AN-SERV-005 - AutomationDirect Technical Support
Contents
1. P2 15 Digital Input Terminal 6 DI6 108 P2 16 Digital Input Terminal 7 DI7 0 P2 17 Digital Input Terminal 8 DI8 0 P2 18 Digital Output Terminal 1 DO1 101 P2 19 Digital Output Terminal 2 DO2 103 P2 20 Digital Output Terminal 3 DO3 109 P2 21 Digital Output Terminal 4 DO4 105 P2 22 Digital Output Terminal 5 DO5 107 P2 23 Notch Filter Resonance Suppression 1000 P2 24 Notch Filter Attenuation Resonance Suppression 0 P2 25 Low pass Filter Resonance Suppression 2 P2 26 External Anti Interference Gain 0 P2 27 Gain Boost Control 0 P2 28 Gain Boost Switching Time 10 P2 29 Gain Boost Switching Condition 10000 P2 30 Auxiliary Function 0 P2 31 Auto and Easy Tuning Mode Response Level 68 P2 32 Tuning Mode 4 P2 33 Reserved 0 P2 34 Overspeed Fault Threshold 5000 P2 35 Position Deviation Fault Window 30000 P2 36 Position 1 Velocity 122 P2 37 Position 2 Velocity 122 P2 38 Position 3 Velocity 1000 P2 39 Position 4 Velocity 1000 P2 40 Position 5 Velocity 1000 P2 41 Position 6 Velocity 1000 18 Application Note AN SERV 005 P2 42 Position 7 Velocity P2 43 Position 8 Velocity P2 44 Digital Output Mode P2 45 Index Mode Output Signal Delay Time P2 46 Index Mode Stations P2 47 Position Deviation Clear Delay Time P2 48 Backlash Compensation Index Mode P2 49 Jitter Suppression P2 50 Clear Position Mode P2 51 Servo Enable Command P2 52 Dwell Tim2. 09 Preset Velocity Command Limit 1 100 P1 10 Preset Velocity Command Limit 2 200 P1 11 Preset Velocity Command Limit 3 300 P1 12 Preset Torque Command Limit 1 100 P1 13 Preset Torque Command Limit 2 100 P1 14 Preset Torque Command Limit 3 100 P1 15 Position 1 Command Revolutions 3 P1 16 Position 1 Command Counts 5555 P1 17 Position 2 Command Revolutions 3 P1 18 Position 2 Command Counts 5556 P1 19 Position 3 Command Revolutions 0 P1 20 Position 3 Command Counts 0 P1 21 Position 4 Command Revolutions 0 16 P P P P P P P P P P P P P P P P P P P P P P P P P P1 P1 P1 P1 P1 P1 P1 P1 P1 week Sek ee eR eds ek a ed OS ee Re ee eek ee ey ea a eed es a ee a Application Note AN SERV 005 SSS 22 Position 4 Command Counts 23 Position 5 Command Revolutions 24 Position 5 Command Counts 25 Position 6 Command Revolutions 26 Position 6 Command Counts 27 Position 7 Command Revolutions 28 Position 7 Command Counts 29 Position 8 Command Revolutions 30 Position 8 Command Counts 31 Motor Code 32 Motor Stop Mode Selection 33 Position Control Mode Internal Indexer 34 Acceleration Time Internal Indexer 35 Deceleration Time Internal Indexer 36 Accel Decel S Curve 37 Inertia Mismatch Ratio 38 Zero Speed Output Threshold 39 Target Speed Output Threshold 40 Max Analog Velocity Cmd
3. 18 using a digital input on the servo drive There is no need to use MODBUS communications here with this control criteria even though this is other option General control diagram The control system can be comprised of the Sureservo drive the PLC and the accessories such as the thumbs pushbuttons to acknowledge that the operators are with the hands free the home sensor a proximity switch etc See the following diagram to see the relationship among the various devices Touch screen panel PLC DLO6 ZIP link Servo Drive 230 Volt single phase Rotary table Home sensor Operator s pushbuttons servomotor Wiring between PLC and servo drive Application Note AN SERV 005 il See on diagram below the selection of the functions and the corresponding outputs The C more panel has been selected to start the system as well as generate the Home search The operators acknowledgement and the stop are hardwired X2 will receive the signal from the servo drive to report Home completed and X3 will rec
4. N m with the ratio 8 1 with some margin There is a trade off between the higher ratio and the torque available In this case the torque on the motor side would be 37 8 4 625 N m at efficiency of 100 This takes us to a large motor such is the SVM 210 Let s increase the ratio to make it 64 1 In this case would be 37 64 0 578 N m The motor would be SVL 202 This motor SVL 202 has a rated torque of 0 64 N m Notice that if the reducer is selected with a ratio of about 120 1 or more the motor will go to higher speeds with lower power or equivalent torque This exercise is left to the reader The corresponding 20 degrees will correspond to 20x64 degrees or 1280 degrees that corresponds to approximately 12890 360 3 revolutions and 5555 fractions of a revolution This is the angle to move for one step This can be treated as an increment which is constant Notice that there is an small error due to approximation on the completion of one table revolution 3 5555 revolutions x18 steps 63 998 revs and not 64 revolutions In this assumption the 200 Watt sureservo motor could do the job if the efficiency were 100 which is not the case We may adjust the motor if necessary after re doing calculations to include the inertias In this case we could have an available continuous torque of 0 64 N m x32x0 94 efficiency 38 5 N m slightly above the the gearbox rated torque of 37 N m For this specific case we the inertia of t
5. TRUE then there is a jump to Stage 1 Power ON Stage 1 At start we SET Y10 Servo Power and Y11 Servo Enable Y10 and Y 11 turn on Stage 1 will monitor various inputs to determine where program control will JUMP to IF C113 Search Home button on the touch screen panel goes TRUE then there is a jump to S2 Home Stage IF X2 Homing completed AND C114 Start indexing button on the touch screen panel are TRUE then there is a jump to S3 Run Stage IF X12 Stop All PB is FALSE then there is a jump to ISG O Initial Stage Stage 2 When S2 Home Stage is active the on delay timer T5 Home Trigger Duration is enabled IF the stage S2 is TRUE AND the timer done bit T5 is FALSE then turn on Output Y12 Home Command IF the timer done bit T5 is TRUE AND X2 Homing completed are TRUE then there is a jump to Stage 1 Power up IF X12 Stop All PB is FALSE there is a jump to Stage ISG O Initial Stage Stage 3 IF the count on the counter CTO is CTAO 9 then SET the output Y14 Turn ON Position Command Select 0 This will call Position 2 from the Servo Position 2 has the offset necessary to make an exact 360 degree revolution IF the count on the counter CTO is CTAO lt gt 9 then RST Y14 Turn off Position Command Select 0 9 Application Note AN SERV 005 lt lt lt amp amp E 10 IF X7 Operator Start AND X1 At zero speed are TRUE then th
6. about 25 seconds They may complete the actions before this time Notice that this action is the same as the sequence C And then the sequence will continue on the same way until a complete table rotation has been done At this time the counter can be reset It might exist an offset due to the errors in calculations The step 9 will be incremented in other slightly different increment to compensate the offset errors caused by calculation and keep the 18 steps exactly at 360 degrees The cycle can be repeated as many times as necessary Let s expand on the errors of the calculation The total counts for a complete rotary table revolution are 64 revolutions when there is a gear reducer of ratio 64 1 also we have seen that every move will be done with 3 revolutions and 5555 counts Let s see what is the addition of all the moves 3x18 steps gives 54 revolutions 0 5555x18 gives 9 999 revolutions That is at the end of the 18 steps there is a total of 63 999 revolutions and then an error of 64 63 9999 or 0 0001 revolutions This can be compensated in several ways and one of them is to add another increment in any of the steps to reach exactly 64 revolutions when the rotary table makes one complete revolution Application Note AN SERV 005 EII That is on step 9 we will add an increment of 3 revolutions and 5556 counts this can be selected with a position select 0 PLC output digital output to change in this case the parameters P1 17 and P1
7. motion of every step occurs in 3 seconds In this case the total time for the 18 steps is 3x18 54 seconds The rest of the time is the time allowed for loading the air brakes into the rotating table The time to load and unload the devices is about 25 seconds Friction torque on the rotary table is 10 N m obtained empirically The inertia of the rotary table is 130 Kg m including the widgets j ml App notes AN SERV 005 1 Application Note AN SERV 005 Kinematic studies Let s consider one motion in the time of 3 seconds We will consider a speed trapezoidal profile of 1 25 second acceleration 0 5 second constant speed and 1 25 seconds for deceleration See the planned motion trapezoidal profile below Time seconds What is the maximum speed that the rotary table will develop If the angle is 20 degrees then the maximum speed on the trapezoidal profile is determined by 20 1 75 11 428 deg s or 11 428 360 0 03175 rev s or 1 905 rpm or even in in radians 11 428 360 2 a 0 19945 rad s approximately The speed is really very slow Let s estimate that the servo motor could run up to a rated speed to 3000 rpm We will do later some calculations to define the proper motor to be used here If the rotary table rotates at the maximum speed of 1 905 rpm the ratio could be up to 3000 rpm 1 905 rpm 1574 1 A selection of a gearhead with a bigger ratio will be useful to increase the torque to the load and also reduce the
8. reflected inertia and reach a inertia ratio close to the ideal ratio in the range 10 1 or smaller However practical gear head sizes do not go above a ratio 512 1 Dynamics Let s do some torque calculations to size the motor The dynamic torque will be given by the well known formula Tm Tr Jxdw dt The static torque is given by the frictions in the gear reducer and the rotary table We know that the inertia of the rotary table is 130 Kg m it is important to check that the dynamical forces will be below the available motor torque For this specific case we do not know for now the inertia of the motor and the gear reducer at this time We will calculate the torque needed to move the rotary table and then we will decide what motor and gear head to use The acceleration dw dt is calculated by knowing that the ramp to go to the maximum speed is 1 25 second per the figure above and the maximum speed is 0 19945 rad s that is the acceleration dw dt is 0 15956 rad s The dynamic torque on the rotary table shaft while accelerating is then T Jxdw dt 130 Kg m2 x0 17453 rad s 20 74 N m Application Note AN SERV 005 SSS Let s add the friction torque If 10 N m is considered on the load side we will have a total torque during acceleration of 30 74 N m The result when decelerating is 20 74 10 N m 10 74 N m Let s select a right angle gear head from Neugart USA type PLS70 that has at least a torque output of 37
9. Application Note AN SERV 005 THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND These documents are provided by our technical support department to assist others We do not guarantee that the data is suitable for your particular application nor we assume any responsibility for them in your application PRODUCT FAMILY SureServo Number AN SERV 005 Subject Sureservo position with incremental position Date issued Nov 18 2007 Revision First edition In this example we will control the position of a rotary table that test widgets In this example we will determine the kinematics of the movement the sizing of the servo motor and discuss some design considerations and we will show how to wire the servo drive to the PLC DLO6 We will show the detailed wiring of the drive the PLC program code and the servo drive parameter values at the end we suggest actions to tune the servo The control will be done with a C more panel See the following diagram to understand the concept lt gt Device The rotary table rotates 18 steps in only one direction to complete a total revolution that is rotates 20 degrees in the circle per each step every time the table stops a device is loaded into the table by operators do some adjustments and then when the conditions are set the new motion is initiated Let s assume that the
10. KO Initial Stage after PLC OUT powerup INITIAL STAGE So Step position CTAO As long as Initial Stage ISG 0 is active keep Coils and Outputs Reset Latches when Initial Stage after PLC SureServo is at Zero powerup Speed X1 INITIAL STAGE Mov Started Coil so co C17 3 i RST This is the external contactor supplying power to SureServo SERVO POWER Y10 VAT RST External Control Power or System Power input Control Power is Active MCR STOP ALL PB POWER ON X6 X12 S1 4 be hot JMP SG Control Power is Active POWER ON S1 This rung turns on YO the contactor providing power to the SureServo drive and Y1 Servo Enable signal to DI 1 on drive This is the external contactor supplying Control Power is Active power to SureServo POWER ON SERVO POWER S1 Y10 6 SET This is the signal to Digital Input 1 on SureServo SERVO ENABLE Y11 SET Starts the HOME STAGE SG 2 which initiates and monitors the Homing Sequence of the SureServo This is the signal to Digital Input 2 on SureServo Home Homing Sequence Trigger operation HOME PB HOME STG C113 S2 7 JMP 12 Application Note AN SERV 005 Sel Ladder program continued 10 SG Homing Sequence Starts the RUN STAGE SG2 HOMING CMPLT START INDEX PB x2 C114 l AE STOP ALL PB X12 Starts the ADVANCE 1 STATION STAGE SG 4 This is the signal to Digital Input 2 on SureServo Home Trigger STOP ALL PB Operator
11. Start HOME PB X12 C10 X7 C113 H e e aIl operation HOME STG S2 12 13 14 15 Sends 0 3 sec signal from Y2 Home Command to Digital Input 2 Home Trigger on This stage defines the increment INCREMENT STG S3 JMP Resets Index Counter CTO Index Cntr Rst C20 SET Initial Stage after PLC powerup INITIAL STAGE so JMP This stage defines the increment INCREMENT STG s3 JMP When X2 is true HOMING COMPLETE signal comes from Digital Output 3 HOMING COMPLETE Stage will JUMP back to Stage 1 Home Trigger Signal duration 0 3 sec Home Trig Dur HOMING CMPLT T5 X2 STOP ALL PB X12 SG This stage defines the increment INCREMENT STG s3 SureServo Homing Sequence TMR operation Home Trigger Signal HOME STG duration 0 3 sec 52 Home Trig Dur Ld T5 K3 Homing Sequence Home Trigger Signal operation duration 0 3 sec HOME STG Home Trig Dur HOME COMMAND S2 T5 Y12 c OUT Control Power is Active POWER ON S1 JMP Initial Stage after PLC powerup INITIAL STAGE so JMP 13 Application Note AN SERV 005 gar Ladder program continued 17 18 19 20 21 ISG This rung monitors the value in Counter 0 CT 0 and when equal to 9 activates Y4 which sends signal to Digital Input 4 on SureServo This selects Position 2 Command P1 17 1 18 and P2 37 This Position Command has the calculated OFFSET v
12. alue that makes sure the Load Index Table will move a full 360 degrees Step position CTAO K9 L EC Step position CTAO K9 Operator PB S must both be made for the duration of 0 5 seconds in this example Digital Output 2 from SureServo triggers this input that the SureServo 23 24 25 14 Digital Input 4 on SureServo POS CMD SLCT 0 Y14 SET Digital Input 4 on SureServo POS CMD SLCT 0 Y14 RST 18 station Index Table Counter INDEX CNTR CTO is stopped Advance 1 station Operator Start AT ZERO SPEED ADV 1 STG X7 X1 S4 1 1 I JMP This stage defines the Resets Index Counter increment CTO INCREMENT STG Index Cntr Rst s3 C20 i RST Initial Stage after PLC powerup STOP ALL PB INITIAL STAGE X12 so JMP Advance 1 station ADV 1 STG S4 TMR Advance 1 station ADVANCE 1 STATION ADV 1 STG TIMER Sai ADV 1 STA TMR 1 oT T6 K3 ADVANCE 1 STATION Digital Input 5 on Advance 1 station TIMER SureServo ADV 1 STG ADV 1 STA TMR TRIGGER COMMAND S4 T6 Y16 n __ OUT Resets Index Counter CTO Index Cntr Rst C20 OUT Application Note AN SERV 005 SSS Ladder program continued Digital Output 4 from SureServo triggers this CNT input that the SureServo Advance 1 station is At Position 18 station Index Table ADV 1 STG AT POSITION Counter S4 Fk INDEX CNTR 26 it CTO Resets Index Counter CTO K18 Index Cntr Rst C20 Digita
13. e 1 Auto Index Mode P2 53 Dwell Time 2 Auto Index Mode P2 54 Dwell Time 3 Auto Index Mode P2 55 Dwell Time 4 Auto Index Mode P2 56 Dwell Time 5 Auto Index Mode P2 57 Dwell Time 6 Auto Index Mode P2 58 Dwell Time 7 Auto Index Mode P2 59 Dwell Time 8 Auto Index Mode P2 60 Electronic Gear Numerator 2 P2 61 Electronic Gear Numerator 3 P2 62 Electronic Gear Numerator 4 P2 63 Velocity and Position Deviation Scaling Factor P3 00 Communication Address P3 01 Transmission Speed P3 02 Communication Protocol P3 03 Communication Fault Action P3 04 Communication Watchdog Time Out P3 05 Communication Selection P3 06 Reserved P3 07 Communication Response Delay Time P4 00 Fault Record Most recent N P4 01 Fault Record N 1 P4 02 Fault Record N 2 P4 03 Fault Record N 3 P4 04 Fault Record N 4 P4 05 JOG Function P4 06 Force Outputs Command P4 07 Input Status 1000 1000 0 CHD ODF FODD COQ DwWwnNHOoA HARA OOo cCC COC SCOP Ooo a 7 160 I 19 Application Note AN SERV 005 Ee P4 08 Reserved 8 P4 09 Output Status 11 P4 22 Analog Velocity Input Offset 0 P4 23 Analog Torque Input Offset 0 20
14. e X6 oS 7 PBA1 PBA2 PBB1 fi SEH x7 ses shoh E STOP PORT 2 TOUCH PANEL Encoder SVC EFL 010 Encoder Cable Set Application Note AN SERV 005 Eee PLC and C more touch panel programming The servo drive has to be programmed to follow the criteria defined The maximum speed is defined on parameter P1 55 the acceleration time and deceleration time defined on parameters P1 34 and P1 35 are defined based on this speed the speed is defined in units of rpm In this case would recommend to use 122 on the parameter P1 55 and 1 25 seconds on P1 34 and P1 35 P1 36 can be set to 10 or 20 to make a slight s curve P1 47 is the configuration for the Home search procedure When the parameter setting is completed it is necessary to remove the control power of the servo drive for a couple of seconds to allow the saving the parameters into the drive This is true for any parameter marked with 3 in user manual In order to check that the drive has the proper setting on all the parameters we recommend to print the parameters with the help of the Sureservo Pro software A list of parameters is shown at the end of this document The C more panel has the following objets See the figure below ROTARY TABLE 18 STEPS POVWER OFF Seno not ready Speed O Home not done MO FAULT SEARCH Stat HiME indexing A button Search home associated to C113 The signal C113
15. eive the signal from the servo drive to report At position Additionally the home sensor will be wired directly to the digital input DI3 In the diagram below are shown the control connections between the drive and the PLC necessary to make the system work as required User supplied 24 VDC a SVC PFL 0X0 Power Cable Set Servo Motor MCCB MC Servo Drive 230 VAC gT i 5 r 10 i e R TERE Single phase er s P or Three phase D 0 0 T 50 60 Hz C O L1 Internally u L2 Supplied D0 06DD1 Sii 12Vdc V w O a VCC EG C2 N Y10 _ Servo power V REF CN2 A GND TA aE nternally B Supplied c3 PULL HI 24 VDC z vop CM1 COM GND COM 4 Y11 Servo Enable_101 DH 1 33 _t Y12 Home search 127 Lo Oo DI2 Home sensor DI3 st Y14 Pos select 0 111 Di4 DI5 Trigger 108 Ler Y15 gg Di6 CN1 co DI7 DI8 CN1 CN1 Servo read ervo ready DOi a ent D01 _ At Zero speed rT DO2 ai e pat Home completed nag af DO3 ae a m At Position DO4 ae CN3 Fault Do4 it lt 4 DO5 y Do5 noe m Fo JEY Power ON Lat
16. ere is a jump to Stage S4 Advance 1 stage IF X12 Stop All PB is FALSE THEN there is a jump to Stage ISG O Initial Stage Stage 4 IF the stage S4 is TRUE start the timer T6 Trigger Command Duration When S4 Power On is TRUE AND T6 is FALSE then SET the PLC output Y16 Trigger Command IF CTO Index Counter is TRUE THEN OUT C20 Index Counter Reset IF S4 AND X3 At Position are TRUE THEN increment count in CTO Index Counter IF C20 Index Counter Reset is TRUE THEN RST CTO Resets index counter IF the timer done bit T6 Trigger Command Duration is TRUE THEN RST Y16 Trigger Command Turn OFF Y16 In normal Indexing Operation the program will be toggling back and forth between stage 1 Power On then Stage 3 to check the count and define the increment to be used and stage 4 This represents Stage 1 Power ON Stage going thru the Operator signal X7 to start the force to go to Stage 3 Stage 3 defines the increment and then jumps to Stage 4 When in Stage 4 the output Y16 is active for the time defined in T6 the actual Servo signal to move and move completion When the move has been confirmed Stage 4 will jump back to Stage 1 and wait for the next operator signal on X7 Startup procedures The program has to be tested in conjunction with the servo drive The recommended steps are a Test the operation of the drive with a basic jog command No PLC has been connected b Connect the servo enable and
17. es every action they may generate Finally make backups of the programs The servo should be connected to the load in normal condition The first attempt to tune the system might result in a behavior as that shown in the figure below This is I PrintinColor _ Show Data Point Markers J ShowLegend 1000 4 000 4 000 4 1000 00 000 01 000 02 000 03 000 04 000 05 000 06 000 07 000 08 000 09 000 10 001 figuration ingle Capture z Seconds of Data to Capture 10 z Visible Time Range First fio z Seconds C Last an extreme case The target of the tuning should result in a behavior similar to as the following figure x lala I Printin Color _ Show Data Point Markers J ShowLegend _ alal 40005 2000 4 04 04 2000 4 40004 00 000 01 000 02 000 03 000 04 000 05 000 06 000 07 000 08 000 al Scope Configuration One Shot Single Capture 7 Seconds of Data to Capture fe z Visible Time Range A fe z Seconds ast 11 Application Note AN SERV 005 mr Ladder program ISG Initial Stage after PLC powerup INITIAL STAGE so At first scan reset Index Counter to 0 Accomplished by LD KO to CTAO _FirstScan LD SPO 2
18. he motor is 0 18x10 Kg m and the gear reducer inertia is 0 000102x10 kg m Let s now calculate the inertia referred to the motor side Motor inertia 0 180 x10 kg m Gear inertia 0 0001 x10 kg m Coupling estimated 0 050 x 10 kg m Rotary table inertia ratio 130 647 317 38 x10 kg m Total inertia referred to motor 317 61x10 Kg m The acceleration referred to the motor side is 10 212 rad s 0 15956 rad s x64 The dynamic torque on the motor side is T Jxdw dt y 0 3243 N m Let s add the friction torque If 10 N m is considered on the load side we will have a friction torque on the motor side of 10 64 0 92 0 1698 N m and the total torque during acceleration is 0 4941N m on the load side is 31 624 N m The result when decelerating is 0 3243 0 1698 N m 0 1545 N m On the load side is 9 888 N m Note that the addition of the motor and gearhead inertia was not significant in this case The motor torque when at steady speed is 0 1698 N m referred to the motor side which is insignificant in this example The load side reflect to 10 867 N m Application Note AN SERV 005 gt N NH Ww Buf be aononn oe Con pom point Touch panel for operation The maximum speed that the servomotor will run will be 1 905x64 121 92 rpm e Speed Torque N m A load torque time chart is shown below Oo on time seconds trol c
19. l Output 2 from Digital Output 4 from Advance 1 station ADVANCE 1 STATION SureServo triggers this input that the SureServo SureServo triggers this input that the SureServo TIMER is stopped is At Position ADV 1 STG ADV 1 STA TMR AT ZERO SPEED AT POSITION S4 T6 X1 X3 27 1 1 1 1 STOP ALL PB X12 28 29 Control Power is Active POWER ON S1 JMP Initial Stage after PLC powerup INITIAL STAGE so JMP END Application Note AN SERV 005 lt _ lt lt _ _ amp amp amp E E amp E amp _ amp _ _ amp _ _ Automation Direct SureServo PRO Drives Configuration Report Report Generated 10 9 2007 6 38 41 PM Config Name AN SERV 005 Servo Config ssc Motor Code 11 Rev 2 001 Parameter Value P0 00 Software Version 2001 P0 01 Drive Fault Code 0 P0 02 Drive Status Front panel display 0 P0 03 Analog Monitor Outputs 1 P0 04 Status Monitor 1 0 P0 05 Status Monitor 0 P0 06 Status Monitor 3 0 P0 07 Status Monitor 4 0 P0 08 Status Monitor 5 0 P1 00 External Pulse Input Type 2 P1 01 Control Mode and Output Direction 1 P1 02 Speed and Torque Limit 0 P1 03 Output Polarity Setting 0 P1 04 Analog Monitor Output Scaling 1 CH1 100 P1 05 Analog Monitor Output Scaling 2 CH2 100 P1 06 Analog Velocity Command Low pass Filter 0 P1 07 Analog Torque Command Low pass Filter 0 P1 08 Position Command Low pass Filter 0 P1
20. on is determined by a proximity sensor located in DI3 defined with parameter P2 12 as 124 The mechanical zero is different from the sensor position C A position counter CTO arbitrarily defined will keep the position number When the PLC is energized the counter should be reset and the count will be 0 When the Home completed output signal is generated defined as DO3 arbitrarily the counter CTO will increment the count to 1 This would allow the operators to load the untested piece and unload the tested one if there is one there and for safety reasons they should press pushbuttons to acknowledge the completion of the loading and unloading This is one criteria The code can be done differently if desired D The operators are ready in about 25 seconds or less Let s define the input of these pushbuttons X7 arbitrarily defined E When both acknowledgements occur the PLC can generate the trigger to move the rotary table one step The increment will be defined in P1 15 and P1 16 being P1 15 3 revolutions and P1 16 5555 counts The trigger to move command will be defined in DI5 with parameter P2 13 set as 108 F The servo will execute the move and then when completed the move it will turn on the At position output that arbitrarily will be D04 The counter CTO will increment the count to 2 with this This would allow the operators to load the untested piece and unload the tested one if there The operators are again ready in
21. or Velocity Limit 41 Max Analog Torque Cmd or Torque Limit 42 On Delay Time of Electromagnetic Brake 43 Off Delay Time of Electromagnetic Brake 44 Electronic Gear Numerator 1 45 Electronic Gear Denominator 46 Encoder Output Scaling Factor 47 Homing Mode 48 Homing Speed 1 Fast Search Speed 49 Homing Speed 2 Creep Speed 50 Home Position Offset Revolutions 51 Home Position Offset Counts 52 Regenerative Resistor Value 53 Regenerative Resistor Capacity 54 In Position Window 55 Maximum Speed Limit P2 00 Proportional Position Loop Gain KPP P2 01 Position Loop Gain Boost P2 02 Position Feed Forward Gain KFF P2 03 Smoothing Constant of Position Feed Forward Gain oloo0o0o00o0000 1250 1250 10 1761 10 3000 3000 100 20 20 222 60 30 40 60 100 122 35 100 5000 17 Application Note AN SERV 005 lt lt _ lt amp E P2 04 Velocity Loop Proportional Gain KVP 500 P2 05 Velocity Loop Gain Boost 100 P2 06 Velocity Loop Integral Compensation KVI 100 P2 07 Velocity Feed Forward Gain KVF 0 P2 08 Factory Defaults and Security 0 P2 09 Bounce Filter 2 P2 10 Digital Input Terminal 1 DI1 101 P2 11 Digital Input Terminal 2 DI2 127 P2 12 Digital Input Terminal 3 DI3 124 DI1 DI2 DI3 P2 13 Digital Input Terminal 4 D14 111 P2 14 Digital Input Terminal 5 DI5 0 DI6 DI7
22. riteria The next step will be to define the PLC control See the figure below to follow the explanation on the next description PBA1 PBA2 20 degrees Loading point PBB1 PBB2 There are 2 operators that are loading and unloading the pieces they have a button close to the panel to authorize the next move when the air brake has been loaded or unloaded respectively This is a touch panel of the type C more The pushbuttons are activated by the operators for safety reasons to give the permissive to start the next step cycle It is necessary to have a means to return to Home in case there is a power shutdown during the operation to define the proper initial position The operation mode will be incremental mode with registers Pr Parameter P1 01 should be 101 There are other options not described here By the requirements of the control the PLC and the panel should know at any time the step that the table is located This can be done with a simple counter as explained later Application Note AN SERV 005 NE The sequence of operation will be the following A When the control is powered up first the PLC turns on and this will by logic and a contactor turn on the the servo drive then the servo is enabled B The operator should generate a command to Search Home with the digital input DI2 arbitrarily defined from the panel the parameter P2 11 should be 127 the servo is enabled with DI1 The Home positi
23. test the operation of the PLC when connected to the drive c Connect all the other servo inputs and test the operation of home search You can monitor the servo with the help of the Sureservo Pro software d Test the outputs of the drive e Make a complete sequence running the 18 steps The count at the end of one rotary revolution should be 64 revolutions on the Sureservo drive f Tune the drive if necessary The load motor inertias ratio is about 1700 in this case but the motor is not performing too sharp in this example The tuning can be done with the help of the SureServo Pro software The standard white cable SVC PCCFG CBL is used to connect the PC with the servo Create a new configuration give a name reset the parameters to default setting 10 on parameter P2 08 and use the parameters defined earlier For this action go to the menu Utilities gt Current config gt Print current config The tuning of the system can be done with any of the methods offered by the drive Application Note AN SERV 005 The task here is to move the load without overshoots from the home position to all the positions In this case only one position tuning may be needed because the other positions are basically the same movement Finally document all the project for future troubleshooting and housekeeping Also create an operating manual for the operators that do not have to understand all the details but they have to understand what mak
24. will turn on every time the pushbutton is touched A button Start indexing associated to C114 The signal C114 will turn on every time the pushbutton is touched A numeric display Step associated to the memory V1000 which is the current value of the counter CTO An indicator of Power ON or not associated to the PLC output Y10 Power On is true when the output Y10 is ON An indicator of Servo ready or Servo not ready associated to X5 Servo ready is true when X5 is ON An indicator of At zero speed or not associated to X1 At zero Speed is true when Application Note AN SERV 005 Sel X1 is ON An indicator of Home completed or not associated to X2 Home completed is true when X2 is ON An indicator of At position or not associated to X3 The servo output signal At position is true when X3 is ON 5 indicators of the stages associated to SO to S6 The next step is to create the PLC program code We decided to use stage programming in this case See on the next section details of the code that will be programmed into the PLC PLC programming explanation Stage 0 At PLC power up The first PLC scan or the return to Stage O will load a value of KO to CTAO Basically the counter counts are reset to zero As long as no jumps to other stages occur this stage will keep CO C17 and PLC outputs Y10 Y17 reset This is a safety feature When X6 The selector switch to give the signal power ON becomes
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