User Manual for Gantry Model
Contents
1. 14 4 3 Basic Movement Code All of the sample codes below operate under the condition that the E Stop is not activated and that Manual Control is not disabled 4 3 1 Lift Hestop L13 3 HforbidMan L13 5 EmasterPowerL4 4 A HAH Htilt_Pos L26 1 M15 N EN ENO api IN OOT p EL run Press L0 When one of the lift buttons is pressed M1 2 M1 3 M1 4 a pressure value greater than the resting pressure 8000 psi is sent to the lift regulator REG2 which raises the stage A greater difference between the regu lator pressure and the resting pressure will result in the stage moving faster When the button is released the resting pressure value is sent to the regulator to maintain the stage s position When one of the Lower buttons is pressed M1 5 M1 6 M1 7 a pressure value less than the resting pres sure 8000 psi is sent to the lift regulator REG2 allowing the stage to lower A greater difference between the regulator pressure and the resting pressure will result in the stage moving faster When the button is released the resting pressure value is sent to the regulator to maintain the stage s position 15 4 3 2 Tilt Hestop L13 3 HrorbidMan L13 5 HmasterPowerl44 Hlift_Pos L26 0 M22 1H Htilt L4 0 PL 1 Hilt L4 0 c n 1 M23 HilatL4 1 5 1 HilatiL41 y a 1 When one of the tilt buttons is pressed M2 0 M2 1 M2 2 the tilt control signal is set to High which will2. e The Left SPIN button will rotate the stage Counter Clockwise 3 NOTE Movement will only occur while a button is being pressed Once it is no longer held down the stage will stop moving 4 To return the stage to its initial position press the HOME button FLAT ol ll er RESETTING ear a j Figure 2 8 The Manual Control Screen 5 If any of the stage s movement become erratic or out of control press the E STOP button to immediately cease all movements Chapter 3 How It Works The stage can be separated into two separate systems the control system and the pneumatic system The systems work together to control stage movement See Figure x This section will explain the physical aspect of how movement is achieved Diagram of Components Physical Connections PLC Expansion Mist Separator Controller Solenoid Valve Solenoid Valve H Bridee E z 1 2 Electrical Connection Tilt Cylinders Lift Cylinders y Air Pneumatic Connection E Figure 3 1 Wiring and Pneumatic Diagram 3 1 PLC Components The PLC components make up the control system of the stage These components are responsible for the regulating the lift tilt and rotation of the stage For lift and tilt motion see section PNEUMATICS PLC Components PLC Expansion Regulator Regulator 2 A m solenoid Valve Solenoid Valve iy 5 iy os 1 2 Figure 3 2 PLC Diagram 3 1 1 motor The motor s
3. cause the appropriate side of the tilt solenoid SP1 to open A pressure value is sent to the regulator REG1 to control the speed of the action more pressure more speed for as long as the button is pressed When the button is released the tilt control signal is reset to Low causing the solenoid to return to its closed position stopping the movement When one of the Flatten buttons is pressed M2 3 M2 4 M2 5 the flatten control signal is set to High which will cause the tilt solenoid SP2 to open the side opposite that used for tilting A pressure value is sent to the regulator REG2 to control the speed of the action more pressure more speed When the button is released the flatten control signal is reset to Low causing the solenoid to return to its closed position stopping the movement 16 4 3 3 Spin Hestop 113 3 HrorbidMan L13 5 HmasterPowernL4 4 41 0 HH e Heycle Ly Hpulze L w3 KAT Hcycle L y Hpulse L yd Hm_reverse L4 3 P 5 1 Hm_run ld 2 1 m_reverse L4 3 N RA 1 Hm_run ld 2 a l When the Spin Right button M1 0 is initially pressed the motor is set High turned on As long as the button is continued to be held down a value of 4 is set for the PWM cycle and a value of 3 is set for the PWM pulse When the button is released the motor is reset to Low turned off When the Spin Left button M1 1 is initially pressed the motor is reversed and set High turned on As long as t
4. must also be inspected and replaced on a regular basis to keep a smooth operation of the lift The support columns located on stage left and right are 4 foot diameter steel tubes and are approximately 70 feet in length The bottoms of the columns are connected to the floor and to the roof of the building They are also mounted to the enormous frame that goes along the perimeter of the lift system Because of the structure and mounting of the columns it created a 75 foot tall building within the MGM Grand The tubes were fitted with acoustical dampers that keep them from acting like pipe organs 1 3 Gantry Model An approximate 1 20 scale model of the KA lift system was constructed The model has almost all the mov ing capabilities of the larger lift 3 D modeling software was used for conversions of the actual dimensions of the real system Due to the small size of the lift it needed some redesigning of some parts Some parts had to be simplified while other parts were eliminated completely from the design Every attempt was made to keep the small design similar to the original but components such as the hammerheads and knuckle needed to be redesigned for practical set up and assembly Other components that were eliminated were the brake system This lessened the complexity of the scale model The drive system for the main lift and its tilt functions were switched from hydraulics to pneumatics Two pneumatic cylinders are anchored at the rear of
5. triggers a mechanical switch This controls the flow of fluid as the electric current changes the state of the valve It is normally closed and applied electric current allows air to flow through see SOLENOID VALVE 3 2 3 Lift Tilt Air Cylinders Dual action cylinders that provide lift and tilt motion The air cylinders are composed of an outer cylinder and a piston rod In this application dual action air cylinders are used This means that air can be input at either end of the cylinder to push the piston rod in either direction The linear motion of the rod creates the lift and tilt movement of the stage 11 Chapter 4 Software 4 1 STEP 7 overview 4 1 1 LAD logic 4 2 Tutorial Programs 4 2 1 Contacts and Outputs Morm_Open Output Nonm_ Closed Output AA 2 Figure 4 1 Contacts and Outputs This sample showcases the most basic symbols found in STEP 7 the contact or switch and the output The contact symbol consists of two parallel lines while the output symbol is the closed set of parentheses also called a coil There are two basic types of contacts normally open and normally closed As seen above in the second line of the example the normally closed contact is represented by two parallel lines with a between them When a normally open contact is closed or turned ON it s read as TRUE A contact can be turned ON through the activation of an input sensor or by an output elsew
6. On the underside of the sand cliff deck there is a pivot joint that is referred to as the wrist or knuckle This joint is attached to one end of the outrigger arm A 10 foot diameter Rotek bearing is located where the joint and the outrigger arm meet These types of Rotek bearings are usually used in tower cranes Four gigantic 70 foot stroke hydraulic cylinders guide the movement of the entire stage sand cliff deck the knuckle the outrigger arm the torsion tube and hammerheads The torsion tube is mounted on the gantry lift and is responsible for the vertical motion of the deck This torsion tube or torque tube is a massive 6 foot diameter cross tube The ends of the tube are connected to two hammerheads on both sides of the tube These hammerheads run along a track that is connected to the support columns The hammerheads are responsible for the vertical motion of the lift the tube does not rotate in any way The two hammerheads are guided by 75 ton and 150 ton capacity Hilman rollers that that travel on steel plates on the columns The rollers manufactured by the Hilman Company of Marlboro New Jersey are used to move much heavier loads such as oil rig components bridges and entire buildings The gantry lift has two sets of dual piston electromagnetically actuated brakes One set is located on ei ther side of the support column brakes These brakes are usually used for mining but were modified to fit the design of the lift They
7. User Manual for Gantry Model Alan Oliver Kelly Jeremy etc August 20 2009 Contents 2 ee TN EA E ee ee 2 Par acneceanes i 4 senor cnaepeeunumnnonnnanca gt La Gamer Model usos io raso wwe Ee AAA 3 2 How to Use it 4 2 1 Start up Checklist ee 4 2 2 Sequence Gontral krket egaret Erra aak ena eee 6 23 Manual Control osos mido amp 6 RES REAR EE Rw wR ew ARA 7 8 tee ee eee ee eee eee eee eee eee en eae eee ee eae 9 Dull MOO x ok keane Oo OR eee Oo Reese ee ee eee eee ee Oo eee eee 9 3 2 Pneumatics sae cde en bbe eed PRs eb PEARS HSCASE HE BES HEHE SSESG ES 10 3 2 1 Variable Pressure Regulator te 11 arrasa 11 TEE 11 12 La ass as AAA 12 ATTE ETE 12 hee OO MMe ee eee eee eww eee ee eee we oe ee Be 12 TETERA 12 4 2 2 Set and Resetl 13 2 it 13 ARRE 14 ees aaa aaa aaa aora eee eee ee 14 43 Basic Movement Coda 15 A o A E Rae eee ewe eee eee 15 Ao VW oe we ee hee eRe eee eee ee Eee eee 16 AE 17 5 Troubleshooting 18 Chapter 1 Introduction 1 1 Introduction Cirque du Soleil French for Circus of the Sun was founded in 1984 by Guy Lalibert What started out with 73 employees in Montreal Quebec now has more than 3 800 employees in over 40 countries The company s annual revenue exceeds 600 million which come from its tent performances and permanent show locations Las Vegas is home to several
8. he button is continued to be held down a value of 4 is set for the PWM cycle and a value of 3 is set for the PWM pulse When the button is released the motor is reversed again back to its original direction and reset to Low turned off 17 Chapter 5 Troubleshooting e The PLC doesn t work Make sure it s plugged in Make sure it s in run mode Try troubleshooting the program For further assistance consult the PLC s operation manual model doesn t move when the lift button is pressed Make sure the PLC is turned on in run mode the stop switch is off and the start switch is on Make sure the air tank is open with the regulator set to 100 PSI Make sure the pneumatics lines are all hooked up Make sure the electronic regulator is functioning properly Make sure there is nothing obstructing the movement of the air ram Make sure the output and input LEDs on the PLC are turning on stage won t tilt when the button is pressed Make sure the PLC is turned on in run mode the stop switch is off and the start switch is on Make sure the air tank is open with the regulator set to 100 PSI Make sure all of the pneumatics lines are hooked up Make sure the electronic regulator is functioning properly Make sure there is nothing obstructing the movement of the stage Make sure the output and input LEDs on the PLC are turning on stage won t rotate when Pulse Width Modulation is applied Make sure the PLC is turned on i
9. here in the program This is your basic switch much like a light switch On the other hand a normally closed contact is TRUE when the contact is open or OFF The best example of this would be an emergency stop button As long as the button is not depressed everything can keep working but when it is pressed functions must cease The output is activated when there is a TRUE path leading to it When this is the case a certain contact is turned ON This contact could be just another variable used elsewhere in the program or it could turn on a device attached to the PLC 12 4 2 2 Set and Reset NO Switch Resel_Adrs ye of Points MO Switch set Adrs s _of_Points Figure 4 2 Set and Reset These are variations on the standard output coil Reset and Set They can be used to turn multiple contacts at sequential addresses on or off The Reset command represented by a coil with an R inside turns the contact located at the address represented by Reset Adrs ON as well as the the number of locations after the address represented by _ of Points The Set command operates in the same fashion except it turns the contacts ON In both cases the contacts will remain in their new state until changed elsewhere in the program 4 2 3 Positive and Negative Transition NO_Swilch Pos_Edge EF 2 Meg_Edge Figure 4 3 Positive and Negative Transition The Positi
10. n run mode the stop switch is off and the start switch is on Make sure the motor is wired properly to the H Bridge circuit and power Make sure there are no shorts on the H Bridge circuit Make sure there is nothing obstructing the movement of the stage Make sure the output and input LEDs on the PLC are turning on stage doesn t change direction when the direction switch is applied Make sure the H Bridge circuit is properly attached to the PLC Make sure there are no shorts on the H Bridge circuit Make sure the output and input LEDs on the PLC are turning on 18
11. permanent Cirque du Soleil productions and that includes Love at the Mirage and Zumanity at New York New York Other productions are O at the Bellagio and Mystere at Treasure Island Love is a tribute show to the Beatles music while O a play on the French word for water eau is a show that is completely immersed in water 1 2 KA background KA is one of Cirque du Soleil s most recent and technologically advanced permanent productions at the MGM Grand in Las Vegas Nevada The primary feature of the production is the main stage platform also known as the Sand Cliff Deck It is attached to a Gantry Lift System that allows the deck to have multiple degrees of freedom The gantry lift system can lift the stage vertically up to 70 feet at 2 feet per second It can also tilt the deck forward to 110 degrees It also has the ability to rotate the deck continuously at 2 rotations per minute Hydraulics are utilized to lift and tilt the deck and electric motors help rotate the deck Mining and manufacturing equipment and parts were some of the main components used to make the stage of KA The Sand Cliff Deck measures 25 by 50 by 6 and weighs approximately 80 000 pounds It is mounted on a knuckle like mechanism that allows the deck to rotate up to two revolutions per minute The Sand Cliff Deck and knuckle mechanism are connected to a cantilevered torsion tube There is an outrigger arm that extends outward toward the audience
12. speed is controlled by an H bridge chip which receives a pulse width modulated PWM signal from the PLC Atttached to the output shaft of the motor is a small spur gear which meshes with a larger gear attached to the stage 3 2 Pneumatics Pneumatics is the use of pressurize gas to create motion In this application an air compressor provides the air used to power the pneumatic components The PLC controls the pneumatic system by regulating air pressure and flow By varying these two factors as outputs to the air cylinders dynamic movement of the stage is achieved There is a total of four output air lines two per solenoid valve Each air cylinder has two inputs for a total of eight in the system Because of this each output air line from the solenoid uses a T splitter to double the output lines which allows one valve to control a cylinder pair Mist Separator Filter Pneumatic Components aa AIR Regulator Reculator 2 fr G E S Solenoid Valve Solenoid Valve lt i e f ay ey Tit Cylinders Lif Cylinders Figure 3 3 Pneumatic Diagram 10 3 2 1 Variable Pressure Regulator Varies the air pressure of incoming air to control the speed of the pneumatic air cylinders 3 2 2 4 Way 3 Position Solenoid Valve Controls the passage of air to the lift and tilt air cylinders A solenoid is a coil of wire through which an electric current passes through creating an electromagnet that
13. st first press the OFF button to switch it to ON in order to activate sequence control NOS REPEAT OFF Figure 2 5 The Sequence Screen 2 Select the numbered sequence you want to run by tapping the corresponding SEQ button Once a Sequence is selected the Gantry model will perform all sequences that follow it in numerical order After completion of the 5th sequence the stage will return to its home position and stop running 3 The Gantry can be set to repeatedly cycle through all 5 sequences numerically by tapping the REPEAT button to the left of the SEQ 1 button REPEAT Figure 2 6 The Manual Control Screen 4 To end a sequence prematurely or to return the gantry to its initial position press the HOME button 2 3 Manual Control 1 After selecting USE the sequence screen will take approximately 15 seconds to load To begin manually controling the gantry press the to Manual button Once the manual control screen has appeared press the OFF button to switch it to ON in order to activate manual control Figure 2 7 The Manual Control Screen 2 Press the corresponding button to perform the desired action e The UP buttons will lift the stage upwards e The DOWN buttons will lower the stage e The TILT buttons will tilt the stage towards its vertical position e The FLAT buttons will tilt the stage towards its horizontal position The Right SPIN button will rotate the stage Clockwise
14. that can be done such as Greater Than gt Less Than lt and Equal To The Compare commands are represented by a contact symbol with the appropriate mathematical representation followed by the letter identifier for the type of value being compared inside the lines In the top line in the example above if the integer value stored at Value Adrs is less than or equal to the value of Compared Val the output Less Than will be turned ON In the bottom line of the example is the integer value stored at Value Adrs is greater than or equal to the value of Compared Val the output Greater Than will be turned ON 4 2 5 Moving Words OUT Destination Figure 4 5 Moving Words The Move function is another straightforward command When the EN input receives a TRUE signal the function writes a certain value from the IN terminal to a location designated at the OUT terminal If the operation is successful the ENO output sends a TRUE signal on to the rest of the line If for some reason the operation cannot be completed an error message is registered and ENO outputs a FALSE signal There are different versions of the command used to move certain types of values such as words or integers In the above example the MOV W function is writing the word value Word to the address represented by Destination
15. the torsion tube and the front of the connector that joins the stage to the knuckle These pneumatic cylinders are responsible for the tilting motion of the stage Chapter 2 How to Use it 2 1 Start up Checklist 1 Check the output psi the larger dial next to the husky knob on the air compressor to make sure the tank is at 95 psi The husky knob is the control to adjust this number If the master psi the smaller dial above the larger one is less than 95 psi you will need to turn on the compressor until the master psi is at least 95 psi The compressor will automatically turn off if the pressure reaches 120 psi Figure 2 1 The Master and Output Dials 2 Hook up the nozzle from the filter system to the air compressor It slides into the brass fitting below the husky knob but may take a little effort Figure 2 2 The Output Nozzle 3 Rotate the large red E Stop button clockwise to turn on the LCD screen Figure 2 3 The LCD Screen 4 After the title screen appears press the USE button to begin operating the gantry model Or If you wish to learn more about the gantry model and how it works press the TOUR button 1 20th Scale Model of the KA Stage Kyler Nelson Nick Skadberg Jillian Rasmussen Figure 2 4 The Title Screen 2 2 Sequence Control 1 After selecting USE the sequence screen will take approximately 15 seconds to load To begin running sequences once the Sequence screen has appeared you mu
16. ve and Negative Transition commands are very useful when you need a certain action to occur just once when a switch has been turned on or off The Positive Transition is represented by a contact symbol with a P between the lines and is set to TRUE for only one scan when the preceding contact is turned ON For example when NO Switch is first turned ON the output Pos Edge is also turned ON but only for one scan After the initial scan even if NO Switch is still ON the Positive Transition contact is no longer TRUE and so Pos Edge is turned OFF The Negative Transition command is represented by a contact symbol with an N between the lines and works in the exact opposite manner as the Positive Transition It is set to TRUE for one scan when the preceding contact is turned OFF So in the example above when NO Switch is turned OFF the output Neg Edge is turned ON for a single scan After that single scan Neg Edge is returned to its OFF state 13 4 2 4 Comparing Values E Les 5_Than Compared Vall Value _Adrs Greater Than i Compared Val Figure 4 4 Comparing Values The Compare command does exactly what it says compares the value stored at one address to another value One use of the Compare command is to activate other commands based on the value of a timer There are several different types of comparisons
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