DirectSOFT5 - AutomationDirect
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1. S3 and S4 They are located on upper factory default left corner of the circuit board Jumper in 1 3 position Step CW Step CCW Foe aeo d Jumper S4 LED c Step Pulse Noise Filter Jumper 54 Step Pulse Noise Filter Jumper in 1 7 position 2MHz ui Se Jumper 83 Jumper in 1 3 position 150 kHz Step Pulse Type factory default VAUTOMATIONDIRECT Comore Pirect Koyo 5urestep 09 46 STP DRV 6575 Microstepping Drive Dip Switch Settings 1 of 3 SW 1 amp 2 Reduce power consumption and heat generation by limiting motor running current to 100 90 or 80 of maximum Current should be increased to 120 if microstepping Torque is reduced increased by the same Current Reduction ERE GET ER TOC ON SW 4 Reduce power consumption and heat generation by limiting motor idle current to 90 or 50 of running current 100 90 80 120 Use 120 when microsteppin pping Holding torque is reduced by the same 90 Idle Current Reduction y ON 50 90 SW 3 Anti resonance and damping feature improve motor performance Set motor and load inertia range to 0 4 or 5 10x Load Inertia do 5 10x 0 4 VAUTOMATIONDIRECT C morg Direct Koyo Sureste micro STP DRV 6575 Microstepping Drive Dip Switch Settings 2of3 SW 5 6 amp 7 For smoother motion and more precise speed set the pulse step resolution to 200002. kc T3 Rotary Encoder 100 ppr B channel X4 E K2 Comore gt H step micro Timer T3 15 used to detect if the Stepper Motor 1s Jammed or has stalled by means of monitoring the B channel pulses that are produced by the encoder when the Stepper Motor is rotating The Timer is enable by the Step Drive Run signal YO and is programmed with a time of 0 2 seconds The encoder pulses input X4 are programmed into the Timer s reset and causes the Timer to be constantly reset as long as the Stepper Motor 1s rotating VAUTOMATIONDIRECT C more BIreCt Koyo step DirectSOFTS5 Detect No Stepper Motor Motion 14 of 15 22 49 If Timer 13 times out indicating no Stepper Motor rotation internal relay C7 1s latched 1n through itself and a normally closed C7 contact is used in the Step Drive Run YO output circuit to stop the Stepper Motor from running The No Step Motion circuit is reset by taking the Cycle Control internal relay C4 out of Feeder Run mode No Step Motion latch to stop all motion based on no rotation from the step motor Could be caused by a jam pf the slotted disk loss of power to the stepper drive or a problem with the stepper motor and or encoder Press the Feeder Stop push button Fl Key on the The latch circuit is reset by taking the unit out of the Run mode C more Micro Graphic panel to reset Timer to detect loss of O
3. VAUTOMATIONDIRECT Comore Birect Koyo micro LOGIC Motion Control Video Rundown and References cont d 02 30 This handout can be used to follow along with the video and can also be useful as a refresher to the steps required to create a working Motion Control System using a DirectLOGIC DLOS PLC with DC outputs programmed with the PLC s builtin High Speed Pulse Output using Mode 30 controlling an AutomationDirect SureStep Stepper System interfaced with a C more Micro Graphic panel monitored with ADC sensors and constructed using ADC wiring components For additional information on AutomationDirect s products that are a good choice for a Motion Control application please refer to the Automation Notebook article titled Starting with Steppers under the Tech Thread Part of 2 published in Issue 21 Fall 2011 and Part 2 of 2 published in Issue 22 Spring 2012 Various stepper motor control methods are discussed in this article Links to Part 1 amp 2 are shown below The eight part video series titled Motion Control DirectLOGIC Micro PLC CTRIO Module to SureStep Stepping System with C more Micro Graphic Panel HMI is another excellent resource detailing Motion Control System information 6 Part Video Series http bit ly 17Oho YU Link to Starting with Steppers Part 1 http bit ly JSUOtN Link to Starting with Steppers Part 2 http bit ly IQSjUb VAUTOMATIONDIRECT mare Pi
4. Jam detected latch C6 circuit and start timer T2 to allow stepper rotor to reverse direction of slotted disk for a set amount of time result of the Stepper Motor Power Supply current that goes to the Stepper Motor Drive has exceeded the Set Point value Jam amount of time AcuAMP Relay C6 Over Current Jam Detected The signal 1s used as a one shot and latches in C6 l OUT the circuit through internal relay C6 Jam Detected Timer T2 programmed for 10 seconds is Relay C6 Timer T2 Jam Detected Jam Timer used to set how long Stepper Motor 15 ran C6 T2 LAC in the reverse direction to clear the potential Jam When Timer 12 times out the Reverse Rotation circuit is de energized and the Stepper Motor returns to running in its Rung 13 normal direction Timer T2 15 set for 10 seconds Reverse rotation of Time how long to slotted disk for a set reverse direction of the amount of time slotted disk K100 VAUTOMATIONDIRECT more BIreCt Koyo step 21 25 DirectSOFTS Stepper Motor Forward Reverse Logic 12 of 15 Reverse stepper motor direction by loading constant KO into double memory address V2321 2322 The reversing is done to try and clear any part jam Reverse rotation of slotted disk for a set amount of time Relay C6 Jam Detected C6 J4 OUTD Change stepper motor direction back f
5. to 50 Amps he wiring for the current going to the stepper drive power supply uses ten 10 DC current sensor The output signal from the AcuAMP turns to increase the sensitivity is 4 to 20 mA and represents to 50 Amps as setup on The Base for the DLO5 PLC is zero so constat KO 15 assigned the Sensor There is only one expansion slot available on the DLOS PLC so the Slot is assigned to The 4 to 20 mA signal is wired into a FO O4AD 1 analog constant K1 input module located in the expansion slot of the DLOS The F0 04AD 1 analog input module inclused 4 channels Number of Input Channels shown in the instruction is set to constant PLC The Input Data Format is set to Binary so constat K1 is used lo Increase the current input resolution ten turns are Memory Address V2000 is used for the Input Data Address wrapped through the current sensor s aperture allowing 5 Amps to produce full scale output Analog Input Module Pointer Setup ANLGIN The ANLGIN IBox instruction is used to configure the Base 0 Slot module with the Pointer Setup method as shown Base Number of Input Channels Input Data Format 0 BCD 1 BIN equals Slot 15 there are four input channels ee er thus K4 is used Input Data Format in binary equals K1 and Data Address assigned to V2000 VAUTOMATIONDIRECT Pirect Koyo Sureste micro DirectSOFT5 Jam Detected via S
6. ve n 434 HAT e w CA wg Se y d E t 4 D 4 e u r VAUTOMATIONDIRECT Comore PirectKoyo Estep micro STP DRV 6575 Microstepping Drive Motor Selection 08 36 STP DRV 6575 Motor Selection Table Use the Rotary Switch to select the motor being used based on either the stepper motor s part number or set by the Rotary Switch stepper motor s current rating In this example the stepper motor used is part number STP MTR 17060D so the Rotary Switch 1s set to position 8 Holding mH Torque oz in 2 Motor Current Arg phase Roter Inertia Inductance Resistance 42 Drive Current peak sine A end E EM 3 custom NEMA 17 ES Le Y p custom NEMA 34 1 Tu os ar fo ox 25 120 sc v 240 7 17060 2 0 115 0 56 3 30 2 00 883 37 240 c 5 cese 5 Ea COE SIP MTR 17060D VAUTOMATIONDIRECT Comore Pifect Koyo 2075 STP DRV 6575 Microstepping Drive S3 amp S4 Jumper Settings 09 04 In most cases S3 amp 54 jumpers for the STP DRV 6575 Microstepping Drive can be used per the factory defaults but can be adjusted as shown here STP DRV 6575 Jumper S3 Step Pulse Type J in 1 2 E lt amp Di Remove connectors and cover to access Jumpers umperin 1 Z position step
7. video to show the following operations gt Normal Operation fast slow speed change based on encoder marker pulse and encoder A channel pulse counting Exit Tube Full Part Feeder stops until parts clear Part Feeder Station gt Hopper Empty Part Feeder stops until parts are added Control Enclosure Overload Part Feeder reverses direction for 10 seconds to clear a potential jam No Motion Detected Part Feeder stops and an alarm message appears on the C more panel VAUTOMATIONDIRECT Direct Koyo Sureste micro Please note Learn AutomationDirect com is an online streaming tutorial site offering training and information on a wide range of practical automation products THE LEARN AUTOMATIONDIRECT COM WEBSITE AND THE TRAINING AND INFORMATION PROVIDED IN CONNECTION THEREWITH IS SUPPLIED AS 15 These video presentations and other documents are provided by our associates to assist others in learning the products we sell and service We make no representation warranty or guaranty whether expressed implied or statutory regarding the LEARN AUTOMATIONDIRECT COM website on the training information and the content including without limitation the implied warranties of merchantability or fitness for a particular purpose and any representation warranty or guaranty that the foregoing will be accurate complete uninterrupted error free or non infringing is suitable for your p
8. Multi Wire 2 step Connector 1 To 4 20 Analog Input odule FROM SHEET 1 OF 2 24 VDC P S1 pn STP MTR 17T060D o o 4 20mA Analog input Module 3 S m x m 25 H xD 2D AC L G LG AC N 95 240 JOVA 50 60HZ DLOSPLC c2 8 DC INPUT 12 24 VDC ee sink source vO zT 6 DC OUTPUT Bora 6 27 VDC sinking ED DC Current yE 1 0A point max 1 H Sensor pin 00 0500 STP DRV 6575 Multi Wire 4 ne Mode Switch vz run JE TERM Multi Wi x ulti Wire Slat Connector 1 PORT1 PORTZ more 3 Micro Graphic LEDs Panel EA1 53MLW N PWR O S RUN D a v ERR O e TX1 O Communications Cable Multi Wire RX1 O pn DV 1000C TH RX2 Comore Direc Koyo Su step 06 19 Schematic Diagram Part Feeder Station DL05 PLC Stepper System amp HMI Sheet 2 of 2 VAUTOMATIONDIRECT Comore 2 Sureste micro F0 04AD 1 Analog Input Module Jumper Settings 06 50 To detect if the Part Feeder is jammed current from SureStep F0 04AD 1 Jumper J3 Selection power supply to the SureStep drive is monitored using an AcuAMP DC Current Sensor F0 04AD 1 The 4 20mA signal from the DCT100 42 24 F AcuAMP Current Sensor is wired into channel of the F0 04AD 1 Analog Current Input Module The position of jumper J3 on the F0 04AD 1 4 Channel Analog Current Input Module determines the input s
9. OUT Shorten Rev Time Counts Encoder Pulses Feeder Disk Counter CTO Fast Speed Fast Speed Count C1 CTO m j micro DirectSOFTS5 Slotted Disk Fast Slow Speed Encoder Pulse Counter 7 of 15 00 Counter CTO counts the encoder s A channel pulses via DLOS PLC input to determine how long the stepper motor stays 1n High Speed before switching back to Slow Speed VAUTOMATIONDIRECT Comore Pest Koyo A pre set of 85 counts is used in the application M which calculates to be 85 times 360 degrees Count up to 85 pulses to allow the stepper motor to stay in high speed before switching to low speed to obtain the fastest cycle time between each part being dispensed equals 306 degrees 1n High Speed and 54 degrees Shorten Rev Time Rotary Encoder UDC in Slow Speed which is over the point the part IS Feeder Disk 100 ppr TEM E Fast Speed A channel sien dropped into the Exit Tube Of course the count C1 3 ee The Encoder s A channel produces 100 pulses per revolution at pre set can be adjusted to produce different results _Off Ihe Z channel marker pulse occurrence point in SP2 the slotted disk s rotation 1s adjusted by loosening Counts Encoder Pulses the Set screws on the stepper motor and holding Counter CTO E Fast Speed Count the encoder in position while rotation the slotted disk then tightening the set screws sisi VAUTOMATIONDIRECT Comore Pirec
10. Speed HAPS Cycle Control Cycle Control Relay C4 C more F3 LED Feeder Run Run Indicator C4 2010 2 L our VAUTOMATIONDIRECT Direct Koyo Sureste DirectSOFT5 Hopper Empty amp Exit Tube Full Delay Timers 4 of 15 5861 Timer to keep Part Feeder running for a time period after the Part Hopper not Empty Capacitive Sensor Is no longer detecting the parts inthe hopper The timer allows removing as many parts as possible before stopping the rotary slotted disk TMR Capacitive Sensor Stop Stepper Motor if Input X2 Hopper is Empty Hopper Not Empty Timer TO Hopper Delay T TO K100 Timer used to allow a part to drop past the Exit Tube Fiber Optic Photo Sensor without stopping the stepper motor If the parts back up to block the Exit Tube Photo Sensor thru beam for the amount of time programmed in our case 1 0 second then the stepper motor is halted until the parts clear the photo sensor TMR Fiber Optic Sensor Stop Stepper Motor if Exit Input X1 Tube if Full Exit Tube Full Timer m Exit Full Delay v1 T1 K10 Timer allows the Part Feeder slotted disk to continue to run for 10 seconds after no more parts are detected in the hopper The Hopper is Empty detector is a Capacitive Sensor timer resets anytime parts are detected A Fiber Optic Photo Sensor is used to detect if the Parts back up 1n the Exit Tube Timer 1 is used so th
11. series of red flashes The pattern repeats until the alarm 1s cleared VAUTOMATIONDIRECT Comore 0164 SU st p STP DRV 6575 Alarm Codes Status LED Alarm Code no alarm motor disabled flashing green alarm motor enabled flashing red configuration or memory error 1 green 4 red power supply voltage too high 1 green 5 red over current short circuit 1 green 6 red open motor winding 2 green 3 red internal voltage out of range 2 green 4red power supply voltage too low Does not disable the motor The alarm will clear about 30 seconds after the fault is corrected Disables the motor Cannot be cleared until power is cycled T The over current short circuit alarm typically indicates that an electrical fault exists somewhere in the system external to the drive This alarm does not serve as motor overload protection micro DirectSOFTS Setting Up HSIO Mode 30 Pulse Output 1 of 15 EA VAUTOMATIONDIRECT Comore Pirect Koyo 29 ams The first steps n programming the Firstocan LD 2 High Speed Pulse Output Mode 30 atas function that is built into the DLOS ud PLC requires loading parameters into the assigned V memory registers Initialize the 0105 PLC High Speed Pulse Output Mode 30 for the HSIO mode 02320 Load the constant K30 into memory address V7633 Constant value K30 is loaded into Profile Parameter Table beginning Octal Address 2 7633 to enab
12. 12800 5000 2000 400 smooth 400 200 smooth or 200 steps rev 400 400 200 SW 8 The Self Test function Dip Sm Switch position 8 when in the On position automatically rotates the motor back and forth two turns in each direction in order to confirm that the motor 1s operational Meer WAUTOMATIONDIRECT Comore Pirect Koyo step STP DRV 6575 Microstepping Drive Dip Switch Settings 3 of 3 The STP DRV 6575 Drive Dip Switches for the Part Feeder Station are set as follows gt Current Reduction 80 Application does not require full torque so 80 1s used to reduce heat gt Load Inertia 0 4X Application has little loading so lower inertia can be used gt Idle Current Reduction 50 Reduce power consumption to 50 which reduces heat produced at idle Step Resolution 400 steps rev Smooth Produces the best running results for the application Self Test Off ea EN S 7 334 25 A ae co V t eL eu t t a a v A 7 T DD e E 4 rz x ee T AE zi SIP DRV 6575 Self Test OFF steps rev Idle Current Reduction Load Inertia Current Reduction micro LOGIC STP DRV 6575 Microstepping Drive Alarm Codes 11 55 In the event of a drive fault or alarm the green LED will flash one or two times followed by a
13. Motion Control DirectLOGIC DLO5 PLC HSIO Mode 30 Pulse Output to SureStep Stepper Drive with C more Micro Graphic Panel HMI Part 1 of 1 Part Feeder Station VID L PC DL HSIO STP 001 QUTOMATIONON CCT VAUTOMATIONDIRECT Comore 5urestens micro LOGIC Motion Control Video Rundown and References 00 55 This LEARN video covers the Part Feeder Station that uses Application amp Equipment the DirectLOGIC DLOS PLC s built in High Speed Pulse Output referred to as Mode 30 to control a SureStep Stepper System A C more Micro Graphic panel is used as Hardware Setup Jumper amp Dip Switches the operator interface Various sensors are also used with the DirectSOFTS Ladder Logic amp Boxes Part Feeder to control operational functions C more Micro Graphic Panel HMI Wiring Schematic Diagram The Part Feeder Station is the first stage of an overall application based on various Motion Control systems The Operational Demonstration first and second stage are controlled with SureStep Stepper systems using ADC products with the final stage based on AutomationDirect s SureServo Servo System To the right 15 a list of topics covered in this video Links pointing to available technical information from AutomationDirect have been included such as the example on the SureStep User Manual shown below Link to SureStep Stepping Systems User Manual http bit ly rsdgUO
14. anel are the DirectLOGIC DLOS PLC AcuAMP DC current sensor 24 VDC power supply used for the PLC s DC inputs and also 24 VDC power to the AcuAMP and the master control power circuitry relay Control Enclosure The SureStep stepper motor drive and stepper motor power supply are also mounted to the enclosure s panel AutomationDirect s terminal blocks wire duct DIN rail and machine tool wire are used to construct and wire the control panel enclosure AutomationDirect multi wire connector multi conductor flexible control cable is used to connect the control panel enclosure to the Part Feeder Station VAUTOMATIONDIRECT more TEC Koyo Application Schematic Diagrams The next two slides represent the schematic diagrams of the Part Feeder Station PE 2 Control Enclosure Panel The first schematic diagram shows the power circuitry which includes the Master Control circuitry with relay Power On push button and Emergency Stop push button The ADC Rhino 24 VDC power supply used to provide power to the PLC s DC inputs and power to the AcuAMP DC current sensor 1s also shown on the first schematic diagram The second schematic diagram includes the DirectLOGIC DLOS5 PLC SureStep stepper system motor power supply and drive Koyo incremental encoder AcuAMP DC current sensor 4 20 mA analog current input module fiber optic photoelectric and Capacitive proximity sensors and C more Micro Graph
15. articular application nor do we assume any responsibility for the use of this information in your application User suggestions corrections and feedback are not only welcomed but are essential to the maintenance of current content and the creation of new content If there is a training idea or correction to an existing presentation you would like us to consider please complete and submit the suggestion form that 1s shown as a Suggestions link at the bottom of every page Thank you Copyright 2014 AutomationDirect com Incorporated All Rights Reserved Worldwide
16. at every part that triggers the Fiber Optic photo sensor doesn t stop the Part Feeder slotted disk and the part has to block the photo sensor for one second before the action 1s paused VAUTOMATIONDIRECT Direct Koyo Sureste micro DirectSOFTS5 Execute HSIO Mode 30 Parameters Out YO 5 of 15 Bee The rung shown here controls the execution of the Velocity Profile that was setup with the HSIO Mode 30 parameters 1n rungs and 2 Out YO produces the step pulses that are wired into the stepper drive Contact C4 15 the Feeder Run signal that 1s shown 1 rung 3 YO is used to command the stepper motor drive to execute the parameters that were created at part of the Mode 30 setup Timers TO and Tl contacts In this application a Velocity Profile is used The Profile will cause the stepper motor to enable the rung when the Hopper run at the speed and direction that was loaded The speed and direction can be altered on the fly In this application the stepper motor s speed is increased to reduce the 1S not Empty and the Exit Tube 1S rotational time based on an Encoder marker pulse and counting Encoder pulses The direction is reversed if a is detected due to an increase in stepper motor current draw not Full respectively otop Stepper Motor if Exit Stop Stepper Motor If No stepper motor Executes the HSIO Mode Contact 7 1S the contact from Cycle Control Tube if Full Hopper is Empty rotation is detected 30 Parame
17. c self test switch selectable Operates from a 24 to 65 VDC power supply Running current from 0 5 to 7 5A Link to Microstepping Drive Data Sheet http bit ly 17mkQLQ VAUTOMATIONDIRECT Comore SU step micro STP DRV 6575 Microstepping Drive Wiring 07 58 STP DRV 6575 Terminals Switches Indicators External wiring to the STP DRV 6575 Microstepping Drive is accomplished by using the two separate pluggable screw terminal connectors The power connections for the supplied DC power and the stepper motor leads share a six J Status LEDs position connector The digital inputs and one output share an eight position E mo connector LY FAULT Also seen in diagram to the right are Status LEDs Rotary Switch used l EN to select the Stepper Motor based on part number or current rating and the 4 EE 8 position Dip Switch used to select the drive s operating parameters 1 STEP STEP DIP Switches b A ah si A i EA n PES 1 S t T zc tr e i 2 ic ra lt X a J S v un b iT A m i OV SERIA ex Gee ie a lt Nocte EN essc n 2 eee 995 5 oc T i niuv E OOt WE sari X TN M E S 5 5 TP DR 6 j clus ug
18. ic panel The wiring for the Part Feeder controls uses different colored machine tool wires for the various conductors to help identify individual circuits whereas wire numbering could have been just as easily used Follow the codes for your application micro 401 120 VAC 60 HZ 1 Part Feeder Power Wiring Sheet 1 of 2 05 58 Schematic Diagram 104 Part Feeder Station T Power Wiring w m Sheet 1 of 2 EMERGENCY w HH T A MASTER CONTROL VIOLET Oo RELAY oie we T 2 110 204 VAUTOMATIONDIRECT Comore Birect Koyo SU step PB1 GCX1131 750 26 120 wi 7T50 2C SKT BLU WHT BLU 51 5 PSP24 0605 BLU BLK BLU WHT 121 TO SHEET 2 OF 2 TO SHEET 2 OF 2 120 VAC 24 VDC P 21 WAUTOMATIONDIRECT FROM SHEET 1 OF 2 120 VAC Stepper Motor Power Supply Flexible Coupling Between Stepper Motor amp Encoder um Controls Fast slow Switch Points T mem WHT Out B iro BLU OV SHIELD OOBD Optical Fibers Part Exit Tube Full Optical Snesor Fiber Amp pin SSF 0N 0E c r FB3 20 Detects Hopper micro Part Feeder DLO5 PLC Stepper System amp HMI Sheet 2 of 2 DCT100 42 24 F Feeder Slotted Disk Stepper Motor Stepper Motor Cable Connector Output Power Detects over ZU current as a an Aa result of a jam ak 4
19. ignal level The chooses are 4 20mA or 0 20mA The module ships with the jumper not connecting the two pins so that 1n this position the expected input signal 15 4 20mA Input Signal Input Signal FO O4AD 1 F0 04AD 1 VAUTOMATIONDIRECT Direct Koyo Sureste micro SIP DRV 6575 Microstepping Drive Block Diagram Features Low cost digital step motor driver in compact package Operates from Step amp Direction signals or Step CW amp Step 24 65 VDC e from external CCW Jumper selectable Supply 3 355V Enable input amp Fault output Regulators Optically isolated I O SLE yi Status LEDs Digital filters prevent position error from electrical noise on Voltage command signals jumper selectable 150 kHz or 2M Hz Rene AMPLIFIER Rotary switch easily selects from many popular motors Sensors Electronic damping and anti resonance Optical Digital T Ne e Automatic idle current reduction to reduce heat when motor is Isolation Filter Overcurren not moving switch selectable 50 or 90 of running current Switch selectable step resolution 200 full step 400 half Isolation Filter step 2 000 5 000 12 500 or 20 000 steps per revolution Optica ptica Switch selectable microstep emulation provides smoother more Isolation reliable motion in full and half step modes Current Idle Current Steps Rev Load Inertia Self Test hh a Motor Selection 12345678 Automati
20. k for the note below the video that mentions take away training PDF s and Demo projects P mm Link to DirectLOGIC PLCs Web site http bit ly Nyasby micro C more Micro Graphic Panel HMI The C more panel used in the example application consists of just one screen for simplicity The HMI used in the example application 1s a 3 non touch panel with green and red backlights ADC part number EAI S3ML N From the panel the Part Feeder can be started and stopped using the F1 and F2 function keys Indicators are used to show the Feeder in Run or Off mode The stepper motor Fast Slow speed 1s displayed The stepper motor power supply Amperage from the AcuAMP current sensor is displayed and the OverCurrent Set Point is displayed and can be incremented up or down with the F4 and F5 function keys Indicators are also included for the Exit Tube Full and Hopper Empty sensors VAUTOMATIONDIRECT ie Direct Koyo Sureste NOTE A complete commented C more Micro Graph c panel project for the Motion Control demo presented here is available for downloading from the LEARN website Look for the note below the video that mentions take away training PDF s and Demo projects Molior HAPS Link to C more Micro Graphic Web site http bit ly Lvukxg VAUTOMATIONDIRECT more Koyo SU s micro Part Feeder Station Demonstration The Part Feeder Station 1s demonstrated in the
21. le Mode 30 for Load Address 02320 into memory address 7 630 zi generating output pulses Select pulse and direction for physical YO and Y1 functions Load constant K103 into memory address V7637 The Octal address 0232 1S loaded 2 9 The last three instructions loads constant KO into memory locations V7635 amp V7636 to into V7630 to designate the beginning select no filter time for inputs X1 and X2 of the Profile Parameter Table Pulse and direction is selected by loading constant K103 into V7637 VAUTOMATIONDIRECT Comore Pirect Koyo 5urester DirectSOFTS Setting Up HSIO Mode 30 Pulse Output cont d 2 of 15 EEA Continuing the setup of the High Speed Pulse Output Mode 30 function additional parameters are loaded into the Profile Parameter Table The constant K2000 is loaded into V SPO e memory address V2320 to select a Velocity K2000 Profile move Part Feeder DLO5 PLC High Speed Output to SureStep Stepper System 2320 Constant K80000000 is loaded into double Continue DLO5 PLC High Speed Pulse Output Mode 30 setup word size V memory address V2321 2322 to oelect Velocity Profile K80000000 select CCW direction Load constant K2000 into memory address V 2320 OUTD Select CCW direction for the Velocity Profile need to use double word size V2321 Load double word constan
22. nce the situation for the loss of motion is corrected Encoder pulses No stepper motor no motion PORTO DETUR the Part Feeder can be put back into normal operation imer T3 Relay by pressing the Feeder Start push button F2 Key on OUT the C more Micro Graphic panel No stepper motor rotation is detected Cycle Control Relay C7 Relay C4 No Step Motion Feeder Run C C4 VAUTOMATIONDIRECT Comore Direct Koyo Sureste micro DirectSOFT5 Documented Project 15 of 15 23 27 The DirectSOFTS5 ladder logic program as shown in this video 1s not overly complicated The commented project is a good example of the various programming elements that are available to the end user A majority of the programming basics that are a part of DirectSOFTS5 are covered in the example project including a control program that is used to configure the Mode 30 pulse output by loading parameters into predefined memory locations timers to allow detection of parts and encoder pulses a counter to accumulate rotary encoder pulses for motion detection value compare logic instructions outputs addressed by bit of word logic latching internal relays assigned contacts from the C more Micro Graphic panel and an Box instruction to configure the analog current input module B NOTE A complete commented DirectSOFT5 project for the Motion Control demo presented here is available for downloading from the LEARN website Loo
23. or normal by loading constant K8O0000000 into double memory address V2321 2322 when Jam Timer times out and drops out the Jam detected latch Reverse rotation of slotted disk for a set amount of time Relay C6 Jam Detected C6 1 OUTD K80000000 The logic shown here determines the direction of the Stepper Motor It switches between the normal Counter Clockwise direction to a Clockwise direction With the Reverse Rotation internal relay C6 energized via a rising edge one shot the constant KO is loaded into the Profile Parameter Table memory register V2321 2322 to produce a CCW direction With C6 de energized via a falling edge one shot the constant K80000000 s loaded into memory register V2321 2322 to produce a CW direction WAUTOMATIONDIRECT DirectSOF T5 No Motion Detection via Encoder Pulses 13 of 15 otepper Motor Motion Detector Any time the Velocity Profile is being executed thru the Mode 30 YO signal then Timer starts timig As long as pulses from Encoder s B channel are being produced indication that the stepper motor is rotating then the Motion Timer is continually being reset If the timer times out 0 2 seconds then the No Step Motion relay C will latch in and stop the Mode 30 YO output from energizing which stops all motion TMRA Timer to detect loss of Encoder pulses Executes the HSIO Mode 30 Parameters p hd indicating no motion Timer T3 YO Motion Timer
24. rect Koyo Sureste Application Part Feeder Station om The Part Feeder Station was designed to dispense one part at a time into a tube that carries the sequenced parts to the next station The parts in this example application consists of six different colored Part Feeder Station marbles steel balls and brass balls The parts are all approximately 14mm in diameter The parts are stored in a cylindrical polycarbonate hopper slotted polycarbonate disk coupled to an AutomationDirect NEMA 17 stepper motor 1s used to rotate the disk The slot in the disk allows one part at a time to drop into the slot as it rotates The part then falls into the exit tube when it 1s positioned over the opening The Part Feeder mechanism 15 built using T slotted 80 20 framing It includes a part hopper slotted disk driven with a SureStep stepper motor and a coupled Koyo encoder to provide speed control and jam detection There is also a fiber optic photoelectric sensor to detect when the exit tube is full and a capacitive proximity sensor to determine when the part hopper 1s empty VAUTOMATIONDIRECT more MIRC Koyo step Application Control Panel Enclosure 04 42 The Part Feeder Station controls are housed in a non metallic JIC NEMA 4X enclosure with a window through the door A C more Mu cro Graphic panel and the master control power circuitry push buttons are mounted through the enclosure s window Located on the enclosure s p
25. t K80000000 into memory address V2321 2322 Select an initial velocity of 100 pulses per second X10 multiplier is used Load constant K10 into memory address V2323 UT Note The memory address V2323 controls the stepper motor SPEED stepper motor SPEED 15 set with initial velocity of 100 pulses per second by loading constant K10 into V memory address V2323 The loaded value is multiplied by a factor of 10 VAUTOMATIONDIRECT Comore Efrect koyo Sureste DirectSOFT5 Cycle Control Start Stop Logic 3 of 15 14 48 The rung shown here is used to latch in the Feeder Run signal using the and F2 function keys located on the C more Micro Graphic panel 2 1s the Start pushbutton and F1 is the Stop pushbutton Cycle Control Logic Start Stop circuit from F1 and F2 function keys on the C more Memory address V2010 15 assigned in the C more Micro Graphic panel The F3 LED indicator is also illuminated on the C more to show the Micro Graphic panel as LED Control Word for Part Feeder is in a Run condition the Function Key and LED object Out Bit B2010 2 Bit of word B2010 2 is memory address V2010 assigned in the C more Function Key object to control LED on Function Key 3 controls the LED on Function Key 3 Cycle Control Cycle Control C more Micro C2 C more Micro C3 Feeder Stop PB Feeder Start PB Cycle Control Relay C4 Fescer Sun
26. t koyo SU step micro DirectSOFTS Slotted Disk Fast Slow Speed Change Logic 8 of 15 The logic shown here determines the running velocity of the Slow speed f con ani KIO bike memog addess DON Stepper Motor It switches between Slow Speed at 100 pulses This equates to a velocity of 100 pulses per second X10 multiplier per second and Fast Speed at 300 pulses per second Shorten Rev Time Feeder Disk A With the Fast Speed internal relay de energized the Fast constant is loaded into the Profile Parameter Table memory register V2323 This value times a multiplier of 10 produces a Slow Speed velocity of 100 pps With Cl energized the constant K30 is loaded into memory register Lond consist KEU inio memory address V2323 V 2323 to produce a Fast Speed velocity of 300 pps This equates to a velocity of 300 pulses per second X10 multiplier C1 Speed shorten Rev Time Feeder Disk Fast Speed C1 Slotted VAUTOMATIONDIRECT Direct Koyo Sureste micro DirectSOFT5 Analog Input Box Instruction 9 of 15 19 24 The Analog Input 1 instruction is used to setup the 04 0 1 4 channel analog The current from the Stepper Motor Power Supply to the current input module The analog input module is jumpered to accept a 4 to 20 mA signal Stepper Motor Drive is monitored using an AcuAMP from an AcuAMP DC current sensor The current sensor s input range 15 set for
27. tepper Motor Over Current 100f 15 E028 The measured current that is drawn from the stepper motor power supply by the stepper motor drive is constantly updated in memory register V2000 as was setup using the Analog Input Module Pointer Setup IBox instruction shown in the previous slide The Driver Current is compared in the rung shown Compare the current from the AcuAMP Current Sensor in memory address V2000 to the oet Point that is set on the C more Micro Graphic panel via memory address V2100 here to a Set Point value entered In memory register If the current is equal to or exceeds the set point an indication that the Part Feeder V2100 through the C more Micro Graphic panel If Slotted Disk is jammed then internal relay C5 is actuated producing a one shot pulse to the latch circuit in the next rung the Driver Current 1s equal to or greater than the Over Current Set Point then internal relay C5 1s energized Driver Current Driver Current Jam 4 AcuAMP C more Micro Val AcuAMP This condition indicates that a Jam has occurred and 4 20mA Output Over Current SP Over Current V2000 V2100 C5 signals the next set of rungs to reverse the direction of gt jp the Stepper Motor with the intensions of clearing the Jam VAUTOMATIONDIRECT Direct Koyo Sureste micro DirectSOFTS Jam Detected via Reverse Timer 11 of 15 21 00 This rung looks for the C5 Jam signal as
28. ters Relay C4 Timer T1 Timer TO Relay C7 Mode 30 YO Sig the circuit that detects if there 1s Feeder Run Exit Full Delay Hopper MT Delay No Step Motion otep Drive Run 1 TO YO no motion from the stepper C4 af H A OUT uo motor indicating a Jam or motor failure VAUTOMATIONDIRECT Direct Koyo Sureste micro DirectSOFTS Slotted Disk Fast Slow Speed Circuit 6 of 15 1724 The encoder that 1s coupled to the Stepper Motor 1s used for several functions In this rung the encoder s marker pulse labeled Z channel which occurs once per revolution 1s used to switch the Velocity Profile to a higher rotational speed to increase how many parts per time period are dispensed The marker pulse provides a one shot signal that is Detect the Encoder s Z channel pulse that occurs once per revolution latched in through internal relay for Fast Speed Latch in the Z channel signal to start counting the 100 pulses per revolution to determine the distance to keep the stepper motor in high speed This is used to shorten the time no The latch 15 held in while counter 15 used to count a pre set amount of the encoder s A channel 100 shorten Rev Time Rotary Encoder 1 pulse per rev Feeder Disk pulses per revolution to determine at what rotational Z channel Fast Speed position to switch back to Slow Speed X0 D
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