 3 1 3 1 1 Positioning controller Positioning controllers use programs and parameters to send positioning commands to the servo amplifier Contents related to programs and parameters are described below Command pulse control method There are two types of control formats used for outputting command pulses from an FX Series posit
13. When the positioning START command turns ON the operation begins with the specified settings The ladder program example on the following page can be programmed with an FX2N c or FX3u c PLC and does not require an actuator i e servo system for testing The following inputs are used in the program Error reset STOP command Forward rotation limit Reverse rotation limit 2 speed positioning START command Tab 4 17 Used inputs FX Positioning Control Systems 4 39 Learning to Use the FX Familiy for Positioning Control FX2N 1PG E positioning Magoa FNC79 FO KO Ko K4000 KI o ana pise Unit No BFM Pulse No of rate transfer points o KO Ki Ktooo Ki 2 Unit No BFM Feed No of rate transfer points a KO K3 H32 Ki 9 Unit No BFM Parameter No of setting transfer points pty KO Ka K40000 Ki 4 Unit No BFM Maximum No of speed transfer points p KO K6 KO Ki 5 Unit No BFM Bias No of speed transfer points or KO K15 K100 K1 6 Unit No BFM Accel No of Decel transfer time points M8000 D KO K28 K3M20 Ki 7 am Unit No BFM Status No of info transfer M20 M31 points M27 ans KO K29 D20 Ki Error ag UnitNo BFM Error No of
14. When the pulse number corresponding to the movement distance is input to the servo amplifier of the AC servo motor positioning can be performed at high speed in proportion to the pulse frequency Guideline of stopping precision Approximately 0 01 to 0 05 mm The stop precision shows a value in a case where the low speed is 10 to 100 mm s Servo motor Pulses are fed MOOD back Moving part lt gt Ball screw Pulse generator amplifier Programmable controller Position controller Movement distance 1200a0da eps Fig 1 13 Schematic drawing Pulse command method Using the pulse command method with a servo amplifier the weak points described above for speed control are improved A pulse encoder is attached to the servo motor to detect the motor rotation quantity workpiece movement distance and feed the information directly to the servo amplifier in order to continuously and directly control the high speed positioning operation to the target position This method allows the workpiece to stop with better precision and eliminates the coasting and dispersion distance at stop Furthermore limit switches to stop normal positioning operations along with counting methods from the PLC are not needed FX Positioning Control Systems 1 9 The Basics of Positioning Control Positioning method type 1 10 Pa MITSUBISHI ELECTRIC Advantages for using an AC servo system Positioning by AC Servo System
15. dynamic brake is actuated When the dynamic brake is not actuated gt Time Power OFF Contacts of dynamic brake ON 325010da eps Fig 3 8 Dynamic brake function Pa MITSUBISHI ELECTRIC Drive mechanism Components of Positioning Control and their Roles 3 3 Drive mechanism The drive mechanism converts the rotation motion of the servo motor into reciprocating or vertical motion through a speed reducer timing belt ball screw etc to move the machine 3 3 1 Concept of drive system movement quantity The following diagram is a representative AC servo motor positioning system Fig 3 9 AC servo motor positioning Ae Vo PB 1 n AS No Pf fo Encoder Moving part _Y _ system Servo Speed Ci motor reducer TL n No Servo amplifier SUL fo Position controller y 331010da eps Transfer distance per pulse mm pulse Moving part speed during quick feed mm min Lead of ball screw mm rev Speed reduction ratio Transfer distance per rotation of motor mm rev Number of rotations of motor during quick feed rev min Feedback pulse number pulse rev Command pulse frequence during quick feed pulse sec The servo motor stops with the precision A which is within 1 pulse against the command pulse The movement quantity of the workpie
16. mode The acceleration time Pr 7 is set to 1 sec The deceleration time Pr 8 is specified The deceleration time Pr 8 is set to 1 sec The parameters are written at one time Contents of D200 D207 Pr 1 Pr 2 Pr 7 and Pr 8 The maximum frequency Pr 1 is set to 120 Hz K12000 Pr 1 The minimum frequency Pr 2 is set to 5 Hz K500 Pr 2 The acceleration time Pr 7 is set to 1 sec K10 Pr 7 The deceleration time Pr 8 is set to 1 sec K10 Pr 8 8 8 98 8 6 0 0 9000 0S Reset driving of write instruction Tab 4 15 Description of program example in fig 4 16 2 FX Positioning Control Systems 4 31 Learning to Use the FX Familiy for Positioning Control Inverter Drive Control Inverter Inverter Operation CH 1 station instruction Speed number code Wa AA E ENEN EEEE iE AE tc a ae Se eee a Use this for FK2N C PLCs FNC180 Sem Ki KO HOED D10 NA NA M8002 ji SET M11 1 Initial Pulse M11 r FNC 12 K4oo0 D10 f2 Driving of MOVP write 40Hz Operation instruction AA speed WA EEPE Use this for FX3G or FK3U C PLCs i FNC271 i IVDR KO HOED D10 K1 Function Inverter Inverter Operation number station instruction Speed Control number code M8029 Execution completion flag X000 R
17. 5 DC servosystem 0 20 cette 1 4 1 2 6 General purpose inverter and general purpose motor 1 4 12 7 AC SENO SYSTEM Aa ee Se R ie Wadia ate Geena ean ee ae 1 5 1 3 Positioningmethodtype 1 6 LSA Speed Controls II AAA 1 6 t32 Pason Como inoan aE ee ee EE AAA ES S 1 9 2 Positioning by AC Servo System 2 1 Advantages for using an AC servo system 2 1 2 2 Examples of AC servo systems 2 2 2 2 1 Constantfeed 2 2 Zae TADPING III AWA IAA IA R RE 2 2 2 2 3 Drilling in steel HII 2 3 2 2 4 gt ndex table AA AA idle dees EA 2 3 2 2 5 Lifter moving up down 2 4 2 2 66 Carttravel control 2 4 22 7 Carrier tobotu 08 22t waa ie eee Pitt ka 2 5 3 Components of Positioning Control and their Roles 3 1 Positioning controller 0 0 IIIA IA AA 3 4 3 1 1 Command pulse control method 3 4 3 1 2 Basic parameter settings 3 5 3 1 3 Zero pointreturnfunction 3 5 3 2 Servo Amplifier and Servo Motor 3 8 3 2 1 Positioning control in accordance with command pulse 3 8 3 2 2 Deviation counter function
18. BD Terminal board 50m 422020da eps FX 2n ROM E1 Function extension memory casette 422010da eps p or Fh FX2N CNV BD FX2Nc 485ADP Terminal block mh PA FX2N CNV BD FXoN 485ADP Terminal block 422030da eps 500 m x FX 2nc ROM CE1 Function extension memory board 422040da eps or FX2nc 485ADP Terminal block 500 m FXon 485ADP Terminal block 422050da eps Tab 4 9 Applicable communication interface boards and adapters for data exchange with frequency inverters Pa MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Familiy for Positioning Control Total FX Series Communication equipment option extension distance 1 oO Owes ua 50m FX3G 485 BD Terminal block FX3G 485 BD_front eps FX
19. Control Systems 2 1 Positioning by AC Servo System Examples of AC servo systems 2 2 2 2 1 2 2 2 Examples of AC servo systems Positioning indicates the operation to move an object such as a workpiece or tool drill or cutter from one point to another point and to stop it with efficiency and precision In other words the principle of positioning is the control of speed in accordance with the position performed to promptly eliminate the remaining distance to the target position The flexibility to change the target position electrically and easily is an important requirement Several cases of positioning using an AC servo motor are systematically shown below Constant feed Description In the press shear process for cutting punching etc the processed material is positioned with high precision to produce a constant sized product Fig 2 2 Schematic drawing Press main unit Constant feed 220010da Tapping Description In order to tap a workpiece Quick feed Cutting feed and Quick return are performed repeatedly Workpiece Fig 2 3 Schematic drawing 4 Drill Tapping M Slide N 7 Hz HE SAA ping ii R Ball e Quick Cutti screw f feed feed 1M Feed lt Pulley motor Quick return 220020da eps Pa MITSUBISHI ELECTRIC Examples of AC servo systems Positioning by AC Servo System
20. Positioning window Setting item Setting value Bias speed Hz 500 Maximum speed Hz 100 000 Creep speed Hz 1000 Zero return speed Hz 50 000 Acceleration time ms 100 Deceleration time ms 100 Interrupt input for DVIT instruction Tab 4 6 Settings for YOOO The Bias speed corresponds to the minimum speed G Can only be set for a FK3U or FX3UC main unit 4130a0da eps Pa MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control Click the Individual setting button The Positioning instruction settings window will appear In this window click on the YO tab to display the positioning table for YOOO pulse output destination Set the data in the positioning table as follows Positioning instruction settings led ogm i ae Poshorng lable seling wall nct be mbakeod when the PLC s powered on p a ja 4130b0da eps Fig 4 9 Positioning instruction settings window Be sure to change the Rotation direction signal to Y004 Setting item Setting value Rotation direction signal Y004 First device RO Positioning type DDRVI Drive to increment No 1 Number of pulses PLS 999 999 Frequency Hz 30 000 Positioning type DDRVI Drive to increment Number of pulses PLS 999 9990 Frequency Hz 30 000 Positioning type DDRVA Drive to absolute Number of pulses PLS 500 000 Frequency Hz 100 000
21. The regenerative resistor absorbs this electric power and functions as a brake called a regenerative brake A regenerative brake is required to prevent regenerative over voltage in the servo amplifier when the load inertia is large and operations are frequently performed The regenerative resistor is required when the regenerative power generation quantity during deceleration exceeds the allowable regenerative electric power of the servo amplifier FX Positioning Control Systems 3 9 Components of Positioning Control and their Roles Servo Amplifier and Servo Motor 3 2 5 Dynamic brake function When a circuit inside the servo amplifier is disabled by a power interruption in the AC power of the main circuit or actuation of the protective circuit the terminals of the servo motor are short circuited via resistors the rotation energy is consumed as heat then the motor immediately stops without free run When the motor stops by elimination of the rotation energy the brake is not effective and the motor runs freely Main circuit AC power supply U Converter Inverter yv 7 AC to DC DC to AC wi eae PLG Position controller poet gt BIA These contacts of the a ee dynamic brake turn ON rotations of motor ji i when the power is interrupted Number of Motor stop characteristics when the
22. Transfer distance per pulse mm AS as T x Electronic gear ratio Command pulse frequency during quick feed PLS AS 1 fo x No x S Al 60 During the above process the Electronic gear ratio often CMX CDV for Mitsubishi servos and Speed reduction ratio can be adjusted to fit the application s needs In each of the absolute and incremental positioning methods the entire movement distance of the machine should not exceed the maximum allowable pulse output number from the positioning controller Pa MITSUBISHI ELECTRIC Drive mechanism Components of Positioning Control and their Roles 3 3 2 Setting the target position In positioning control the target position can be set by the following two methods specified by the controllers parameter settings Available command units are mm i inch degree or pulse Absolute method In this method a point absolute address is specified for positioning while the zero point is regarded as the reference The start point is arbitrary Address 100 e Startpoint Address 100 P Series Address 150 gt Address 300 Address 150 rr ane Address 100 lt i H Address 150 H 0 100 150 300 Zero point Point A Point B Point C 332010da eps Fig 3 10 Setting the target position absolute method Incremental method In this method positioning is performed through specification of the movement directi
23. a case where the low speed is 10 to 100 mm s Inductive motor Pulses are fed N00 back Pulse TE Programmable controller Moving part lt lt Ball screw Inverter High speed Low speed High speed counter unit Movement distance 120090da eps Fig 1 9 Schematic drawing Pulse count method In speed control applications with inverters stop precision is not very accurate With the limit switch method a system operates without any feedback to the controller to indicate the location of the workpiece With the pulse count method the speed can be changed and the stop command can be executed at specific distances at specific timings according to the feedback from the pulse generator connected to the motor Both the limit switch method and the pulse count method however are subject to a loss in stop precision due to the dispersion of distance that occurs for workpieces at different speeds When automatically stopping a moving part driven by a motor stop the motor by a position signal using a limit switch or pulse count comparison In general conditions turn on the brake at the same time FX Positioning Control Systems 1 7 The Basics of Positioning Control Positioning method type The moving part continues by a coasting distance until it completely stops after the stop command is given The coasting distance is not controlled and it is represented as the shaded part in the figure belo
24. any other uses or application of the products shall be deemed to be improper Relevant safety regulations All safety and accident prevention regulations relevant to your specific application must be observed in the system design installation configuration maintenance servicing and testing of these products The regulations listed below are particularly important in this regard This list does not claim to be complete however you are responsible for being familiar with and conforming to the regulations applicable to you in your location VDE Standards VDE 0100 Regulations for the erection of power installations with rated voltages below 1000 V VDE 0105 Operation of power installations VDE 0113 Electrical installations with electronic equipment VDE 0160 Electronic equipment for use in power installations VDE 0550 0551 Regulations for transformers VDE 0700 Safety of electrical appliances for household use and similar applications VDE 0860 Safety regulations for mains powered electronic appliances and their accessories for household use and similar applications FX Positioning Control Systems Fire safety regulations 0 Accident prevention regulations VBG Nr 4 Electrical systems and equipment Safety warnings in this manual In this manual warnings that are relevant for safety are identified as follows DANGER Failure to observe the safety warnings identified with this sy
25. button FX Positioning Control Systems 4 27 Learning to Use the FX Familiy for Positioning Control Inverter Drive Control Create the ladder program as shown below Once the ladder program is complete click on Online from the top menu bar in GX Developer and select Write to PLC The Write to PLC window will appear Click the Param Prog button and then click the Execute button The parameters and the created program will be transferred to the PLC To enable the transferred parameters stop the PLC and then restart it Write to PLC Connecting interface COM1 lt gt PLC module PLC Connection Station No Host PLC type PX3UICI Ka File selection Device data Program Common TParamebiod Selectal Cancel all selections pms Cae lose 43 Program Mi MAIN F Device comment Transfer setup COMMENT Related functions Parameter Keyword setup Fig 4 15 Write to PLC window Inputs PLC parameter Remote operation Clear PLC memory 423080da Outputs Reverse rotation limit Inverter running RUN Forward rotation limit Forward rotation Forward rotation command input Reverse rotation Reverse rotation command input Up to frequency SU Overload is applied OL Frequency detection FU Tab 4 14 Used inputs and outputs Alarm occurrence a MITSUBISHI ELECTRIC Inverter Drive C
26. by pressing the System reset kuji button This is necessary to refresh the servo parameters FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control FX3U 20SSC H positioning 4 6 3 X axis Operation test window Testing and monitoring operations With the parameters and table information saved to the FX3u 20SSC H module from section 4 6 3 and the PLC in STOP mode testing is performed by using TEST MODE in FX Configurator FP Enter TEST MODE by pressing the Test On Off 7 button After entering TEST MODE click on the Operation Test X axis Al button to display the Next select the XY axis table operation from the X axis Pattern combination box and click on the Start button to begin positioning Note that because the table operation includes a Jump command the operation will continuously loop from row 0 to row 20 X axis Operation test Position start Feed present value CHG Speed CHG OPR JOGIMPG Monitor item Present address 0 PLS READY BUSY READY Error code X axis Pattern Operation speed present value 0 Hz Table No being executed X axis Y axis Table operation start No Mode selection xY axis table operation 0 Positioning at 1 step speed interrupt stop at 1 step speed Positioning at 2 step speed Interrupt stop at 2 step speed interrupt stop Variable speed operation IMPG operation Linear interpolation Linear interpolation interrupt V
27. c PLC and MR J3 B servo system Without these components the program cannot be tested Input points from the PLC include X axis Forward rotation limit START command XY axis table operation X axis Forward rotation JOG STOP command X axis Reverse rotation JOG Error reset X and Y axis Zero return X axis Reverse rotation limit START command X axis 1 speed operation Tab 4 28 Used inputs 4 66 a MITSUBISHI ELECTRIC FX3U 20SSC H positioning Learning to Use the FX Familiy for Positioning Control hd FNC 12 UN Do o a DMOV GO KIWA BFM X axis current address FNC 12 UN DMOV Gioo 2100 BFM Y axis current address FNC 12 UN MOV G28 D10 BFM X axis status information FNC 12 UN MOV G128 Bate BFM Y axis status information X000 H mH VES Forward rotation limit X010 i C e Reverse rotation limit cia FNC 12 UN Ki X e pmove 100000 amp 14012 o gt X axis BFM JOG JOG speed X002 PLS M24 1680 Positioning parameter enable command V V 465010da eps Fig 4 37 Program example 1 The forward and reverse rotation limit switches must be wired so that they are turned ON by default Normally closed contacts When these limit switches turn OFF due to the workpiece going out of bou
28. command Stop outputting Y000 pulses Immediate stop FX1S FX1N FX3G FX3G FX3U C Pulse output monitor flag OFF when Y000 is READY ON when Y000 is BUSY FX1S FX1N FX3G FX3G FX3U C Instruction execution abnormally complete flag Programmed immediately after a positioning instruction Turns ON when an instruction fails to complete correctly and stays ON until the instruction stops being driven FX3G FX3U C CLEAR signal output function enable Y000 Zero return direction specification Enables an output to be used for the CLEAR signal for YOOO OFF gt Reverse rotation ON gt Forward rotation Forward rotation limit Forward pulses on Y000 stop when this relay turns ON Reverse rotation limit Reverse pulses on Y000 stop when this relay turns ON Y000 Positioning instruction activation OFF when a positioning instruction is not active ON when a positioning instruction is active CLEAR signal device specification function enable Enables the output terminal for the CLEAR sig nal to be changed for Y000 FX3G FX3U C Bias speed Hz Sets the bias speed for YOOO FX1S FX1N FX3G FX3U C Maximum speed Hz Sets the maximum speed for positioning instruc tions on YOOO FX1S FX1N FX3G FX3U C Acceleration decelera tion time ms Sets the acceleration and deceleration time FX1S FX1N Acceleration tim
29. damage or core breaks in the signal lines cannot cause undefined states in the equipment You are responsible for taking the necessary precautions to ensure that programs interrupted by brownouts and power failures can be restarted properly and safely In particular you must ensure that dangerous conditions cannot occur under any circumstances even for brief periods EMERGENCY OFF facilities conforming to EN 60204 IEC 204 and VDE 0113 must remain fully operative at all times and in all PLC operating modes The EMERGENCY OFF facility reset function must be designed so that it cannot ever cause an uncontrolled or undefined restart You must implement both hardware and software safety precautions to prevent the possibility of undefined control system states caused by signal line cable or core breaks When using modules always ensure that all electrical and mechanical specifications and requirements are observed exactly FX Positioning Control Systems III Pa MITSUBISHI ELECTRIC Table of Contents Table of Contents Safety Guidelines 1 The Basics of Positioning Conirol 1 1 What is positioning control 1 1 T2 Actuators for positioning IA E eae 1 2 Ta PNEUMATICS HI ed PAE EAE eae 1 2 Teo Brake MOOT ii ee rete See Mes Coe ERE pepe eae KAA 1 2 12 3 Clutch brake iis pte Gea ap hk oe ek Sd Seed Ge a et re 1 3 1 2 4 Steppingmotor 1 3 1 2
30. engineers have been playing active roles Positioning is all about motion and motion often involves speed and precision And since speed can be directly related to productivity positioning is an area of much development When the speed of a machine increases a problem with the stop precision is often generated In order to solve this problem diversified grades of positioning controllers have been required and developed Improving machine efficiency generates immeasurable added value including reduced labor costs and improved conservation of machine floor space for the same quantity of production If there are no problems related to the positioning aspect of a machine it may mean that the machine is not running as efficiently as it could be This is where the science of developing and retrofitting an optimum positioning control system comes in FX Positioning Control Systems 1 1 The Basics of Positioning Control Actuators for positioning 1 2 Actuators for positioning The options available for positioning control depend on the type of actuator driving the system An actuator is a mechanical device that moves or controls a specific element or a series of elements within a system Ina mechanical system an actuator is often used with a sensor to detect the motion or position of a workpiece The following illustrations provide examples of diversified actuators their features and their weak points 1 2 1 Pneumatic Features and Drawb
31. fig 4 37 3 FX Positioning Control Systems 4 69 Learning to Use the FX Familiy for Positioning Control FX3U 20SSC H positioning a MITSUBISHI ELECTRIC Index AC servo system Advantages Block diagram Accelaration time Actuator type AC servo system Brake motor Clutch brake DC servo system General purpose inverter General purpose motor Pneumatic Stepping motor 000 Brake Dynamic brake 200 05s Regenerative brake Command pulse control FP RP method PLS DIR method Command pulses Control method Limit Switch 0 0000 Pulse command Pulse count Deceleration time Deviation counter DOG search function DOG type zero return DTBL instruction FX Positioning Control Systems Index E Encoder Absolute type 3 6 Incremental type 3 5 Relative type 3 5 Equation Command pulse frequency 3 12 Moving speed 3 11 Number of rotations 3 12 Transfer distance per pulse 3 12 Transfer distance per rotation 3 12 F Feed quantity 3 5 Feedspeed 3 5 Fow IIIA 4 53 FREQROL Inverter
32. insert the stop contact before the positioning instruction so that STL instruction cannot be turned off reset until pulse output monitor flag M8340 or M8147 for Y000 is turned off To prevent simultaneous activation of positioning instructions the instruction activation tim ing should be delayed by 1 scan time FX Positioning Control Systems 4 9 Learning to Use the FX Familiy for Positioning Control FX PLC positioning Description Zero return Zero return instruction CLEAR signal Y010 FX3G FX3U C YOO2 FX1S FX1N Zero return completion flag End of zero return Self reset Waiting for 1 scan time Positioning in forward rotation direction Moves to absolute position 500 000 using the drive to absolute instruction YO04 ON Forward rotation positioning completion flag O10 0000o Ooo Ends the positioning operation in the forward rotation derection Self reset Tab 4 5 Description of progam example in fig 4 3 3 Pa MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control V y stt S21 H M52 X004 1 at POA K100 K100000 Y000 Yo H Waiting for Stop E 1 scan time command Designation Output Pulse Rotation 2 of absolute pulse output direction 3 position frequency destination signal
33. interpolation operations to be placed on a flow chart for positioning Take a minute to familiarize yourself with the layout and menu items of the software The panel on the left side of the screen is required for selecting the Flow Code and Func components to place into the Flow Chart window To place an item into the Flow Chart window click on the item once and then click anywhere within the Flow Chart window Once an item has been placed in the Flow Chart window it can be dragged to any position Items are connected by using the wire tool NZI to drag a wire between each item Creating a Flow Chart The flow chart on the next page demonstrates basic positioning using the FX2N 20GM Since this program is designed to be used without a mechanical plotter an electrical zero point is used for reference Re create the diagram on the next page by using the Code and Func buttons on the left panel of the VPS software to select and place each function block FX Positioning Control Systems 4 53 Learning to Use the FX Familiy for Positioning Control FX2N 10GM and FX2N 20GM positioning x 110 Y 200 K 200 mew 200 K 150 AtoB Wait 2 seconds BtoC Turn YO ON Wait 2 seconds CtoD DtoE EtoF FtoG Turn YO OFF Wait 2 seconds GtoH Many programs can be stored in a GM controller at one time This example uses program number 0 The DRV Ret command is used to move from the start
34. positioning Output pulse a a ae Bias speed 100 500 Hz a cer 500 Hz lt Reverse positioning YA after zero return Acceleration deceleration time 0 ms 413070da eps Reguired hardware and software are as follows FX3G PLC version 1 00 or later or FX3u c PLC version 2 20 or later GX Developer 8 23Z or later or GX IEC Developer or GX Works2 4 12 Pa MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control Parameters for the DTBL instruction are set for example in GX Developer as shown below Double click Parameter and then PLC parameter from the project tree on the left side of the screen If the project tree is not displayed on the screen click View on the menu bar and then click Project Data List MELSOFT series GX Developer Unset project LD Edit mode MAIN 1 Step 7 Project Edit Find Replace Convert View Online Diagnostics Tools Window Help al aft uu HS Z EE onea S Alale sls ele ale wulet sel tol 35126 te ae ane ae ot _ FS sF5 F6 sF6 F F F9 sF9 cF9 cPI0 sF sF8 aF aF8 aF5 caF5 cafl0 F10 aF9 xl Unset project k Program a Device commen g Parameter A osama EL Device memory 413080da epsi Fig 4 6 Project window Click on the Memory capacity tab and then enter a check in the Positioning Instr
35. represent the HIGH status and the LOW status of the waveform The command pulse pattern in the figure assumes negative logic Pa MITSUBISHI ELECTRIC Positioning controller Components of Positioning Control and their Roles 3 1 2 Basic parameter settings To send a series of pulses a pulse train to a servo amplifier positioning controllers use a specified feed quantity which is proportional to the number of pulses A feed speed must also be specified to control the number of pulses output per second Feed quantity The feed quantity determined by the target address tells the servo system how far to move the workpiece So for example if a servo motor encoder generates 8 192 pulses for one rotation the command pulse number 8 192 can be output to rotate the servo motor by 1 rotation Feed speed The feed speed defines the amount of travel per unit of time for the workpiece When a servo motor encoder generates 8 192 pulses for one rotation the command pulse frequency speed 8 192 pulses s should be output to rotate the servo motor by 1 rotation per second Decrease the pulse frequency to rotate the servo motor at a lower speed Increase the pulse frequency to rotate the servo motor at a higher speed Acceleration deceleration time When the start command is given acceleration operation at constant speed and deceleration are performed for positioning Set the acceleration time and the deceleration time in the controller s
36. time 00 ms 413010da eps Fig 4 2 Configuration for the program example See marker in program fig 4 3 3 See marker in program fig 4 3 3 See marker Din program fig 4 3 4 Inputs Outputs Immediate stop Pulse train output Zero return command CLEAR signal Forward rotation positioning command Rotation direction signal Reverse rotation positioning command CLEAR signal Stop command Near point signal DOG Servo ready Tab 4 4 Used inputs and outputs FX Positioning Control Systems 4 5 Learning to Use the FX Familiy for Positioning Control FX PLC positioning X000 Use this for FX3G and FK3U C PLCs 7 M8349 Immediate stop i i X006 vagom T PREN E N E E S S SDL eS SECU EEE ENAS ET 1 Use this for FX1S and FXin PLCs 1 Alay i 8145 i RST M10 2 RST M11 RST M12 O Use this for FX3G and FX3u c PLCs M8000 FNC 12 H0010 D8464 RUN monitor i MOVP e464 M8341 UsothisforFXisandFXINPLOCs tt ti tststi lt O dL M8140 O V V 413020da eps Fig 4 3 Program example 1 Description Stops outputting Y000 pulses Immediate stop Resets zero return completion flag Resets forward rotation positioning completion flag Resets reverse rotation positioning completion flag
37. 00 Positioning complete 2 sec One operation k cycle 443030da eps Fig 4 22 Timing chart The positioning complete flag will only be ON at the very beginning of the program when it is not the first time to operate the equipment and the power has not been recycled a MITSUBISHI ELECTRIC FX2N 10PG positioning Learning to Use the FX Familiy for Positioning Control M8002 Initial pulse M8000 RUN monitor M25 Error flag X000 Error reset X001 STOP X002 Forward rotation limit X003 Reverse rotation limit FNC 79 KO K32 K4000 K1 Unit No BFM No of transfer points KO K1 Unit No No of transfer FNC 79 Unit No BFM Parameter No of setting transfer points Unit No BFM Maximum No of speed transfer Unit No BFM transfer points K1 Unit No BFM No of i transfer points KO K12 K100 K1 Unit No BFM Decel No of time transfer points FNC 78 Unit No BFM Status No of info transfer M20 M31 points FNC 78 Unit No BFM Error No of code transfer points 443040da eps Fig 4 23 Program example 1 The forward and reverse rotation limit switches must be wired so that they are turned ON by default Normally closed contacts When these limit switches turn OFF due to the workpiece going out of bounds M2 or M3 will turn ON and cause the pulse opera
38. 07 i RST C100 START atl FNC 79 KO K26 K4Mo K1 RUN TO monitor Unit No BFM Operation No of commands transfer M0 M15 points FNC 78 DFROM KO K24 D10 K1 Unit No BFM Current No of address transfer points END 443050da eps Fig 4 23 Program example 2 FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control FX2N 10PG positioning Description Use relative positioning START positioning Set 1 speed positioning H1 27 Set the Target address 1 K50 14 13 Set the Operation speed 1 K50000 16 15 Counter to repeat operation 2 times Y000 indicator light 2 second timer Reset C100 Write operation commands to the FX2n 10PG 26 K4M0 ae oo Monitor the current address mm 24 25 D11 D10 Tab 4 21 Description of program example in fig 4 23 2 a MITSUBISHI ELECTRIC FX2N 10GM and FX2N 20GM positioning Learning to Use the FX Familiy for Positioning Control 4 5 4 5 1 FX2n 10GM and FX2n 20GM positioning The FX2N 10GM and FX2n 20GM controllers also referred to as the 10GM and 20GM are unique in that they can operate as individual stand alone units with their own programming language power supplies and separate sets of inputs and outputs This means that the 10GM and 20GM can be used with or without a
39. 10 000 000 10 000 000 XY axis positioning at 2 step speed 10 000 000 10 000 000 10 000 000 10 000 000 XY axis positioning at 2 step speed 10 000 000 10 000 000 10 000 000 10 000 000 Dwell Circular interpolation CNT CCW 7 000 000 5 000 000 0 0 5 000 000 Dwell XY axis positioning at 2 step speed 10 000 000 15 000 000 5 000 000 7 500 000 XY axis positioning at 2 step speed 5 000 000 7 500 000 10 000 000 15 000 000 Dwell Linear interpolation 20 000 000 26 214 400 20 000 000 Dwell Jump End Pa MITSUBISHI ELECTRIC FX3U 20SSC H positioning Learning to Use the FX Familiy for Positioning Control Writing data to the FX3U 20SSC H Write the servo parameters positioning parameters and table information to the FX3u 20SSC H BFM and Flash ROM by pressing the Write to module El button and placing check marks in the following boxes Change the range of table data to be written to 0 25 Write to module COM setting 4 Transmission speed 115 2kbps Module No 0 tem V Positioning parameters V Servo parameters MV Table information IV X axis lv Y axis IV X axis Vv Y axis X axis Y axis MV XY axis 0 125 _ gt Cancel 462080da eps Fig 4 35 Write to module window Next reset the module
40. 10PG 4 43 FX2N 1PG E ere AE 4 36 FX3U 20SSC H 4 60 Speed control 1 6 X XY axis table operation 4 62 Ja MITSUBISHI ELECTRIC HEADQUARTERS EUROPEAN REPRESENTATIVES EUROPEAN REPRESENTATIVES EURASIAN REPRESENTATIVES MITSUBISHI ELECTRIC EUROPE B V EUROPE GEVA AUSTRIA ALFATRADE Ltd MALTA 100 Kazpromavtomatika KAZAKHSTAN German Branch Wiener StraBe 89 99 Paola Hill Ul Zhambyla 28 Gothaer Stra e 8 AT 2500 Baden Malta Paola PLA 1702 KAZ 100017 Karaganda D 40880 Ratingen Phone 43 0 2252 85 55 20 Phone 356 0 21 697 816 Phone 7 7212 50 1000 Phone 49 0 2102 486 0 Fax 43 0 2252 488 60 Fax 356 0 21 697 817 Fax 7 7212 501150 Fax 49 0 2102 486 1120 TECHNIKON BELARUS INTEHSIS srl MOLDOVA MITSUBISHI ELECTRIC EUROPEB V orgsl CZECH REP Oktyabrskaya 19 Off 705 bld Traian 23 1 Czech Branch BY 220030 Minsk MD 2060 Kishinev Avenir Business Park Radlicka 714 113a Phone 375 0 17 210 46 26 Phone 373 0 22 66 4242 MIDDLE EAST REPRESENTATIVES 7 158 00 Praha 5 Fax 375 0 17 210 46 26 Fax 373 0 22 66 4280 LE NENE ITD pam Phone 4go STLA ESCO DRIVES amp AUTOMATION BELGIUM HIFLEX AUTOM TECHNIEKB V NETHERLANDS 33 Al lt aad Al Alee St aX red laal Cull
41. 3 Reverse rotation limit M3 X010 Bit 4 Forward rotation JOG M4 X001 Bit 5 Reverse rotation JOG M5 X002 Bit 6 Zero return M6 X003 Bit 8 Relative Absolute positioning M8 Bit 8 1 Relative positioning Bit 9 START command M9 X004 X005 Y axis Operation command 1 Bit 0 Error reset M100 M115 M100 X007 Bit 6 Zero return M106 X003 X axis Operation command 2 M20 M35 Bit 4 Positioning parameter enable command M24 X001 X002 520 X axis Operation pattern selection Bit 0 1 speed positioning H1 X004 Bit 10 Table operation simultaneous X005 521 Table operation start number 0 Table row 0 Positioning parameter data 14013 14012 X axis JOG speed Tab 4 27 Buffer memory addresses of FX3U 20SSC H FX Positioning Control Systems 1 000 000 Hz PLS sec Learning to Use the FX Familiy for Positioning Control FX3U 20SSC H positioning 4 6 5 Program example The following program uses buffer memory communication to perform JOG positioning 1 speed positioning and table operation control The XY table created in the previous section can be used in this example For this example FX Configurator FP should be used to specify the servos change the maximum speed and to set the zero return mode as described in section 4 6 2 The ladder program is to be used with an FX3u
42. 3G 14 or 24 I O 5 o wa o 500m FX3G CNV ADP FX3U 485ADP MB Terminal block FX3G_24_front eps RS485_FX3G eps 1 e o CT CH1 50 m FX3G 485 BD Terminal block FX3G 485 BD_front eps nj i eg o i 500m FX3G CNV ADP FX3U 485ADP MB aa Terminal block Pason RS485_FX3G eps FX3G MITSUBISHI 40 or 60 1 0 U Wa CH 2 50m FX3G 485 BD Terminal block FX3G 485 BD_front eps CH 1 bp E 500m FK3G CNV ADP FX3U 232ADP MB FX3U 485ADP MB or Terminal block FX3U 485ADP MB FX3G_24_front eps RS485_FX3G_ch2 eps Tab 4 9 Applicable communication interface boards and adapters for data exchange with frequency inverters FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control Inverter Drive Control Total FX Series Communication equipment option extension distance L CH 1 Fh 50m T FX3u 485 BD Terminal block 422070dab eps TL 500 m UU FX3U CNV BD FX3u 485ADP MB a Terminal block sinned 422080dab eps pe CH 1 FX3U il 500 m FX3U L1 BD FX3u 485ADP MB Terminal block RS485_FX3U_ch2_1 eps CH 1 TL 500 m T FX3U CNV BD FX3U CIADP FX3u 485ADP MB Terminal block 422060da eps RS485_FX3U_ch2_2 eps 500 m FX3u
43. 44 1 Ovemiewofcontrol 4 43 4 4 2 Important buffer memory locations 4 44 4 4 3 Programekample 4 45 4 5 FX2N 10GM and FX2N 20GM positioning 4 51 45 1 Overviewofcontrol 4 51 4 5 2 Using dedicated software to set positioning for the FX2N 20GM 4 52 4 5 3 Testing and monitoringoperations 4 58 4 6 FX3U 20SSC H positioning 4 60 46 1 Overiewofcontrol 4 60 4 6 2 Using dedicated software to set positioning for the FX3U 20SSC H 4 61 4 6 3 Testing and monitoringoperations 4 64 4 6 4 Important buffer memory locations 4 65 4 6 5 Programekample 4 66 Index VI Aa MITSUBISHI ELECTRIC What is positioning control The Basics of Positioning Control 1 1 1 The Basics of Positioning Control What is positioning control The positioning controller together with the programmable logic controller personal computer and operator interface is one of the four main units of FA factory automation Among these units the positioning controller plays an important role and is regarded as the center of the mechatronics field in which many senior
44. 485ADP MB Terminal block 4220a0dab eps CH 1 FX3UC 500 m FX3U CIADP FX3u 485ADP MB Terminal block 422090da eps RS485_FX3UC_D_DS_ch2 Tab 4 9 Applicable communication interface boards and adapters for data exchange with frequency inverters FX3u 232 BD FX3u 422 BD FX3U 485 BD or FX3U USB BD FX3U 232ADP MB or FX3u 485ADP MB Pa MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Familiy for Positioning Control To use the special inverter communication instructions from the PLC inverter and PLC communication parameters must be set The FX2N C FX3G and FX3u c PLCs include the following special instructions to communicate with one or more inverters FX2N C FX3G FX3U C Function Description IVCK Monitors operations of an inverter IVDR Controls operations of an inverter IVRD Reads a parameter from an inverter IVWR Writes a parameter to an inverter IVBWR Writes a block of parameters to an inverter Tab 4 10 Instructions to communicate with inverters This instruction is only available for FX3u c PLCs The programmable controller special relays and inverter instruction codes listed in the table below are used in Section 4 2 3 For information on memory addresses that contain error codes and inverter communication operation statuses refer to the FX Series User s Manual Data Communication Edition JY997D16901 Function nam
45. 5 number S M8029 8 tk seT m2 H 2 Execution completion flag g Pee er ee ee se PO ee eee re ee OM on i eee eee ge Go i 4 Use this for FX3G and FX3U C PLCs 2 i m8340 M52 Ss 1 RST sa HO ol Yo000 Waiting for A i Outputting 1 scan time NS AAA AAA WAA AAA aH i Use this for FX1S and FX1N PLCs M8147 M52 m if RST sa H _ Yo00 Waiting for Outputting 1 scan time M8000 B RUN monitor RET END 413050da eps Fig 4 3 Program example 4 To stop the positioning operation be sure to insert the stop contact before the positioning instruction so that STL instruction cannot be turned off reset until pulse output monitor flag M8340 or M8147 for Y000 is turned off To prevent simultaneous activation of positioning instructions the instruction activation tim ing should be delayed by 1 scan time Number Description Positioning in reverse rotation direction Moves to absolute position 100 using the drive to Absolute instruction YO04 OFF Reverse rotation positioning completion flag Ends the positioning operation in the reverse rotation direction Self reset Waiting for 1 scan time Tab 4 5 Description of progam example in fig 4 3 4 FX Positioning Control Systems 4 11 Learning to Use the FX Familiy for Positioning Control FX PLC positioning Programming example for a FX3G or FX3u c PLC The following program is similar
46. C 12 move K12000 D201 2 120 Hz i i FNC 12 i Move K D202 Pr 2 i FNC 12 movp K500 D203 4 i 5 Hz i i FNC 12 i Move K7 D204 Pr 7 FNC 12 move K10 D205 6 l 1s FNC 12 move K8 D206 0 Pr 8 i i FNC 12 i i movp K10 D207 i 1s i FNC 274 weve KO K4 D200 Ki O Inverter Write4 D200to CH1 i F station parameters D207 f i number i Use this for FK2N C PLCs FNC 180 EXTR K13 KO K1 K12000 i Function Inverter Pri 120 Hz i Number station i Write number FNC 180 Sai KE KO K2 K500 oO Function Inverter Pr 2 5 Hz i Number station i Write number i FNC 180 San Ke KO K7 K10 12 i Function Inverter Pr 7 1s Number station 1 i Write number FNC 180 LI Sar Ke KO K8 K10 13 i Function Inverter Pr 8 1s Number station 1 Write number M8029 T RST M10 14 Execution completion flag y y 4230a0da eps Fig 4 16 Program example 2 Pa MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Familiy for Positioning Control Function Number Description The maximum frequency Pr 1 is specified The maximum frequency Pr 1 is set to 120 Hz The minimum frequency Pr 2 is specified The minimum frequency Pr 2 is set to 5 Hz The acceleration time Pr 7 is specified Writing parameters to the inverter while the PLC is in RUN
47. Enables the zero return operation with CLEAR signal outputting function CLEAR signal Y010 Return to the zero point with CLEAR signal output Y002 Tab 4 5 Description of progam example in fig 4 3 1 4 6 Pa MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control 1 Use this for FX3G and FX3u c PLCs i s s20 S21 M8349 g n HE m Ht Cus Return to Positioning Positioning Y000 1 zero point in forward in reverse output stop 1 rotation rotation i Use this for FX1S and FX1N PLCs i S s2 S2 M8145 JI m m H Cus o 1 Return to Positioning Positioning Y000 i zero point in forward in reverse output stop i rotation rotation i S Use this for AK and PU AA M8002 i Moy K100000 D8343 eo Initial pulse i i FNC 12 H K D8342 l i MOV 200 FNC 12 kioo MOV D8348 O FNC 12 NOV K100 D8349 o i Use this for FX1S and FKIN PLCs i FNC 12 i K1 D814 1 BiG 00000 D8146 6 FNC 12 i K500 D8145 i MOV 7 FNC 12 kioo D8148 o MOV X001 M5 mi f RST mio O Return to Operation zero point stopped RST M11 RST M12 11 SET so X002 M5 M10 N RST M11 Positioning Operation Ze
48. Ja MITSUBISHI ELECTRIC MELSEC FX Series Programmable Logic Controllers Introduction to FX Positioning Control Systems Beginners Manual Art no 214562 13 08 2012 ate MITSUBISHI ELECTRIC INDUSTRIAL AUTOMATION Version B Version check Beginners Manual Introduction to FX Positioning Control Systems Art no 214562 Version Revisions Additions Corrections A 05 2008 pdp rw First edition B 08 2012 pdp dk Addition of FX3G main units About This Manual The texts illustration diagrams and examples in this manual are provided for information purposes only They are intended as aids to help explain the operation programming and use of programmable controllers of the programmable logic controllers of the MELSEC FX1s FX1N FX2N FX2Nc FX3G FX3U and FX3uc series If you have any questions about the installation and operation of any of the products described in this manual please contact your local sales office or distributor see back cover You can find the latest information and answers to frequently asked questions on our website at www mitsubishi automation com MITSUBISHI ELECTRIC EUROPE BV reserves the right to make changes to this manual or the technical specifications of its products at any time without notice 05 2008 Safety Guidelines General safety information and precautions For use by qualified staff only This manual is only intended for use by properl
49. PLC to control logic instructions and standard positioning operations Important references for understanding positioning with the FX2nN 10GM and FX2N 20GM are FX2n 10GM FX2N 20GM Hardware Programming Manual JY992D77801 FX PCS VPS WIN E Software Manual JY992D86801 It is assumed that you will have read and understood the above manuals or that you will have them nearby for reference Overview of control Along with the capability to be used for independent control the FX2N 10GM 1 axis of control and FX2N 20GM 2 axes of control can be used as special function blocks in conjunction with an FX2Nc or FX3u c PLC to transfer data back and forth via dedicated buffer memory addresses These addresses overlap with and replace the special M and special D registers in the 10GM and 20GM One particular advantage to using a PLC with the FX2N 10GM is the ability to use the table method where up to 100 positioning operations can be defined and saved for consecutive execution The FX2n 10GM and FX2N 20GM output pulse trains to control a stepper servo motor with a maximum output frequency of 200 000 pulses second 200 kHz This offers the same speed as the FX3u high speed positioning adapters except that the GM controllers use open collector type outputs instead of differential line driver type Combined with standard positioning operations such as 1 speed and 2 speed positioning the 10GM and 20GM include an electrical zero return functi
50. RBT d 0 0 SLOVENIA erg cee ral y vila Jubijana a te oa CORPORATION JAPAN phone 358 0 207 463 540 Phone 386 0 1 513 8116 eel Fax 358 0 207 463 541 Fax 386 0 1 513 8170 8 12 1 chome Harumi Chuo Ku Tokyo 104 6212 UTECO GREECE Beijer Electronics AB SWEDEN Phone 81 3 622 160 60 5 Mavrogenous Str Box 426 ae FN ae 900 fe AE OO 35 8600 one one MITSUBISHI ELECTRIC AUTOMATION Inc USA Fay 30 211 1206 999 Fax 46 0 40 93 23 01 500 Corporate Woods Parkway Vernon Hills IL 60061 MELTRADE Kft HUNGARY Omni Ray AG SWITZERLAND Phone 1 847 478 21 00 Fert utca 14 Im Sch rli 5 Fax 1 847 478 22 53 HU 1107 Budapest CH 8600 D bendorf Phone 36 0 1 431 9726 Phone 41 0 44 802 28 80 Fax 36 0 1 431 9727 Fax 41 0 44 802 28 28 Beijer Electronics SIA LATVIA GTS TURKEY Ritausmas iela 23 Bayraktar Bulvari Nutuk Sok No 5 LV 1058 Riga TR 34775 Yukar Dudullu Umraniye ISTANBUL Phone 371 0 784 2280 Phone 90 0 216 526 39 90 Fax 371 0 784 2281 Fax 90 0 216 526 3995 Beijer Electronics UAB LITHUANIA CSC Automation Ltd UKRAINE Savanoriu Pr 187 4 B M Raskovoyi St LT 02300 Vilnius UA 02660 Kiev Phone 370 0 5 2323101 Phone 380 0 44 494 33 55 Fax 370 0 5 232 2980 Fax 380 0 44 494 33 66 Systemgroup UKRAINE 2 M Krivonosa St UA 03680 Kiev y MITSUBISHI ELECTRIC Phone 380 0 44 490 92 29 Fax 380 0 44 248 88 68 Mitsubishi Electric Europe B V FA Eur
51. S The settings on these windows should be copied for BOTH the X and Y axes before performing positioning Open the Parameter Units window by selecting Parameters Positioning Units from the main menu bar at the top of the screen Parameter Units Specify the same settings for the Y axis deg inch MIN Command Unit omn x Pulse rate 200 Eeed rate 200 Micro m REV C Motor C Mechanical PLS REV Settings 4 gt Speed Cancel Help Fig 4 27 Parameter Units window Open the Parameter Speed window by selecting Parameters Positioning gt Speed from the menu bar at the top of the screen 452040da eps Specify the same settings Parameter Speed for the Y axis Max speed 1300 Hz JOG speed 1200 Hz Speed Hz Bias speed Interpolation 10 ms i o H Backlash 7 PLS D time ms 5400 Acc time Dec time 200 ms 200 ms Units w Machine Zero pa PE e 452050da eps Fig 4 28 Parameter Speed window The Max speed is set very low in order for the VPS software to trace the path during operation through the Monitoring window In turn both the JOG speed and interpolation value must be reduced In practice it is impossible to have the JOG speed set to a value higher than the Max speed setting Pa MITSUBISHI ELECTRIC FX2N 10GM and FX2N 20GM positioning Learning to Use the FX Familiy for Positioning Control 3 Open the Parameter Machine Zero window b
52. START command Mg X007 Operation pattern bo 1 speed positioning operation Status information M20 M31 Pulse rate 4 000 PLS rev Feed rate Parameters 1 000 um rev Bit 1 Bit 0 System of units Bit 1 1 Bit 0 0 Combined system Bit 5 bth ie Bii 4 Multiplication factor Bit 5 1 Bit 4 1 108 Error code Tab 4 19 Buffer memory addresses of FX2n 10PG D20 Using a multiplication factor of 10 changes the units from um to mm Pa MITSUBISHI ELECTRIC FX2N 10PG positioning Learning to Use the FX Familiy for Positioning Control 4 4 3 Program example In the program example that follows a series of three individual 1 speed positioning operations are controlled from the FX2n 10PG with an output signal from the PLC that turns ON between each operation An event timing chart is included on the next page to help understand the logic flow of the program This example uses a conveyor system to carry boxes from one location to another Each intermittent positioning operation positions a box in front of a scanner to scan it for 2 seconds During each 2 second scan Y000 from the PLC turns ON to illuminate an indicator light The number of boxes to be scanned can be varied by changing the value of the counter C100 inthe program Barcode scanner Conveyor belt 443010da eps Fig 4 20 Configurat
53. The following buffer memory addresses are used in the ladder program example below For details on other BFM addresses refer to the FX 1PG FX2n 1PG User s Manual JY992D65301 Item Set value Note Pulse rate 4 000 PLS rev Feed rate 1 000 um rev Parameters a i System of units Bit 1 1 Bit 0 0 Combined system ah A Multiplication factor Bit 5 1 Bit 4 1 108 Maximum speed 40 000 Hz Bias speed 0 Hz Acceleration Deceleration time 100 ms Target address 1 100 mm Operating speed 1 40 000 Hz Target address 2 150 mm Operating speed 2 10 000 Hz Operation command Bit 0 Error reset MO Biti STOP command M1 Bit 2 Forward rotation limit M2 Reverse rotation limit M3 X003 Relative Absolute positioning M7 Bit 7 0 Absolute positioning Two speed positioning START command M10 X007 Current address D11 D10 Status information M20 M31 Error code D20 Tab 4 16 Buffer memory addresses of FX2n 1PG E Using a multiplication factor of 10 changes the units from um to mm FX Positioning Control Systems 4 37 Learning to Use the FX Familiy for Positioning Control FX2N 1PG E positioning 4 3 3 Program example In the example that follows a two speed positioning instruction is used to move a drill 100 mm toward a block of wood with a high speed pulse frequency of 40 KHz When the drill reaches the wood the speed decreases to 10
54. User s Manual Hardware Edition J Y997D16501 FX3uc Series User s Manual Hardware Edition JY997D28701 FX3G FX3uU FX3uc Series User s Manual Positioning Control Edition J Y997D16801 FX2N 1PG User s Manual JY992D65301 FX2N 10PG User s Manual JY992D93401 FX2N 10GM FX2N 10GM User s Manual JY992D77801 It is assumed that you will have read and understood the above manuals or that you will have them close at hand for reference Overview of control Number of Axes The FX1S and FX1N transistor type PLCs support positioning on 2 axes with operation speeds up to 100 000 pulses second 100 kHz The main units FX3G 14MT L and FX3G 24MT L transistor outputs can control up to two axes and the main units FX3G 40MT L and FX3G 60MT L can control a maximum of three axes with up to 100 kHz The FX3U C transistor type PLC main units support positioning speeds up to 100 kHz on 3 axes If two FX3U 2HSY ADP adapters are connected to the FX3u 4 axes are available with operation speeds up to 200 kHz The PLS DIR pulse output method is used for all PLC main units to output pulses as shown in the following table 15 Axis 2nd Axis 34 Axis FX1S FX1N FX3G 14MT O FX3G 24MT Applicable Model FX3U C FX3G 40MT LI FX3G 60MT FX3U 2 FX3U 2HSY ADP DO Pulse Output Direction Output
55. a complex program and increased PLC scan time Different from other FX positioning controllers the FX3u 20SSC H requires connection to a servo system to perform positioning For details on connecting an MR J3 B servo system refer to the appropriate servo manual Setting parameters Prior to setting positioning parameters and servo parameters check to verify the connection between the PLC and the personal computer is valid Since ladder logic in the PLC is not used in this example set the RUN STOP switch on the PLC to STOP Open a new file in FX Configurator FP by clicking on the Make new file D button Expand the tree of folders in the File data list panel on the left hand side of the screen by double clicking on Unset file FX3U 20SSC H Edit and then Monitor Go to Online gt Connection setup gt Comm Test Verify that the devices are communicating properly Double click on Positioning parameters in the File data list panel on the left hand side of the screen to modify the positioning parameters Set items in the Item column for both the X and Y axes as shown Maximum speed 26214400 Hz 26214400 Hz OPR mode 1 Data set 1 Data set J OPR interlock setting D Inyalid D Inyalid 462020da 462030da 462040da eps 5 Next double click on Servo parameters in the File data list panel on the left hand side of the screen to modify the servo parameters Set items from the Kind c
56. acks Air source and high grade piping are required High torque is not available Multi point positioning is complex and very difficult to achieve 0 Change in positioning is difficult Fig 1 1 Schematic drawing Pneumatic 120010da eps 1 2 2 Brake motor Features and Drawbacks 0 Positioning mechanism is simple Repeatability is poor 0 Change in positioning is difficult When optical sensors or limit switches are used for stop Fig 1 2 Schematic drawing Brake motor Motor with brake Limit switch 120020da eps 1 2 Pa MITSUBISHI ELECTRIC Actuators for positioning The Basics of Positioning Control 1 2 3 1 2 4 Clutch brake Features and Drawbacks Frequent positioning is possible Life of friction plate is limited Change in positioning is difficult When optical sensors or limit switches are used for stop Costant quantity feed hopper Q Optical sensor Stepping motor Features and Drawbacks Simple positioning mechanism Fig 1 3 Schematic drawing Clutch Brake 120030da eps f load is heavy motor may step out and displacement can occur Motor capacity is small Precision is poor at high speed Stepping motor FX Positioning Control Systems Fig 1 4 Schematic drawing Stepping motor 120040da eps The Basics of Positioning Control Actuators for positioning 1 2 5 1 2 6 DC servo syst
57. al MELSERVO Series amplifiers are configured with sink type inputs To communicate appropriately with sink type inputs sink type outputs are used on the PLC side Therefore when using a Mitsubishi servo control system a transistor sink output type PLC is used Options for positioning Before choosing a PLC for a positioning system it is important to understand the instructions available for each PLC The FX1s and FX1N include the same set of positioning instructions The only disadvantage to choosing an FX1s PLC for positioning is that it does not include as many I O and that it cannot be expanded with special function blocks for analog or communication control The FX3u combined with high speed positioning adapters can operate with higher pulse output frequencies and includes 3 additional positioning instructions The available instructions for FX PLCs are described in the chart below Applicable Model Positioning Poci Instruction Illustration Description JOG speed JOG operation The motor moves in a speci fied direction depending on the logic and timing of the drive input signal There is no target position JOG command Stop 411020da eps Tab 4 2 Instructions for FX PLCs 1 Pa MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control Applicable Model Positioning Description instruction Instruction Illustration 1 speed positioning
58. am example in fig 4 16 4 pe eae See ee eats ee ee eg this for FX3G or FK3U C PLCs 1 Li Li Li Li Li 0 Li Inverter Inverter Read 1 station instruction destina i number code tion 1 Li wenen Function Inverter Inverter Read number station instruction destina Monitor number code tion 4230d0da eps Fig 4 16 Program example 5 MCR denotes the end of a master control block In this example the master control block NO is only executed when data is not being writ ten to the inverter Description Monitoring operations of Monitor frequency value with D50 HO6F D50 the inverter Tab 4 15 Description of program example in fig 4 16 5 FX Positioning Control Systems 4 35 Learning to Use the FX Familiy for Positioning Control FX2N 1PG E positioning 4 3 4 3 1 FX2n 1PG E positioning The FX2nc and FX3u c PLCs support connection with the FX2N 1PG E special function block Special function blocks are separate pieces of hardware that can be connected to PLCs to enhance control Since special function blocks process information separately from the PLC the scan time of the PLC is not adversely affected during operations controlled by special function blocks This provides an advantage for programming Additionally special function blocks such as the FX2n 1PG E offer separate more advanced control through the use of their own inputs and outputs An importan
59. c controllers to be used with an E500 Series inverter For the communication between PLC and inverter CH 1 is used The travel path and operation pattern are shown below In the program below the section Controlling the inverter to move in the forward or reverse rotation direction drives the inverter in the forward or reverse direction When the forward rotation limit X001 or reverse rotation limit X000 is reached the operation stops For details on connecting the hardware for testing refer to the appropriate product manual Reverse rotation Forward rotation limit X000 limit X001 General purpose motor J v Reverse rotation lt Forward rotation HOFA bit2 is ON HOFA bit1 is ON Acceleration Deceleration uN time Pr 7 time Pr 8 Speed ae Hz S FPS aS RS maa S Pr 20 Accel Decel reference za Pr 20 frequency Default 60Hz 3 Running frequency HOED 40 Hz Time gt s 423010da eps Fig 4 12 Configuration and positioning pattern for the E500 Series inverter Before programming there are several parameter settings that must be set to the inverter and PLC Setting communication parameters for the E500 Series inverter While all operations are stopped i e the RUN indicator on the E500 is OFF use the MODE key fo UP DOWN keys a 2 and the SET key to change an
60. ce is Output pulses from position controller x Ad The moving part speed is fol x A4 Either mm inch degree or pulse can be selected for the positioning command unit Accordingly when data such as the movement quantity per pulse positioning speed or the positioning address in accordance with the positioning command unit are set pulse trains are output for the target address and positioning is performed FX Positioning Control Systems 3 11 Components of Positioning Control and their Roles Drive mechanism Useful equations To define the system illustrated above Af and vg need to be determined using a series of equations The speed of the moving part vg is constrained by the mechanical gearing system between the servo motor and moving part the pitch of the ball screw and the specification of the motor as shown through the following two formulas Transfer distance per rotation of motor mm 1 AS tev PBX a Number of rotations of motor during quick feed rev v Rated number of o mml 2 lt rotations of AS servo motor If No does not exceed the rated speed of the motor this means that the servo system can be used for the application In order to determine if the positioning controller is applicable the command pulse frequency during quick feed fo should be checked to verify it does not exceed the maximum allowable frequency setting for the maximum speed parameter setting of the controller
61. code transfer points X000 Error reset X001 STOP X002 Forward rotation limi amp X003 H Cus e Reverse rotation limit M8000 y GD RUN monitor V Vv 433030da eps Fig 4 19 Program example 1 The forward and reverse rotation limit switches must be wired so that they are turned ON by default Normally closed contacts When these limit switches turn OFF due the workpiece going out of bounds M2 or M3 will turn ON and cause the pulse operation to stop 4 40 Pa MITSUBISHI ELECTRIC FX2N 1PG E positioning Learning to Use the FX Familiy for Positioning Control Number Description Set the pulse rate PLS rev K4000 0 Set the feed rate um rev K1000 2 1 Set the units to um x 103 mm combined system H32 gt 3 Set the maximum speed Hz K40000 5 4 Set the bias speed Hz KO 6 Set the acceleration deceleration time ms K100 15 Read status information K3M20 lt 28 Read error code D20 lt 29 Reset error STOP operation Forward rotation limit Reverse rotation limit 0 2 0 O 9 9 0 0 2 Use absolute positioning Tab 4 18 Description of program example in fig 4 19 1 FX Positioning Control Systems 4 41 Learning to Use the FX Familiy for Positioning Control FX2N 1PG E positioning
62. connect an FX2N 20GM to a personal computer for programming refer to the FX2N 10GM F X2n 20GM Hardware Programming Manual JY992D77801 Operation objective The objective of this example is to use the FX2N 20GM to trace a path using 1 speed linear interpolation and circular interpolation operations Fig 4 24 Path of travel Start point A END point 452010da eps pe o Coordinate Description Y This point can be anywhere X 0 0 Move to zero point wait for 2 seconds 80 100 Output YO turns ON wait for 2 seconds 200 200 200 150 100 Output YO turns OFF wait for 2 seconds 150 70 End point IO 7 Moo oO gt Tab 4 23 Operation details Pa MITSUBISHI ELECTRIC FX2N 10GM and FX2N 20GM positioning Learning to Use the FX Familiy for Positioning Control The output YO is used to imitate a pen or other end effector Each point to point operation is described as follows A to B Return to Electrical Zero B to C High speed positioning 0 C to D Linear interpolation 0 D to E High speed positioning E to F Clockwise circular interpolation Fto G High speed positioning 0 G to H High speed positioning Getting started with FX PCS VPS WIN E Open a new file with VPS and choose FX 2N E 20GM with simultaneous 2 axis This setting allows for linear and circular
63. d or confirm the following parameters Parameter No Parameter item Set value Setting contents External operation mode is selected when power is turned ON Pr 117 Communication station number 00 to 31 Up to eight inverters can be connected Pr 118 Communication speed 96 9600 bps default Data length 7 bit Stop bit 1 bit Pr 79 Operation mode selection 0 Pr 119 Stop bit Data length 10 Parity check presence absence BETO selection Even parity present Pr 122 Communication check time interval Communication check suspension Pr 123 Waiting time setting Set with communication data Pr 124 CRLF presence absence selection With CR without LF Tab 4 13 Communication parameters Pa MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Familiy for Positioning Control Setting communication parameters for the FX2N Cc FX3G FX3u c PLC For example parameters are set in GX Developer as shown below Double click Parameter and then PLC parameter from the project tree on the left side of the screen If the project tree is not displayed on the screen click View on the menu bar and then click Project Data List iP MELSOFT series GX Developer Unset project LD Edit mode MAIN 1 Step 7 Project Edit Find Replace Convert View Online Diagnostics Tools Window Help eft A a mets BQ Z Slo Delta S aAa sl ee BQ wele pol tol 25 2 Ste Ue e tb
64. e ms Sets the acceleration time for YOOO Deceleration time ms Sets the deceleration time for YOOO CLEAR signal device specification Sets the output terminal for the CLEAR signal for YOOO Tab 4 3 Buffer memory addresses of FX1s FX1N FX3G and FX3u c FX3G FX3U C Pa MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control 4 1 3 Program Examples Two positioning examples are included as a reference to get started with PLC programming Hybrid programming example for FX1s FXiN FX3G and FX3u c PLCs The first example below illustrates zero return and absolute positioning control on 1 axis with an FX1S FX1N or FX3uU C PLC Since the special devices for utilizing positioning instructions are different depending on the PLC please note that the following program is a hybrid program and that device addresses must be changed according to the type of PLC A general understanding of step ladder and ladder logic is necessary to use the program Forward 500 000 positioning gt Output pulse frequency A Reverse rotation limit 2 Forward rotation limit 2 ih 100 100 000 Hz gt Pias ie Servo amplifier side Servo amplifier side Z 500 Hz Servo motor J Origin after H zero return Reverse Reverse lt gt Forward positioning rotation rotation Acceleration deceleration
65. e Device Description Applicable PLC RUN monitor M8000 i ON when PLC is in RUN Initial pulse M8002 ON for the first scan only Programmed immediately after an inverter com Instruction execution M8029 munication instruction Turns ON when the pre complete flag ceding instruction finishes its operation and stays ON until the instruction stops being driven FX2N C FX3G FX3U C Tab 4 11 Programmable controller special relays Instruction No of Data Code Digits Applicable Function name Inverter Description Resets the inverter and does not request a Inverter reset 4 digits response Inverter reset takes about 2 2 sec onds to complete Sets the communication operation for the Operation mode 4 digits inverter Running frequency write Changes the drive frequency by writing directly 4 digits to the inverter RAM Sets forward rotation STF or reverse rotation Run command 2 digits STR Inverter status f 2 digits Monitors operation bits of the inverter monitor Output frequency speed 4 digits Monitors the frequency of the inverter Tab 4 12 Inverter instruction codes Applicable for all Mitsubishi FREQROL inverters FX Positioning Control Systems 4 25 Learning to Use the FX Familiy for Positioning Control Inverter Drive Control 4 2 3 Program example The following programming example is a hybrid program for FX2N C FX3G and FX3u
66. e use of a built in Flash ROM the FX3u 20SSC H can store data permanently via non volatile storage Since the flash memory transfers all of its data to the buffer memory of the 20SSC H each time the power is turned ON the flash memory provides extra benefit for applications requiring a default set of data to be automatically loaded This eliminates the need to use a PLC program for setting parameters and table data which can greatly simplify the length and complexity of a ladder program The FX3uU 20SSC H includes an input connector to connect manual pulse generator dials and various switches such as the START DOG and interrupt switches These inputs assist in controlling positioning operations and are necessary to operate instructions such as the interrupt 1 speed constant quantity feed instruction and the DOG type mechanical zero return command Pa MITSUBISHI ELECTRIC FX3U 20SSC H positioning Learning to Use the FX Familiy for Positioning Control 4 6 2 Using dedicated software to set positioning for the FX3u 20SSC H In the example that follows an FX3U 20SSC H is used with FX Configurator FP to perform positioning on two axes with an XY axis table operation FX Configurator FP is convenient for defining servo parameters positioning parameters and table information It is also recommended to be used whenever possible since the use of a sequence program for setting parameters and table data requires many steps and devices resulting in
67. een improved as follows Although the latest systems are completely digital they are equipped with parameters in conformance to diversified mechanical specifications and electrical specifications so that simple set up is possible 0 As frequent operation is enabled by a low inertia motor the maximum torque is increased and the system can be applied to a wide variety of machines The latest systems are equipped with an auto tuning function with which the servo amplifier automatically detects the load inertia moment and adjusts the gain This is possible even if the load inertia moment is unknown The command communication cycle from the controller to the servo amplifier is improved for synchronization accuracy and better speed positioning accuracy The latest systems also allow for long distance wiring reduced noise resistance and simplified wiring The top advantages to using an AC servo system are described below Compact and light servo Robust servo system Easy servo system Good cost performance system servo system In the FA workplace a In accordance with severe AC servo systems are eas An AC servo system with downsized AC servo sys operation conditions a ier to handle than hydraulic good cost performance tem occupying less space tougher AC servo system is equipment Easy systems saves a company in overall is beneficial often required are also flexible for new engineering costs staff FX Positioning
68. em Features and Drawbacks Positioning precision is accurate Maintenance is required for motor brushes 0 It is not suitable for rotation at high speed Fig 1 5 Schematic drawing DC servo system DC servo amplifier 120050da eps General purpose inverter and general purpose motor Features and Drawbacks Multi speed positioning is available using a high speed counter 0 High precision positioning is not available 0 Large torque is not available at start Specialized inverter is required Fig 1 6 Schematic drawing General purpose inverter and general purpose motor General purpose inverter 120060da eps a MITSUBISHI ELECTRIC Actuators for positioning The Basics of Positioning Control 1 2 7 AC servo system Features and Drawbacks 0 Positioning precision is good 0 Maintenance is not required 0 Positioning address can be easily changed 0 It is compact and offers high power Fig 1 7 Schematic drawing AC servo system AC servo amplifier 120030da eps FX Positioning Control Systems 1 5 The Basics of Positioning Control Positioning method type 1 3 Positioning method type In general there are two methods to control the movement of a workpiece speed control and position control For basic more rudimentary positioning speed control can be used with an inverter and general purpose motor For systems where precision is a must se
69. estination 2 number S M8029 8 if SET m12 H a secuton completion M8329 1H M109 Abnormal end X025 M8348 M10 M111 M112 in 1 1 He H RST M12 Oo Position Position Zero Normal Abnormal ing in ing return encol ji Beer ji f ti le positionin ositioning S en being a tion forward fn forward RST M13 6 direction performed flag rotation rotation Y00 direction direction GED mtto 7 F l 030 FNC 152 2 Positioning operation being a DTBL Y000 K4 erformed in reverse gt Station direction command z 5 5 M8029 seT mis H Execution comp etion PEN ag M111 M8329 M112 Abnormal end END 4130e0da eps Fig 4 11 Program example 2 4 19 FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control FX PLC positioning Description Resets forward rotation positioning completion flag JOG operation is being performed Executes No 2 of the positioning table of YOOO pulse output destination Completes the JOG operation Forward rotation positioning completion flag Reverse rotation positioning completion flag Positioning operation being performed in forward rotation direction Executes No 3 of the positioning table of YOOO pulse output destination Forward rotation positioning normal end flag Forward rotation positioning abnormal end flag Positioning operation being performed in reverse rotation direct
70. everse rotation limit X001 t SET M15 5 Forward rotation limit 2002 X000 X001 RST M15 O Forward Reverse Forward rotation rotation rotation command jimit limit C input X003 itt Reverse rotation command input M15 X002 X003 H H H M21 7 i Forward Reverse Oparanon rotation rotation command command inpu input X003 X002 i H M22 8 Reverse Forward rotation rotation command command inpu input M8002 f FNO 12 kam20 D81 Initial Pulse Operation command is withdrawn 9 FNC228 k m20 Det SET M12 LD lt gt Operation The write y command is instruction ithd is driven M wi rawn M 4230b0da eps Fig 4 16 Program example 3 The forward and reverse rotation limit switches must be wired so that they are turned ON by default Normally closed contacts When either of these limit switches turns OFF due to the workpiece going out of bounds the inverter operation will be stopped 4 32 Aa MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Familiy for Positioning Control Function Number Description Setting the operation speed of the inverter to 40 Hz while the PLC is in RUN mode The write instruction is driven The operation speed is set as 40 Hz The preset frequency is written to the inverter C
71. iganlaan 3 Wolweverstraat 22 EG Sarayat Maadi Cairo MITSUBISHI ELECTRIC EUROPE B V FRANCE BE 1831 Diegem NL 2984 CD Ridderkerk Phone 20 0 2 235 98 548 French Branch Phone 32 0 2 717 64 30 Phone 31 0 180 46 6004 Fax 20 0 2 235 96 625 25 Boulevard des Bouvets Fax 32 0 2 717 6431 Fax 31 0 180 44 23 55 TT TTT Rach rite aa Koning amp Hartman bw BELGIUM Koning amp Hartman b v NETHERLANDS 24 Shenkar St Kiryat Arie F ME f l H SIST Woluwelaan 31 Haarlerbergweg 21 23 1L 49001 Petah Tiqva ax 33 0 BE 1800 Vilvoorde NL 1101 CH Amsterdam Phone 972 0 3 922 1824 MITSUBISHI ELECTRIC EUROPE B V IRELAND Phone 32 0 2 257 02 40 Phone 31 0 20 587 76 00 Fax 972 0 3 924 0761 Irish Branch Fax 32 0 2 257 0249 Fax 31 0 20 587 76 05 AED ET Westgate bustness Park Ballymount INEARBT d o o BOSNIA AND HERZEGOVINA Beijer Electronics AS NORWAY 19 H aomanut Street Te u T aigan Aleja Lipa 56 Postboks 487 1L 42505 Netanya F sane 0 i iEn BA 71000 Sarajevo NO 3002 Drammen Phone 972 0 9 863 39 80 ax 353 0 Phone 387 0 33 921 164 Phone 47 0 32 2430 00 Fax 972 0 9 885 2430 MITSUBISHI ELECTRIC EUROPE B V ITALY Fax 387 0 33 524 539 Fax 47 0 32 8485 77 aE NERO EITT aan pana AKHNATON BULGARIA Fonseca S A PORTUGAL Cebaco Center Block A Autostrade DORA hae Biana MB 4 Andrei Ljapchev Blvd PO Box 21 R Jo o Francisco do Casal 87 89 Lebanon Beirut apie el MB BG 1756 Sofia PT 3801 997 Avei
72. ing to Use the FX Familiy for Positioning Control FX2N 10PG positioning 4 4 2 Important buffer memory locations Item Set value The FX2N 10PG contains 1 300 buffer memory BFM addresses which are 16 bit 1 word areas of memory that contain information relevant to the control of positioning operations Most of these addresses are reserved for data to be used in table operations The FX2N c or FX3u c PLC that is connected to the FX2n 10PG can send and receive data to the buffer memory addresses to change and or update information This exchange of information takes place through dedicated PLC instructions known as the FROM TO instructions For FX3u c PLCs the MOV instruction can also be used to transfer data to from special function blocks The following buffer memory addresses are used in the ladder program example below For details on other BFM addresses refer to the FX2nN 10PG User s Manual JY992D93401 Maximum speed 50 000 Hz Bias speed 0 Hz Acceleration time 100 ms Deceleration time 100 ms Target address 1 50 mm Operation speed 1 50 000 Hz Current address D11 D10 mm Operation command Bit 0 Error reset MO X000 Bit 1 STOP M1 X001 Bit 2 Forward rotation limit M2 X002 Bit 3 Reverse rotation limit M3 X003 Bit 8 Relative Absolute positioning M8 Bit 8 1 Relative positioning Bit 9
73. ion The positioning pattern is shown in the following figure Neither the zero point return nor the JOG instructions are used in the ladder program example Frequency Operation speed 1 Hz BFM 16 15 50 000 25 000 0 Target address 1 BFM 14 13 0 50 100 150 200 Distance mm 000 turns ON for 2 sec 443020da eps Fig 4 21 Positioning pattern In order for the program to function correctly for the specified number of repetition cycles the START command input X007 must not be turned ON again during the positioning operation If the START command is turned ON again the counter C100 is reset which clears the number of repetitions FX Positioning Control Systems 4 45 Learning to Use the FX Familiy for Positioning Control FX2N 10PG positioning The following program can be used with an FX2n c or FX3u c PLC and does not require an actuator i e servo system for testing The input and output points include Inputs Outputs Error reset STOP command Indicator lamp ON for 2 sec intervals Forward rotation limit Reverse rotation limit START command Tab 4 20 Used inputs and outputs The following figure is an event timing chart for part of the operation in the program below X007 START M9 START n command C100 0 A TO M26 gt gt I Positioning I Complete Flag Y0
74. ion vies poc Fig 3 6 Positioning pattern of IMI J switch switch 7 DOG search function Initial position Zero point gt Escape operation 313020da eps FX Positioning Control Systems 3 7 Components of Positioning Control and their Roles Servo Amplifier and Servo Motor 3 2 3 2 1 3 2 2 Servo Amplifier and Servo Motor The servo amplifier controls the movement quantity and the speed according to the commands given by the positioning controller The servo motor then transmits rotation to the drive mechanism after receiving signals from the servo amplifier Positioning control in accordance with command pulse In accordance with speed and position command pulses from the positioning controller PWM pulse width modulation control is performed by the main circuit of the servo amplifier in order to drive the motor The rotation speed and the rotation quantity are fed back to the amplifier from the encoder attached to the servo motor Deviation counter function The difference between the command pulses and the feedback pulses counted by the deviation counter in the servo amplifier is called accumulated pulses While the machine is operating at a constant speed the accumulated pulse quantity is almost constant During acceleration and deceleration the accumulated pulse quantity changes more dramatically When the accumulated pulse quantity becomes equivalent to or less than a specified quantity in position set va
75. ion Executes No 4 of the positioning table of YOOO pulse output destination Reverse rotation positioning normal end flag 0 Q 9 0 6 O 7 9 0 2 4 Reverse rotation positioning abnormal end flag Tab 4 9 Description of progam example in fig 4 11 2 Pa MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Familiy for Positioning Control 4 2 4 2 1 Inverter Drive Control A frequency inverter or inverter for short is installed between the mains supply and the motor An inverter converts a fixed voltage and frequency into a variable voltage with a variable frequency Thus the speed of a asynchronous electric motor can be adjusted continuously In factory automation inverters Sometimes known as variable frequency drives are used to efficiently control large current loads through voltage regulation to drive large fans pumps or AC motors Drive control with inverters can lead to great reductions in energy consumption for a factory With a Mitsubishi general purpose inverter connected to an FX2N C FX3G or FX3uU C PLC a motor can be controlled to move at a specific speed Through monitoring feedback or by using limit switches a basic positioning functionality is achieved However as described in section 1 3 the disadvantage to using an inverter to move a workpiece to a specific location is a loss in the stop precision Therefore inverters should not be thought of as po
76. ioning controller PLS DIR Pulse Direction method FP RP Forward Pulse Reverse Pulse method Each method requires two outputs from the controller to control specific signals for direction and pulse control A third method known as the A phase B phase method uses overlapping pulse signals to specify direction PLS DIR method Inthe PLS DIR method one output sends pulses to the drive unit while the other output specifies the direction of travel Forward rotation Reverse rotation Fig 3 2 Timing diagram lt gt lt i i H Li Output 1Pulse train inh i in i i E ra irecti Hi La Output 2Direction L ON i oro i 311010da eps ON and OFF represent the status of the controllers output H and L respectively represent the HIGH status and the LOW status of the waveform The command pulse pattern in the figure assumes negative logic FP RP method In the FP RP method each output has a different direction and operates individually to send pulses to the drive unit Forward rotation Reverse rotation K Fig 3 3 Timing diagram zA T gt Output 1 Forward rotation 1 Lo pulse train FP LI II AA OFFO i La Output 2Reverse rotation Hu Hi pulse train RP Li OFFO ne fe y E 311020da eps ON and OFF represent the status of the controllers output H and L respectively
77. it When the DC power is converted into AC power in the inverter the current supplied I I I to the servo motor is changed by the PWM pulse width modulation control in the control circuit e The deviation counter receives and counts the command pulses from the positioning controller subtracts the feedback pulses from them Manual pulse generator then drives the servo motor until the accumulated pulse number siaii becomes 0 Operation equipment e Gives inputs for manual automatic mode start stop zero point return command manual forward rotation reverse rotation and manual pulse generator to the positioning controller 300010da eps Fig 3 1 Components of Postioning Control 1 3 2 Pa MITSUBISHI ELECTRIC Components of Positioning Control and their Roles Servo motor speed range 1 1 or more 1 1 000 to 1 5 000 e Dedicated to high speed response optimal to positioning control has large start torque large maximum torque and wide variable When a moving element goes beyond a limit switch LS the motor stops Servo motor brake Inthe caseoflargemotor i ff Cd I l Cooling fan 1 m _ pl 1 Limit switch Nearpoint Limit switch eee Sa rere oe LS dog switch Moving element LS i I l Servo C K motor
78. kHz The drill is then driven for 50 mm into the wood before decelerating to stop Drill Wood CZZ 77D gt p VY Z High Low speed speed 433010da eps Fig 4 17 Configuration The two speed positioning operation is illustrated in the following graph Neither the zero point return nor the JOG instructions are used in the ladder program Frequency Hz 40 000 Operation speed 2 Operation speed 1 BFM 24 23 20 000 BFM 20 19 0 100 50 Target address 1 Target BFM 18 17 address 2 BFM 22 21 0 50 100 150 200 433020da eps Fig 4 18 Positioning pattern Pa MITSUBISHI ELECTRIC FX2N 1PG E positioning Learning to Use the FX Familiy for Positioning Control Although the following ladder program is not very complicated it is important to establish good programming practice by paying attention to the order with which the PLC writes and reads to the buffer memory of the FX2N 1PG E Before writing the Operation command START command to the module s BFM from the PLC several settings must be established such as Target addresses 1 amp 2 Operation speeds 1 amp 2 and various settings such as the bias speed maximum speed and the acceleration deceleration time The most critical part of the program is the section where the operation commands are enabled by writing bits MO to M15 to BFM 25
79. l Systems Y000 is postioned by Yo the operation in table number 1 3 YO K3 Axis Table No 411080da eps Learning to Use the FX Familiy for Positioning Control FX PLC positioning 4 1 2 Important memory locations For FX PLC programs using positioning instructions there are several built in special devices to define control parameters and facilitate system operation These devices consist of 1 bit 16 bit and 32 bit address locations and are briefly outlined below according to their use in the example programs in the following section Use this table as a reference to understand the example programs For details on other memory addresses for example operation information for control on Y001 or Y002 refer to the FX3G FX3u FX3uc Series User s Manual Positioning Control Edition JY997D16801 Function name Device Description Applicable PLC RUN monitor M8000 ON when PLC is in RUN FX1S FX1N FX3G FX3U C Initial pulse M8002 ON for the first scan only FX1S FX1N FX3G FX3U C Instruction execution complete flag M8029 Programmed immediately after a positioning instruction Turns ON when the preceding instruction finishes its operation and stays ON until the instruction stops being driven FX1S FX1N FX3G FX3U C CLEAR signal output enable Enables a CLEAR signal to be output to the servo FX1S FX1N Pulse output stop
80. lue after command pulses have stopped the servo amplifier outputs the positioning complete signal The servo motor continues operation even after that Then when the accumulated pulse quantity becomes 0 the servo motor stops The time after the servo motor outputs the positioning complete signal until it stops is called the stop settling time Speed Command speed Motor speed The accumulated pulse quantity is 0 and positioning is completed Accumulated pulses aos gt Time Stop setting time 322010da eps Fig 3 7 Positioning pattern Pa MITSUBISHI ELECTRIC Servo Amplifier and Servo Motor Components of Positioning Control and their Roles 3 2 3 3 2 4 Servo lock function The servo motor is controlled so that the accumulated pulse quantity counted in the deviation counter becomes 0 For example if an external force for forward rotation is applied on the servo motor the servo motor performs the reverse rotation operation to eliminate the accumulated pulses Accumulated pulses in deviation counter Servo motor Minus pulses Reverse rotation operation Plus pulses Forward rotation operation 0 zero Stop Tab 3 1 Control of servo motor by accumulated pulses Regenerative brake function During deceleration because the servo motor rotates by the load inertia of the drive mechanism it functions as a generator and electric power returns to the servo amplifier
81. mbol can result in health and injury hazards for the user WARNING Failure to observe the safety warnings identified with this symbol can result in damage to the equipment or other property II Pa MITSUBISHI ELECTRIC General safety information and precautions The following safety precautions are intended as a general guideline for using PLC systems together with other equipment These precautions must always be observed in the design installation and operation of all control systems DANGER Observe all safety and accident prevention regulations applicable to your specific application Always disconnect all power supplies before performing installation and wiring work or opening any of the assemblies components and devices Assemblies components and devices must always be installed in a shockproof housing fitted with a proper cover and fuses or circuit breakers Devices with a permanent connection to the mains power supply must be integrated in the building installations with an all pole disconnection switch and a suitable fuse Check power cables and lines connected to the equipment regularly for breaks and insulation damage If cable damage is found immediately disconnect the equipment and the cables from the power supply and replace the defective cabling Before using the equipment for the first time check that the power supply rating matches that of the local mains power Take appropriate steps to ensure that cable
82. mioo Ki O RUN i 1 i Inverter Inverter Read CH1 monitor H station instruction destina i i number code tion i Use this for PANG PLCs AA jp noone ere kio Ko HO7A kemio i Function Inverter Inverter Read i j number station instruction destina i Monitor number code tion 1 M100 Y000 pike Indicator lamp etc M101 Y001 Pak Indicator lamp etc M102 TN KUO Reverse i rotation Indicator lamp etc M103 Goy Up to frequency Indicator lamp etc M104 an cee Overload Indicator is applied lamp etc M106 Y006 Frequency is detected Indicator lamp etc M107 Y007 Alarm i occurrence Indicator lamp etc Y Y V V 4230c0da eps Fig 4 16 Program example 4 MC denotes the start of a master control block In this example the master control block NO is only executed when data is not being writ ten to the inverter 4 34 Pa MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Familiy for Positioning Control Function Number Description Controlling the inverter to move in the forward or reverse rotation direction Operation commands are written M20 M27 HOFA Reset driving of write instruction While data is not being written to the inverter data is monitored Monitoring operations of Inverter status is read HO7A M100 M107 the inverter Contents of status according to necessity Tab 4 15 Description of progr
83. mpletion time 0 4 ms Upper 0 Electrical zero point address 0 x10 PLS Lower fo Servo ready check Machine Zero 4 Units Gors Help 452070da eps Fig 4 30 Parameter Settings window None of the parameters in the Parameter Settings window need to be changed When using a mechanical plotter however these settings become more important FX Positioning Control Systems 4 57 Learning to Use the FX Familiy for Positioning Control FX2N 10GM and FX2N 20GM positioning 4 5 3 Testing and monitoring operations After setting the parameters and defining the positioning travel paths described in the previous section testing can be performed as follows Check the communication between the FX2N 20GM and the personal computer by selecting FX GM Com Port and then the Test button Make sure the GM unit is in MANU mode by checking the hardware switch on the unit Download the project by selecting FX GM Write to FX GM from the menu bar at the top of the screen and select the Write after saving file button The program will be downloaded to the 20GM In VPS start the Monitor mode by clicking the Monitor icon on the tool bar as shown below Fig 4 31 VPS icon bar Window Help sala arn 453010da eps The monitor mode window will appear with three windows Monitoring window X axis and Y axis Monitor Mode Sub Task Monitor Mode This is the window that has already At fir
84. n 4 3 special function blocks are separate pieces of hardware that can be connected to a PLC to enhance control Due to the separate processing sequence that takes place in special function blocks through the use of buffer memory data special function blocks provide a distinct advantage to PLC programming through individualized control that expands and improves PLC operations Additionally special function blocks such as the FX2N 10PG include extra input points and output points An important reference for understanding positioning with the FX2n 10PG is FX2n 10PG User s Manual JY992D93401 It is assumed that you will have read the above manual or that you will have it nearby for reference 4 4 1 Overview of control The FX2n 10PG is used to perform point to point positioning operations on 1 axis up to 1 000 000 pulses second 1 MHz With the FX2n 10PG differential line driver type outputs that provide improved stability and better noise immunity a stepper motor or servo motor can be controlled to perform a variety of positioning operations including multi speed positioning and interrupt stop positioning The controller also supports the connection of a manual pulse generator dial to control individual pulses from a position dial Another advantage to using the FX2n 10PG is the ability to use a defined set of positioning operations in table format with up to 200 predefined table operations FX Positioning Control Systems 4 43 Learn
85. n click on the Clear button 453030da eps Fig 4 33 Monitoring Window The next step is to switch the FX2N 20GM to AUTO mode by moving the switch on the unit to AUTO 5 Finally on the Monitoring Window screen click on either the X STARTor Y START buttons The positioning operation will be performed and the plot result should look identical to the one shown in the following picture amp SWOD5 FXVPS E TESTIN 1 VPS Bile Edit Wew Tools FR GM p Coe nf 2 ne FTO I eel wl sels lav fsa eal fol fe f O F x axis and Y axis Monitor Mode a Monitoring Window Turn vo OFF i Sub Ta SD FK 20GM SIM Steps 114 For Help press F1 y 453040da eps Fig 4 34 Resulting path of travel and flow chart To run the program again set a new start position or let it start from where it is clean the plot area and press the X START or Y START button again If the plot does not look like the one above check the flow chart program against the program listed in section 4 5 2 Creating a Flow Chart FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control FX3U 20SSC H positioning 4 6 4 6 1 FX3u 20SSC H positioning The FX3u c PLC supports connection with the FX3u 20SSC H special function block which is an advanced module to perform positioning operations on two axes using Mitsubishi s fiber optic communication servo network kno
86. n operation operation simultaneous FNC 12 UA MOVP KO G521 XY Table BFM row 0 X004 PLS M9 X axis 1 speed operation X005 XY axis Table operation y y 465020da eps Fig 4 37 Program example 2 Aa MITSUBISHI ELECTRIC FX3U 20SSC H positioning Learning to Use the FX Familiy for Positioning Control Number Description Write X axis Operation command 2 K4M20 519 X axis JOG operation is being performed X axis JOG operation is being performed X axis zero return Y axis zero return Set X axis 1 speed positioning H1 520 Set X axis Target address 1 K10000000 501 500 Set X axis Operation speed 1 K2000000 503 502 Use relative positioning Set XY axis simultaneous Table operation H400 520 Set starting row No for XY Table operation KO 521 START positioning 9 6 O 0 8 9 6 6 0 0 6 Tab 4 29 Description of program example in fig 4 37 2 X006 Error reset MES FNC 12 UA J i kam esa monier X operation BFM command 1 MO M15 K4M100 5 Y operation BFM command 1 M100 M115 465030da eps Fig 4 37 Program example 3 Description STOP operation Reset X axis error Reset Y axis error Write X axis Operation command 1 K4M0 518 Write Y axis Operation command 1 K4M100 618 Tab 4 29 Description of program example in
87. nds M2 or M3 will turn ON and cause the pulse operation to stop Number Description Monitor X axis current address 1 0 D1 DO Monitor Y axis current address 101 100 D101 D100 Monitor X axis status info 28 D10 Monitor Y axis status info 128 D110 X axis Forward rotation limit X axis Reverse rotation limit Set the X axis JOG speed Hz K100000 14013 14012 8 Enable the X axis JOG speed Tab 4 29 Description of program example in fig 4 37 1 FX Positioning Control Systems 4 67 FX3U 20SSC H positioning Learning to Use the FX Familiy for Positioning Control Vv ri FNC 12 UA _ Ji mov 2 519 0 RUN monitor X operation BFM command 2 M20 M35 X001 X002 tk C X axis X axis JOG JOG X002 X001 h C o X axis X axis JOG JOG X003 PLS M6 4 Zero return PLS M106 6 X004 X005 aya FNC 12 H1 UO 6 X axis XY axis MOVE G520 1 speed Table X axis BFM operation operation 1 speed positioning FNC 12 UA pmoyp K210000000 Gano 7 X axis Target BFM address 1 FNC 12 K2000000 YA DMOVP G502 X axis BFM Operation speed 1 o X005 X004 ENCE UG m a move 400 G520 axis X axis Table 1 speed XY Table BFM operatio
88. olumn for both the X and Y axes as shown Servo amplifier Servo amplifier series 1 MR J3 B 41 MR J3 B series PYSYN UCLOUUUIT detection system system Syan system WEE EN Servo forced stop 1 Invalid Do not use the 1 Invalid Do not use the selection forced stop signal forced stop signal Basic setting Gain adjustment mode naramateare Auto tunina 1 Auto tunina mode 1 1 Auto tunina mode 1 462050da 462060da eps FX Positioning Control Systems 4 61 Learning to Use the FX Familiy for Positioning Control FX3U 20SSC H positioning Command Code Creating XY axis table operation data Address x PLS y PLS Double click on XY axis Table information in the File data list panel on the left hand side of the screen to open the XY table Maximize the window to enter the following data Arc center i PLS j PLS Incremental address specification X axis positioning at 1 step speed 20 000 000 10 000 000 Y axis positioning at 1 step speed 20 000 000 10 000 000 XY axis positioning at 1 step speed 5 000 000 2 000 000 5 000 000 2 000 000 Circular interpolation CNT CW 0 15 000 000 5 000 000 0 5 000 000 Dwell XY axis positioning at 2 step speed 10 000 000 10 000 000 10 000 000 10 000 000 XY axis positioning at 2 step speed Dwell 10 000 000 10 000 000
89. on and the movement quantity while the current stop position is regarded as the start point Movement quantity 100 i e Startpoint lt Movement quantity 100 gt Endpoint aa aa NI f Movement quantity 100 i gt Movement quantity 100 ___________s Movement quantity 150 Movement quantity 100 Movement quantity 50 H H gt j 0 100 150 300 Zero point Point A Point B Point C 332020da eps Fig 3 11 Setting the target position incremental method FX Positioning Control Systems 3 13 Components of Positioning Control and their Roles Drive mechanism 3 14 Pa MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control p 4 4 1 Learning to Use the FX Familiy for Posi tioning Control FX PLC positioning The FX1s FX1N FX3G and FX3u c Series PLC main units include basic positioning instructions to send command pulses to a stepper motor or servo amplifier While FX PLCs support point to point positioning full control is also available for reading the absolute position from a servo amplifier performing zero return and altering the workpiece speed during operation Important references for understanding positioning with FX PLCs include FX Series Programming Manual JY992D88101 FX3G FX3U FX3uc Series Programming Manual JY997D16601 FX3G Series User s Manual Hardware Edition JY997D31301 FX3U Series
90. on to return the motor s to a specific user defined address without the use of a hardware DOG switch This feature is unique since it is not available with any of the other FX Series controllers The main differences between the FX2N 10GM and FX2N 20GM are listed in the following table FX2n 10GM FX2n 20GM Inputs Outputs 4 inputs 6 outputs 8 inputs 8 outputs Yes Expandable 1 0 No 48 additional 1 0 Built in RAM Memory type EEPROM RAM has battery backup EEPROM cassette optional Memory size 3 8K steps 7 8K steps Table method Yes No CONt1 I O CON1 Control I O CON2 Control CON2 Axis1 CONS Axis1 CON4 Axis2 Connectors Tab 4 22 FX2N 10GM compared with FX2N 20GM FX Positioning Control Systems 4 51 Learning to Use the FX Familiy for Positioning Control FX2N 10GM and FX2N 20GM positioning 4 5 2 Using dedicated software to set positioning for the FX2N 20GM In the example that follows an FX2N 20GM is used with the FX PCS VPS WIN E software to perform positioning on two axes The FX PCS VPS WIN E software also referred to as VPS is beneficial for defining positioning parameters and setting positioning operations Operations can be visually organized in a flow chart format and a monitoring window can be configured with user defined objects To test operations with an FX2N 20GM an actuator i e servo system and PLC are not required For information on the cables necessary to
91. ontents of D10 HOED Reset driving of write instruction Controlling the inverter to move in the forward or reverse rotation direction Operation stop HOFA is set to 00H Operation is driven by input X002 or X003 Forward rotation command b1 of HOFA is set to ON Reverse rotation command b2 of HOFA is set to ON Changes in the operation commands M20 to M27 are detected Tab 4 15 Description of program example in fig 4 16 3 FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control Inverter Drive Control y y Use this for FX3G or FX3u c PLCs a M12 i i FNC271 ko HOFA K2M20 Ki Qo Driving of VDR 1 write 1 Inverter Inverter Write ch 1 r instruction i station instruction value 1 EEEREN ee eee number code aaan Looe Use this for FK2N C PLCs ree kii ko HOFA km Function Inverter Inverter Write i number station instruction value i Control number code M8029 tk RST M12 o Execution completion flag M10 M11 M12 H H H mc no mo Driving of Driving of Driving of write write write instruction instruction instruction NO M70 Use this for PG or FXsu o PLCs 0 i M8ooo if Sve ko HO7A K2
92. ontrol Learning to Use the FX Familiy for Positioning Control M8002 Initial Pulse Use this for FX3G or FK3U C PLCs M10 FNC271 ae IVDR HOFD H9696 write Inverter _ Inverter Write instruction station instruction value number code FNC271 KO HOFB Inverter _ Inverter Write station instruction value number code IVDR Use this for FK2N C PLCs FNC180 EXTR K11 KO HOFD H9696 j Function Inverter Inverter Write i number station instruction value Control number code FNC180 EKTR kii KO HOFB H2 i Function Inverter Inverter Write 1 number station instruction value 1 Control number code 423090da eps Fig 4 16 Program example 1 Function Number Description Writing parame The write instruction is driven ters to the inverter while The inverter is reset H9696 HOFD the PLC is in a Ep e RUN mode Computer link operation is specified H2 gt HOFB Tab 4 15 Description of program example in fig 4 16 1 FX Positioning Control Systems 4 29 Learning to Use the FX Familiy for Positioning Control Inverter Drive Control V Use this for FX3G or FX3u c PLCs FNC 12 Move K D200 o Pr 1 FN
93. opean Business Group Gothaer Stra e 8 D 40880 Ratingen Germany FACTORY AUTOMATION Tel 49 0 2102 4860 Fax 49 0 2102 4861120 info mitsubishi automation com www mitsubishi automation com
94. orme operation Y000 RST M13 M103 J M103 hee operatori is eing periormed X030 FNC 152 vooo Ki Stop DTBL command Pulse Table output number destination number X022 Ww M104 JOG M8329 If Abnormal end 8 O 09 09 6 8 4130d0da eps Fig 4 11 Program example 1 FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control FX PLC positioning Description Stops outputting Y000 pulses Immediate stop Resets zero return completion flag Resets forward rotation positioning completion flag Resets reverse rotation positioning completion flag Normal rotation limit Y000 Reverse rotation limit Y000 Enables the zero return operation with CLEAR signal outputting function CLEAR signal Y020 Performs zero return in the forward rotation direction Zero return is being performed Zero return instruction with DOG search function CLEAR signal Y020 Zero return completion flag Normal end of zero return Abnormal end of zero return 0 Q 9 0 6 O 7 Q 0 2 JOG operation is being performed Executes No 1 of the positioning table of YOOO pulse output destination B Completes the JOG operation Tab 4 9 Description of the progam example in fig 4 11 1
95. p Zero return command JOG command JOG command Forward rotation positioning command Reverse rotation positioning command Forward rotation limit LSF Reverse rotation limit LSR Stop command Tab 4 8 Used inputs and outputs 4 16 Aa MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control DOG search zero return JOG operation X020 1H M8349 Immediate stop X014 A RST M10 Servo ready RST M12 RST M13 X026 j M8343 Forward rotation limit X027 4 M8344 Reverse rotation limit M8000 i FNC 12 Hoo20 D8464 RUN monitor MOVP M8464 M8341 M8000 H M8342 RUN monitor X021 M8348 M101 M102 i ye Wt RST M10 Zero Positioning Normal Abnormal return being d endof end of performer zero zero Y000 return return RST M12 M100 1 RST M13 H Zero return being performed X030 FNC 150 i X01 X004 YI Y004 ae DSZR 010 00 000 00 Stop Near point Zero point Pulse Rotation command signal signal output direction destination signal number M8029 SET M10 ee unon i tion completion flag moi M8329 M102 Abnormal end X022 M8348 M104 H Ww Ww RST M12 H JOG Positioning Completes being i ihe JOG perf
96. parameters Parari ter Fig 3 4 Positioning pattern of L sued acceleration deceleration time Actual Actual acceleration deceleration time time Speed Positioning speed Parameter Parameter Acceleration Deceleration time time 312010da eps Zero point return function Many positioning systems include a home position to where a workpiece may need to return after performing various operations For this reason positioning controllers include a built in function to return a workpiece to a defined position by using a mechanical DOG switch To understand how this works it is necessary to first understand when the function is needed according to the parameter setting of the servo amplifier and the type of servo motor encoder Incremental type servo motor encoder pulse count method When the servo system uses an incremental or relative type encoder the current value of the address stored in the position controller is not remembered or maintained when the power is turned off This means that the address is set to zero every time the power is cycled which can be disadvantageous in an application Accordingly every time the system is re powered it must be calibrated to the correct zero point location by executing the zero point return function FX Positioning Control Systems 3 5 Components of Positioning Control and their Roles Positioning controller NOTE Example V Absolute type servo mo
97. pele F5 sF5 F6 sF6 F F8 F9 sF9 cF9 cFI0 sF sF8 aF7 aF8 aF5 caF5 afo F10 aF9 x Unset project he Program ize 8 Device commen 5 F d Parameter Device memory 423060da eps Fig 4 13 Project window Click on the PLC system 2 tab in the FX parameter window and set the parameters as shown below FX parameter CH1 zl If the box is not checked the parameters will be cleared Operate When the program is transfered to the communication board parameters and 2 D8120 values in the PLC must be cleard upon program transfer setting Protocol Non procedural zi I Control line Data length HAW type 7bit Regular AS 232C v Parity Control mode Even Invalid Stop bit bit 1 Sum check Transmission speed Transmission control procedure 9600 zi Form without CRLF v Station number setting Header 00 H 00H 0FH Time out judge time Terminator 1 X10ms 1 255 Default 423070da eps Fig 4 14 FX parameter window Set CH1 as the channel to be used Puta checkmark in the Operate communication setting checkbox to activate the communication settings Set Protocol to Non procedural Data length to 7bit Parity to Even and Stop bit to bit Set Transmission speed to 9600 to match the speed setting in the inverter Ignore these items 3 Click the End
98. point to the electrical zero point Here the program waits for 2 seconds using a 10ms timer This command indicates a high speed positioning command to position C Here YO is turned ON to mimic the use of an end effector tool This timer allows for a tool to be activated or for an operation to be executed This command is the start of a continuous steady path using linear interpolation to position D Only the X axis is used in this 1 speed positioning instruction to move to position E For a smooth arc to position F circular interpolation is used This example shows the start and end positions as well as the radius r and speed f Only the X axis is used in this 1 speed positioning instruction to move to position G Here YO is turned OFF to mimic the end of use for an end effector A timer is used to ensure the end effector operation has finished completely This command rapidly moves the Y axis for a short distance so that it can reach position H This denotes the end of the program where the controller waits for the next start command 452020da eps Fig 4 25 Flow chart of path of travel on page 4 52 Pa MITSUBISHI ELECTRIC FX2N 10GM and FX2N 20GM positioning Learning to Use the FX Familiy for Positioning Control Creating a Monitor Window Along with the flow chart create a monitoring window similar to the one shown below All of the items on the monitoring window can be found using the Inse
99. r memory includes five separate data areas for Monitor data Control data Table data Positioning parameter data and Servo parameter data With read only or read write access buffer memory addresses use bit and word information to control positioning operations Similar to the FX2n 10PG a large percentage of the BFM is dedicated to the control of table positioning operations Servo parameters Monitor data Control data Table information Positioning parameters Used to monitor the Used to control Used to store prede current position positioning opera fined table data statuses etc Used to store parameters such as the max speed and accel decel times Used to store parame ters relevant to the servo s The following buffer memory addresses are used in the ladder program example below For details on other BFM addresses refer to the FX3u 20SSC H User s Manual JY997D21301 BFM Area BFM Item Set value Monitor data 1 0 X axis current address D1 DO 101 100 Y axis current address D101 D100 28 X axis status information D10 128 Y axis status information D110 Control data 501 500 503 502 X axis Target address 1 X axis Operation speed 1 10 000 000 2 000 000 Hz PLS sec X axis Operation command 1 MO M15 Bit 0 Bit 1 Error reset STOP MO M1 X007 X006 Bit 2 Forward rotation limit M2 X000 Bit
100. ro Esgueira Phone 961 0 1 240430 F IDN 53312 Phone 359 0 2 817 6000 Phone 351 0 234 303 900 Fax 961 0 1 240 438 ax Fax 359 0 2 97 44 061 Fax 351 0 234 303 910 a ee ee EUROPE B V POLAND INEA RBT d o o CROATIA Sirius Trading amp Services stl ROMANIA k i aa Losinjska 4a Aleea Lacul Morii Nr 3 ae 35053 Bali HR 10000 Zagreb RO 060841 Bucuresti Sector 6 AFRICAN REPRESENTATIVE Arkae h D o Phone 385 0 1 36 940 01 02 03 Phone 40 0 21 430 40 06 Eren Di aaa Fax 385 0 1 36 940 03 Fax 40 0 21 430 40 02 CBI Ltd SOUTH AFRICA Private Bag 2016 MITSUBISHI ELECTRIC EUROPE B V RUSSIA TEAOR SA CECH REPUBLIC a SERBIA 74 1600 Isando a oe ee nab 8 floor CZ 708 00 Ostrava Pustkovec SER 113000 Smederevo Enone r a 0 WA a ade ih Phone 420 595 691 150 Phone 381 0 26 615 401 ak 27 0 Shanta Fa 595 691 2 381 0 26 615 401 MITSUBISHI ELECTRIC EUROPE B V SPAIN Cee DENMARK Pra an LOVAKIA SIA WA sio DK 4000 Roskilde SK 911 01 Trencin FC 5190 sait Cugat del Vall s Barcelona Phone 45 0 46 75 76 66 Phone 421 0 32 743 0472 Phone 902 131121 34 935653131 oe TEE Se Fax 34 935891579 re jjer ane Eesti OU ESTONIA Seana i sr o Pre ov SLOVAKIA MITSUBISHI ELECTRIC EUROPE B V UA iing OBC 01 Pretor UK aadi a Phone 372 0 6 518140 Phone 421 0 51 7580 611 Uic Hatfield Herts ALTO SB Far 372 06 1518149 Fax 421 0 51 7580 650 Phone 44 0 1707 27 61 00 Beijer Electronics OY FINLAND INEA
101. ro return in forward stopped completion flag rotation RST M12 SET S20 X003 M5 M10 N RST M11 Positioning Operation ro eun i in reverse stopped completion flag rotation PP RST M12 SET 21 NA NA V 413030da eps Fig 4 3 Program example 2 4 7 FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control FX PLC positioning Description Operation is stopped Sets the maximum speed to 100 000 Hz 100 000 in D8344 D8343 Sets the bias speed to 500 Hz 500 in D8342 Sets the acceleration time to 100 ms 100 in D8348 Sets the deceleration time to 100 ms 100 in D8349 Sets the maximum speed to 100 000 Hz 100 000 in D8147 D8146 Sets the bias speed to 500 Hz 500 in D8145 Sets the acceleration deceleration time to 100 ms 100 in D8148 Resets zero return completion flag Resets forward rotation positioning completion flag Resets reverse rotation positioning completion flag Enters the zero point return state SO Enters the foward rotation positioning state S20 0 Q 9 0 6 O 9 9 oe 0 2 4 Enters the reverse rotation positioning state S21 Tab 4 5 Description of program example in fig 4 3 2 Aa MITSUBISHI ELECTRIC FX PLC positioning Learning to Use the FX Familiy for Positioning Control
102. rt menu at the top of the screen El Monito ring Window 452030da eps Fig 4 26 Monitoring window Item Description Current Position This displays monitors the current address during positioning Plotting Double click on the plot area to change the scale Device Status Select YO 1 point Create a rectangle around Y000 by selecting the rectangle button from the drawing Rectangle toolbar at the top of the screen While the rectangle is selected the background color can be changed by pressing the B Brush Color button X axis Y axis Start Start Manual Operation Stop Stop Jog Jog Jog Jog FX GM Status This is a lamp that automatically monitors positioning operations Tab 4 24 Used items from the Insert menu Setting parameters In addition to the preparation of a positioning program diversified parameters should be set in the FX2n 20GM In this example only a few parameters need to be set When working with various equipment such as a mechanical plotter that uses an X Y plotting table the parameters should be set in accordance with the mechanism being used These settings depend on the specific plotter type and should be located in the documentation provided with the plotter FX Positioning Control Systems 4 55 Learning to Use the FX Familiy for Positioning Control FX2N 10GM and FX2N 20GM positioning Below are the four positioning parameter windows from VP
103. rvo systems are required for the advanced handling of pulse commands 1 3 1 Speed control Limit switch method Two limit switches are provided in places where a system s moving part passes At the first limit switch the motor speed is reduced At the second limit switch the motor turns off and the brake turns on to stop the moving part In this method because position controllers are not required the system configuration can be realized at reasonable cost Guideline of stopping precision Approximately 1 0 to 5 0 mm The stop precision shows a value in a case where the low speed is 10 to 100 mm s Inductive motor Moving part a lt gt Ball screw Limit switch for changeover to low speed Inverter Limit switch for stop High speed Oto 10 V DC Low speed Movement distance 120080da eps Fig 1 8 Schematic drawing Limit switch method 1 6 Pa MITSUBISHI ELECTRIC Positioning method type The Basics of Positioning Control Pulse count method A position detector such as a pulse encoder is set up in a motor or rotation axis The pulse number generated from the position detector is counted by a high speed counter When the pulse number reaches the preset value the moving part stops In this method because limit switches are not used the stop position can be easily changed Guideline of stopping precision Approximately 0 1 to 0 5 mm The stop precision shows a value in
104. sitioning controllers Important references for understanding inverter drive control for this section include FX Series User s Manual Data Communication Edition JY997D16901 Inverter Instruction Manuals It is assumed that you will have read and understood the above manuals or that you will have them close at hand for reference Overview of control Programmable logic controllers and inverters communicate with each other through passing parameter data and control operation data back and forth Inverters when used for variable frequency drive require a frequency command and a start command to operate Mitsubishi s FREQROL Series inverters communicate with FX2N C FX3G and FX3uU Cc PLCs via the Mitsubishi inverter computer link protocol to asynchronously control operations FX Positioning Control Systems 4 21 Learning to Use the FX Familiy for Positioning Control Inverter Drive Control 4 2 2 Using the FX2nN c FX3u c and FREQROL Inverter In order to enable RS485 serial communication to a MELCO inverter s a special BD board or adapter ADP is connected to the main unit FX2N C FX3G or FX3u c The following table describes connection options for using one channel of communication FX Series Communication equipment option Total extension distance pa Fe oe FX2N IRA Roe O Ti SoajO miros Mss JO OU O FX2n 485
105. slippage between the wheels and rails Fig 2 7 Schematic drawing Cart travel control Drive wheel on each of left and right sides 200060da eps 2 4 Pa MITSUBISHI ELECTRIC Examples of AC servo systems Positioning by AC Servo System 2 2 7 Carrier robot Description After the conveyor stops the 2 axis servo system and the arm lifting mechanism transfer workpieces to a palette The workpiece input positions on the palette can be set to many points so that setup change can be easily performed even if the palette position and the palette shape change Travel head Fig 2 8 Schematic drawing a Carrier robot Servo motor to drive Workpiece ji Servo motor to drive travel head Conveyor 200070da eps FX Positioning Control Systems 2 5 Positioning by AC Servo System Examples of AC servo systems a MITSUBISHI ELECTRIC Components of Positioning Control and their Roles 3 Components of Positioning Control and their Roles Positioning control requires a number of components such as a positioning controller servo amplifier servo motor and drive mechanism This section describes the role of each component To begin the following two page spread illustrates how the seven key elements function together to perform positioning FX Positioning Control Systems 3 Components of Positioning Control and their Roles
106. st this window will be empty This window is not needed since been created where the unit will be but as soon as the program is there are not any sub routines controlled and monitored from started the flow chart will appear being used This window can be Each positioning operation will be minimized to create more space on highlighted in RED as it is per the screen formed After minimizing the Sub Task Monitor Mode window resize the Monitoring Window and X axis and Y axis Monitor Mode windows 453020da eps Fig 4 32 X axis and Y axis Monitor mode windows Before starting the operation it is necessary to set the start point This can be done by using the X JOG and Y JOG buttons or by double clicking on the current position X 0 Y 0 display Aa MITSUBISHI ELECTRIC FX2N 10GM and FX2N 20GM positioning Learning to Use the FX Familiy for Positioning Control Double click the current position display in the Monitoring window to set the start point Current Position Object Units System F Pulse FX PLC Write to FX GM EXPLC 4 Read ftom FX GM After editing the current address to X 50 and Y 125 click on the Write to FX GM button for each axis mo As the address information is changed red lines will i appear on the plotter This shows the current position 125 To clear these red lines before positioning double click on the plotting area and the
107. t reference for understanding positioning with the FX2n 1PG E is FXe2n 1PG FX 1PG User s Manual JY992D65301 It is assumed that you will have read the above manual or that you will have it nearby for reference Overview of control The FX2n 1PG E is a popular unit for performing general point to point positioning operations on 1 axis up to 100 000 pulses second 100 kHz A stepper motor or servo motor can be used with the FX2N 1PG E to perform positioning operations Some of the main advantages to using the FX2n 1PG E for positioning as opposed to the FX1s FX1N or FX3U C include The flexible use of the zero point signal PGO Two speed positioning operations with or without interrupt The option to choose the FP RP pulse output method a MITSUBISHI ELECTRIC FX2N 1PG E positioning Learning to Use the FX Familiy for Positioning Control 4 3 2 Important buffer memory locations The FX2n 1PG E contains 32 buffer memory BFM addresses which are 16 bit 1 word areas of memory that contain information relevant to the control of positioning operations The FX2N C or FX3u c PLC that is connected to the FX2n 1PG E can send and receive data to the buffer memory addresses to change and or update information This exchange of information takes place through dedicated PLC instructions known as the FROM TO instructions For FX3u c PLCs the MOV instruction can also be used to transfer data to from special function blocks
108. tion to stop FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control FX2N 10PG positioning Description Set the pulse rate PLS rev K4000 1 0 Set the feed rate um rev K1000 35 34 Set the units to um x 103 mm combined system H32 36 Set the maximum speed Hz K50000 1 0 Set the bias speed Hz KO 2 Set the acceleration deceleration time ms K100 11 Set the acceleration deceleration time ms K100 12 Read status information 28 K3M20 Read error code 37 D20 Reset error STOP operation Forward rotation limit 0960 oo ooo Oooo Reverse rotation limit Tab 4 21 Description of program example in fig 4 23 1 Pa MITSUBISHI ELECTRIC FX2N 10PG positioning Learning to Use the FX Familiy for Positioning Control M8000 Coy RUN monitor X007 START TO 2 sec timer ee FNC 79 as KO K27 H1 K1 Intialipulse Unit No BFM 1 speed No of positioning transfer points FNC 79 DTO KO K13 K50 K1 Unit No BFM Target No of address 1 transfer points FNC 79 DTO KO K15 K50000 K1 Unit No BFM Operation No of speed1 transfer points TO X001 M25 K2 tH C100 2 sec STOP Error timer flag M26 C100 y CD Positioning Counter complete a K20 ee X0
109. to the previous one except that it is programmed only in ladder logic and does not follow a specific sequence of step ladder states Additionally it includes control for relative positioning with JOG and JOG commands a DOG search zero return function and utilization of the DTBL instruction When using an FX3G or FX3u c PLC the DOG search zero return function can be programmed with limit switches wired to the PLC as follows Reverse rotation limit 2 Reverse rotation limit 1 Forward rotation limit 1 Forward rotation limit 2 Servo amplifier side Programmable Programmable Servo amplifier side controller side controller side LSR LSF Servo motor a WA 5 as E lt al aana SASS SSN SNS NN SN SNS SN SN SN SSN SS SN NSS HGS SS SS SNS SS SNS SS SS SN SE ESAS ES EN SESE SENS NS ESS SSNS SSS Reverse rotation lt gt Fomard rotation 413060da eps Fig 4 4 Configuration example for FX3u c PLC The DTBL instruction helps to simplify the programming and is set up beforehand along with positioning parameters such as the bias speed acceleration deceleration etc with GX Developer GX IEC Developer or GX Works2 In this example positioning may be performed arbitrarily along the path in fig 4 5 Using the JOG command the workpiece is moved to any relative position This is not illustrated in the figure below Fig 4 5 Positioning pattern Forward 500 000
110. tor encoder absolute position detection system The absolute position detection system requires an absolute position motor encoder a backup battery on the servo amplifier and a parameter specification setting It is constructed so that the current value stored in the positioning controller is always assured regardless of power outages or movement while the power is turned off The advantage to using this method is that after executing the zero point return function once zero point return it is not needed again The zero point return function does not actuate movement to a physical zero address Instead the zero point return function causes movement in a specified direction positive or negative in order to define the physical zero address after contact with a DOG switch Example of DOG type zero return In the example in Fig 3 5 the DOG which is attached to the workpiece comes in contact with the DOG switch to turn the DOG signal ON which then initiates deceleration to creep speed After the backward end of the DOG passes the DOG switch turning the DOG signal OFF the first detected zero point signal stops the motion turns the CLEAR signal on and sets the zero point address The zero point address specified in the controller s parameters is typically zero When the zero return function finishes the zero point address is written to the current value register of the positioning controller to overwrite the current address Since the
111. uction Settings check box Take note that 9 000 steps are needed to set the positioning data Therefore it is necessary to specify a Memory capacity of 16 000 steps or more FX parameter Memory capacity Device PLC name 1 0 assignment PLC system 1 PLC system 2 Positioning Memory capacity 16000 Comments capacity 0 Block 0 block to 31 block Points File register capacity 0 Block 0 block to 14 block Points Program capacity 7000 Steps Special Function Memory capacity 18 Block Special Function Block Settings 8 Blocks Defaut 413090da eps Fig 4 7 Memory capacity window FX Positioning Control Systems Learning to Use the FX Familiy for Positioning Control FX PLC positioning 3 Click on the Positioning tab and then set YOOO pulse output destination as follows FX parameter Memory capacity Device PLC name 1 0 assignment PLC system 1 PLC system 2 Posi ya 2 Y3 Setting Range Bias speed Hz 0 0 0 1710 or less of Max speed Max speed Hz 100000 100000 100000 10 200 000 Creep speed Hz 1000 1000 1000 10 32 767 Zero retum speed Hz 50000 50000 50000 10 200 000 Acceleration time ms 100 100 100 50 5 000 Deceleration time ms 100 100 100 50 5 000 Interruption input of DVIT g 8 E instruction xI x2 x3 XO X7 Special M j Individual setting Defaut Cancel Fig 4 8
112. w Speed Fig 1 10 Positioning pattern A Coasting distance iN gt Time Stop command Stop 1200b0da eps Dispersion in the stop distance changes as shown below Dispersion is affected by the speed of the workpiece when the stop command is given and the speed reduction time delay after stop Speed Fig 1 11 Positioning pattern A Speed recuction start gt k Time delay Dispersion in stop l TiN Time command Stop Stop 1200c0da eps f the required stop precision is not satisfactory when stopping from the normal operation speed the most effective method to improve the stop precision is to reduce the operation speed However if the operation speed is simply reduced the machine efficiency may also be reduced Therefore in actual operation the motor speed can be reduced from a high speed to a low speed before the motor is stopped as shown below Speed Speed UN ji AN Time delay Poor stop precision High speed Low Improved stop speed precision zi gt Time gt Time RE Stop Speed reduction Stop command Stop command 1200d0da eps Fig 1 12 Positioning pattern 1 8 Pa MITSUBISHI ELECTRIC Positioning method type The Basics of Positioning Control 1 3 2 Position control Pulse command method An AC servo motor which rotates in proportion to the input pulse number is used as the drive motor
113. wn as SSCNET III Servo System Controller Network Important references for understanding positioning with the FX3U 20SSC H include FX3u 20SSC H User s Manual JY997D21301 FX Configurator FP Operation Manual JY997D21801 It is assumed that you will have read the above manuals or that you will have them nearby for reference Overview of control Using an FX3u PLC with the FX3u 20SSC H 20SSC H module and two Mitsubishi MR J3 B servo amplifier systems high speed positioning with pulse output frequencies up to 50 000 000 pulses second 50 MHz is possible on two axes However since motors compatible with the MR J3 B servo amplifier system have a maximum rated speed of 6 000 RPM the maximum controllable speed from the 20SSC H becomes rev PLS 1 PLS 6 000 in x 262 144 rev 0 26 214 400 FT The FX3u 20SSC H provides several advantages compared to other controllers in the FX family FX3U 20SSC H Feature Advantage Bidirectional With SSCNET III the PLC can communicate with the servo amplifier to monitor torque communication servo status flags servo parameters and absolute position data Easy to use wiring Wiring High immunity to noise from external devices Long distance wiring 50m Easy setup of parameters and table data up to 300 table operations per axis Convenient use of monitoring and testing functions Tab 4 25 Features and advantages of FX3U 20SSC H With th
114. x ior Operation speed 1 E Operation speed 2 Hz Table operation start No Mode selection Target address 1 Target address 2 PLS Start Operation speed 1 Hz Operation speed 2 Hz Cancel remaining distance operation Fig 4 36 X axis operation test window To stop positioning click on the All axis stop or Stop button 463030da eps After stopping the table operation a variety of other positioning operations can be tested from the X axis Pattern combination box such as 1 speed positioning 2 speed positioning and linear interpolation For additional control in TEST MODE the other tabs at the top of the X axis Operation test window can be used according to the following information Position start Feed present value Speed CHG OPR JOG MPG CHG Positioning opera tions can be exe cuted from this win dow Target address and operation speed data is defined here The value of the cur rent address can be changed using this window Two operations for changing the speed of the motor are available from this window By clicking on the REQ OPR button zero return is exe cuted JOG operation and manual pulsar oper ation testing can be performed from this window a MITSUBISHI ELECTRIC FX3U 20SSC H positioning Learning to Use the FX Familiy for Positioning Control 4 6 4 Important buffer memory locations The FX3u 20SSC H buffe
115. y selecting Parameters Positioning gt Machine Zero from the menu bar at the top of the screen Parameter Machine Zero Specify the same settings _ for the Y axis Limit switch logic DOG switch logic Direction Normally Open Normally Open Increasing Normally Closed C Normally Closed Decreasing E KAANAA AT AAAA AAAA TEATA EL ELE KA YAWA WA DEAN Creep Speed i Zero return speed 100 Hz i 300 Hz i Dog Switch Option Front end Zero point address zi REP ESS Rearend fo x10 PLS T 1 Not used Speed A w Settings Cancel Help 452060da eps Fig 4 29 Parameter Machine Zero window Count Since mechanical hardware will not be connected to the FX2N 20GM for this example itis not necessary to configure the limit switch and DOG switch settings in the parameters It is however necessary to reduce the Creep speed and the Zero return speed For the last parameter screen open the Parameter Settings window by selecting Parameters Positioning gt Settings from the menu bar at the top of the screen Parameter Settings NO CHANGES Pulse output format Stop mode C Invalid Complete remaining distance C Start from the NEXT step Present value with forward pulses C Jump to END Complete remaining distance interpolation C Start from the NEXT step interpolation C Rotation pulses and direction specification increases C decreases Software limits Positioning co
116. y trained and qualified electrical technicians who are fully acquainted with the relevant automation technology safety standards All work with the hardware described including system design installation configuration maintenance service and testing of the equipment may only be performed by trained electrical technicians with approved qualifications who are fully acquainted with all the applicable automation technology safety standards and regulations Any operations or modifications to the hardware and or software of our products not specifically described in this manual may only be performed by authorised Mitsubishi Electric staff Proper use of the products The programmable logic controllers of the FX1S FX1N FX2N FX2NC FX3G FX3U and FX3uc series are only intended for the specific applications explicitly described in this manual All parameters and settings specified in this manual must be observed The products described have all been designed manufactured tested and documented in strict compliance with the relevant safety standards Unqualified modification of the hardware or software or failure to observe the warnings on the products and in this manual may result in serious personal injury and or damage to property Only peripherals and expansion equipment specifically recommended and approved by Mitsubishi Electric may be used with the programmable logic controllers of the FX1S FX1N FX2N FX2NC FX3G FX3U and FX3uC series All and
117. zero point address is not always zero the zero return function should be thought of as a homing function instead of a return to zero function The zero point return direction zero point address zero signal count return speed deceleration time and creep speed are all set by parameters in the positioning controller Zero point Fig 3 5 Positioning pattern of rinsi DOG type zero return Deceleration time RS Pa activated l 1 Ji 1 ji l DOG switch l l l l 1 l l Zero point Initial position DOG Zero point return switch g direction dn DOG DOG Ai E Forward end Backward end ON CLEAR signal 313010da eps The location of the DOG switch should be adjusted so that the backward end of the DOG is released between two consecutive zero point signals 1 pulse per rotation of the motor In this example the DOG length should not be less than the deceleration distance of the machine A Pa MITSUBISHI ELECTRIC Positioning controller Components of Positioning Control and their Roles DOG search function In some PLC models if the zero point return function is performed while the workpiece is stopped beyond the DOG switch the machine moves until the limit switch is actuated changes direction then returns to the zero point again DOG search function zero point return retry funct

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