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1. RY CAN2 Local PLC Local PLC Local PLC Local PLC RK on Unwinding Printing Stamping Winding Unit Unit Unit Unit Figure 25 Label Printing Machine Schematic Diagram Figure 26 illustrates the control diagram and principal control elements of a printing section Speed of the entire print section is controlled by a TMP Generator virtual master The running speed of a section is modulated slightly to maintain some slack in a loop ahead of the printing section A tension sensor in the web provides input to a routine which periodically makes minute gain gear ratio adjustments to an amplifier in the infeed roll axis producing an increase or decrease in web tension A cam function applied to both dancer axes produces their complementary up down motion Input from a web registration sensor is applied to a Corrector which registers preprinted web as required for subsequent operations within the printing section A print registration sensor provides input for registering the printing station to the web on each printing cycle A PAM with SAM system achieves the level of responsiveness required to perform applications such as multi color printing by distributing many of the control tasks to individual axes Figure 26 illustrates the distribution of t
2. Dimensions i gb i ef 0 bag 7 5 5 D q n d d E E 1 q g 1 n n Y 61 a 40_ la 270 A SAM DA __ 04 amp 07 SAM DA ___ 14 amp 28 SAM DA 50 SAM PA 30 SAM PA 80 NOTE Dimensions are in mm Figure 39 SAM Drive and SAM Supply Dimensions SAM Drive Ordering Key Position Feedback Option P1N discontinued use PAN P3N high resolution sine cosine encoder Brake Control d interface consult factory for availability No Brake Control N PAN 1 Resolver input P5N 1 Resolver input amp 1 high resolution e sine cosine encoder interface Current Rating 14 Optional I O 28 discontinued use E 50 B discontinued use E or F D discontinued use F 400 E Standard User I O configuration 2 inputs AC Supply Rating 480 1 high speed input 1 output 1 analog input HN F Optional User UO configuration 6 10 inputs 4 8 outputs 1 analog input SAM DA A SAM Drives with model numbers ending in A i e SAM DA A have no digi D tal I O those ending in have 10 inputs and 4 outputs Both have one analog NOTE input with 5 volt range These models were supplied supplied prior to 1998 and are currently available for maintenance purposes only About PAM with SAM DOC
3. gt M M 4 tM T T CONVERTER CONVERTER CONVERTER CONVERTER I Measure Mii li liil Product Rate T AMPLIFIER CAM C EN CORRECTOR CAM I gt lt e N A LL GENERATOR GENERATOR S Motion Profile Generators LN LN Figure 23 Packaging Machine Diagram The Result The machine achieves a production speed of greater than 1000 packages per minute which is almost three times that of comparable machines using mechanical systems Throughout the speed range including the acceleration and braking phases the operations of depositing products and removing stacks are carried out in perfect synchronization with the moving collection chain When setting up the machine for different package sizes all necessary adjustments are made from a control console which electronically governs the cycles of all servo driven axes No mechanical adjustments of any kind are needed During product changeover or when restarting the machine after a production stoppage all axes be moved and referenced independently Dry running in order to empty the machine is not necessary About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 37 DM THE PAM WITH SAM SYSTEM As a result of electronic axis control product changeover time is greatly reduced All axis and machine parameters can be saved and recalled at will Container Filling
4. 61 140 Figure42 SAM Supply Dimensions SAM Supply Ordering Key Ge DC Bus Current 400 AC Supply Voltage 480 Internal Dynamic Braking Resistor E External Dynamic Braking Resistor SAM PA 4 zi H About PAM with SAM Page 76 DOC 9032011852 Rev April 8 1999 ADVANTAGES OPPTIMIZED FOR USE WITH SAM DRIVES GEAR BOXES Other System Components BJ General Information Atlas Copco AC Servomotors Atlas Copco AC servomotors provide a number of advantages including High peak torque capability with low rotor inertia for rapid acceleration and deceleration Maximum speeds up to 8000 RPM High power output in a small package Industry standard shaft and flange sizes 25 different motor sizes and more than 80 different models covering a range of 2 to 80 Nm Skewed stator design which provides smooth operation at all speeds Motor enclosure protection to IP65 protection against dust and low pressure water jets Motor shaft seal protection to IP64 protection against dust and water sprayed from all directions Temperature sensor in the motor winding together with overcurrent protection and thermal modeling in the SAM Drive eliminate risk of overheating Two available brake options Optional forced air cooling on larger motors significantly increases continuous operation limit which make them the ideal solution for many applications The full range of Atlas Copco AC s
5. Figure45 CamMaker Graphical Display with Position Velocity and Acceleration Profiles Compiling and Downloading the Application Program PAMCOMP the PAM compiler converts programs created in PAM s application programming language to downloadable executable files PAMCOMP performs a syntax check and verifies symbol assignments The output is a binary executable file Following compilation PAMCOMP is used to download application programs to a PAM About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 81 ul TOOLS FOR PAM AND SAM Tools for Configuring and Tuning the System Introduction Once the integration of a new machine design has progressed to the point where individual axes are operable they may be configured tuned and exercised using the facilities of SAM Tools Configuring a SAM Drive Configuring a SAM Drive entails downloading a parameters file which defines the electrical mechanical and thermal characteristics of the axis motor and integral position feedback device to be controlled SAM Tools includes parameter files for all ACC servo motors so configuring a SAM Drive see Figure 46 is simply a point and click operation Select a parameters file File Name Directories C4 44 SPA c motors sem hd55 D g Cancer m 25 PROMOTON E PARAMS Help gt MOTORS SEM G4 22 SPA HD55 G4 32 SPA D List Files of Type Drives SPA Files SPA MS D
6. 77 Atlas Copco Servomotors 77 Special MOIOIS er oe or e ce i e Deg 77 Protective Components and Safety Interlocks 78 Cables and Wiring 5 78 Auxiliary SUPP Wise sees faa ears cok ince IC UP SENES 78 Software Tools for PAM and SAM 79 Introduction 2 ee cll II clim Dea ri rer EET 79 PAM Tools and SAM Tools 79 Tools for Creating an Application 80 Developing the Application Program Structure 80 Writing the Program Statements 80 Creating and Editing Cam Profiles 81 Compiling and Downloading the Application Program 81 Tools for Configuring and Tuning the System 82 Introductlon EE 82 Configuring a SAM Drive 82 E EE 82 Replicating a SAM Drive 84 Tools for Machine Testing and Monitoring 85 At the Application Level 85 At the Axis Level e a a nee 88 Tools for Ongoing Support 90 Diagnosing and Correcting Problems at the Axis Level 90 Diagnosing and Correcting Program Problems 90 Installing Revisions and Upgra
7. EMC measures safety interlocking circuits error handling Employing these components and methods guarantees that the PAM with SAM System is used as intended and as tested and certified by Atlas Copco Controls engineers as well as by Underwriters Laboratories and other agencies toward compliance with European Directives and standards Cables and Wiring Accessories ACC provides pre assembled motor and communications cables in different standard lengths or custom fabricated to any specified length as well as mating connectors and other wiring accessories The system has been tested and is specified regarding EMC regulations with these accessories Using these specified cables and accessories simplifies the designer s specification and test burdens Auxiliary Supply A 24 VDC auxiliary supply is required for powering a PAM SAM Drives and Supply Units The same 24 VDC supply is generally used for powering all AC Supply Switching and Safety Interlock circuitry as well as other control system PLCs actuators and sensors throughout the machine This power supply may be either a regulated supply with energy reserve or more simply a three phase rectified DC voltage without smoothing capacitor or voltage stabilization Page 78 About PAM with SAM DOC 9032011852 Rev April 8 1999 Software Tools for PAM and SAM Introduction PAM Tools and SAM Tools ACC s ProMotion software package includes a suite of software to
8. Declaration of Conformity SAM according to the EMC Directive 89 336 EEC and to the LVD Directive 73 23 EEC Type of equipment Power conversion equipment and motion controller Brand name or trade mark SOCAPEL SAM Type designation Part number Socapel SAM PA xxx xx x 051 xxxxxx Socapel 050 Manufacturer s name address telephone amp fax no Atlas Copco Controls AB Solkraftsvagen 13 telephone 46 0 8 682 64 00 135 70 Stockholm telefax 46 0 8 682 65 80 Sweden Conformity with the Directives stated above relates to the following reference docu ments Standard or other normative document s EN 50081 2 EMC Generic emission standard Part 2 Industrial environment August 1993 EN 50082 2 EMC Generic immunity standard Part 2 Industrial environment March 1995 EN 60204 1 Safety of machinery Electrical equipment of machines Part1 General requirements October 1992 prEN50178 Electronic equipment for use in power installations December 1995 IEC 664 1 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests October 1992 Installation and use documentation Socapel SAM User s Manual December 1997 part number 025 8003 A As manufacturer we declare under our sole responsibility that the products to which this declaration relates follow the provisions of the EMC and Low Voltage Directives stated above as long as they a
9. The same PAM and SAM Tools introduced in the preceding pages of this chapter are valuable to the user providing ongoing support of application programs and the machines they control Diagnosing and Correcting Problems at the Axis Level The SAM Tools Trace and Panels tools are especially valuable for isolating the causes of problems at the axis level Traces may be setup to trigger on an event capturing data prior to and following the trigger point Using the Panels tool the state of an axis the values of it s parameters and variables may be interrogated or modified or axis functions exercised Since Trace setups trace data and panels are data files they may be saved recalled or electronically transmitted just like any other file This capability greatly facilitates analysis and correction of problems when a machine is located at a distance from the personnel providing support Benchmark data in the form of trace files recorded at machine commissioning may be compared with current response data to isolate what has changed Diagnosing and Correcting Program Problems PAM Tools Trace and Snapshot tools provide a powerful capability to diagnose problems in application program flow In the case of a hung program the Snapshot tool displays the state alive active suspended dead of all program tasks and sequences The PAM Trace tool setup to trigger when the application program activates or deactivates the wrong task ca
10. ON PAGE 51 The SAM Drive is a modern high performance digital motion controller with an integral power stage SAM Drives execute motion I O and program tasks in response to data and commands from PAM providing enhanced system performance through distribution and sharing of system functions SAM Drives are available with continuous power output ratings of 1 5 up to 30 kVA and control motors with shaft output power ratings from 200W up to 30kW A high speed fiber optic bus links PAM and all SAM Drives in a closed ring configuration for exchange of program status I O and motion information The use of fiber optic technology assures immunity from electrical noise a high data exchange rate and capability for wide physical spacing between system components The SAM Supply provides rectified DC power to each SAM Drive at a voltage proportional to the AC supply voltage ACC Atlas Copco Controls manufactures two families of SAM Drives and SAM Supplies which are optimized for operation at 400 and 480 VAC respectively No transformer is required when the AC supply voltage is within the specified range for the system For completeness the necessary main power switching protection and safety components are represented as a single block called the Feeding Section in Figure 1 An external 24 VDC power source not shown supplies logic power to the PAM SAM Drives and SAM Supplies ACC supplies a complete line of AC servo motors configured a
11. Page 88 About PAM with SAM DOC 9032011852 Rev April 8 1999 SOFTWARE TOOLS FOR PAM AND SAM EE butan wilh nguments list bax 2 n Eyes buon is L att CEO il fixed Ze MN argument box ker butan adjustable argument buton wiih dual numera eniry box a baciean m entry box disalay bos Figure 55 A Custom Control Panel Recording SAM Drive Activity The SAM Activity log displays SAM Drive activity including selected changes in SAM status Log entries see Figure 56 provide clear statements about what has changed and are easily interpretable by individuals not intimately familiar with SAM In addition interactions between a SAM Drive and SAM Tools are logged 42 SAM Tools COM1 Oy E File Device Software Parameters Application Advanced View Window Help DEE 2 13 11218 6S C T3 See BE amp Log 0001 1 06 COM1 038BE130 DSP no acknowledge COM 0100M020 Serial eeprom system 1 2 mode COM 01C7E065 Bad reiceved bloc crc COM1 0100M020 Serial eeprom system 1 2 mode COM1 0100 0 0 Dspware restored D1 torctrl V1 2 33 06 MAY 1 COM1 0200M200 Kernel running COM1 0300M007 No Application COM1 0300 000 Parameters restored Ready SBEZ V1 3 03 SFEB V1 3 00 RUNNING Figure56 Example of SAM Activity Log About PAM with SAM DOC 9032011852 Rev 8 1999 Page 89 uU TOOLS FOR PAM AND SAM Tools for Ongoing Support
12. 1999 ABOUT THE PAM WITH SAM SYSTEM NE AMPLIFIER Amplifier THE EQUIVALENT TO An Amplifier outputs a flow of values equal to it s input flow of values times it s gain This is exactly an analogous to a gear ratio in a mechanical system Amplifier blocks are used wherever the equivalent of a gear ratio is needed An amplifier may have a gain less than or greater than one or even zero Gain may be changed dynamically during application execution A slew rate may be specified to limit the rate at which step changes in gain are implemented Figure 6 illustrates a useful application of an amplifier block where one axis must be periodically stopped while the remainder of the machine continues to operate In this scenario the amplifier gain is set to zero but actual deceleration rate is limited by the gain slew rate The Amplifier also has an output offset parameter which provides a useful phase adjustment capability GENET OR CONVERTER AXIS N d d AMPLIFIER CONVERTER AXIS gt imimrg D a Figure 6 Use of Amplifier Pipe Block to stop one Axis CAM CAM oe PRODUCE USER The Cam block is used to generate motion profiles of any shape Profiles are PROBES described in tables which map output values to input values Cam blocks have gain as well as offset adjustment
13. Frequently the logical control portion is executed locally within the same SAM Drive providing extremely short reaction times About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 27 DM THE PAM WITH SAM SYSTEM LINKS PAM AND SAM DRIVES IN A CLOSED RING EVENT BASED COMMUNICATIONS SYSTEMS UTILIZE AVAILABLE BANDWIDTH MORE EFFICIENTLY EVERY MESSAGE INCLUDES A CRC FRAME High Speed Event based Fiber Optic Fieldbus The PAM Ring PAM and all SAM Drives in a system are linked by a high speed fiber optic bus in a closed ring configuration see Figure 15 with PAM serving as the bus master Frames messages containing commands and data from PAM and addressed to a SAM Drive or group of SAM Drives are passed from drive to drive around the ring At each SAM Drive fiber optic bus interface circuitry receives and retransmits frames to the next drive on the ring Each SAM Drive on the ring is assigned a unique address by which it recognizes messages for itself A percentage of the frames placed onto the PAM Ring are empty SAM Drives utilize empty frames for communicating with PAM The last SAM in the ring transmits the original message back to PAM where it is used to verify the integrity of the PAM Ring A PAM Ring can accommodate up to 127 SAM Drives and one PAM A fiber optic cable segment may be up to 100 meters in length with no adjustment required for any length cable LLL SMI Dine SMI bin
14. ce E Es Operator Controls c bk Fiber Optic Ring c 2 o 5 um o o 9 S 2 lt 4 Figure 17 with SAM system under Control of a PC PLC Host About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 31 DM THE PAM WITH SAM SYSTEM PAM Module plugged into a Siemens PLC Backplane PAM MAY BE As illustrated in Figure 18 A PAM with SAM system may be directly interfaced with GE P a Siemens Simatic S5 PLC models 115U 135U and 155U enabling a bidirectional exchange of variables parameters or programs over it s data bus An available PAM option permits direct installation of PAM in an S5 chassis PLC Siemens Operator Controls KA E 2 9 o g E lt o D c 2 we o Figure 18 PAM with SAM directly interfaced to a Siemens Simatic S5 Data Bus PAM as an Intelligent Slave in a PC based System DIRECT INTERFACE A PAM with SAM system may be directly interfaced to a PC based machine MACHINE co controller via PAM s PC104 slave interface which supports 16 bit bidirectional CONTROLLERS exchange of data variables and programs Figure 19 illustrates a configuration where all machine control functions are integrated into an industrial PC ACC can provide a library of routines for users who are creating their own PC based
15. 28 50 04 o7 14 28 50 AC Supply Vac 400 10 380 10 6 480 10 460 15 5 96 415 6 10 frequency Hz 48 62 48 62 DC Bus Voltage Input Nominal value Mod 565 680 minimum value 1 0 0 maximum value Voc 625 750 Output Current 3 Lon 4 kHz Asus 35 8 15 28 58 7 15 22 55 4 kHz 2 Bel 10 13 34 49 84 10 12 33 465 79 Lon 8 kHz Arus 3 65 15 20 34 25 6 115 165 30 ken 8 kHz 2 Arus 8 10 28 38 e 73 8 26 34 8 56 Losses Pisis 4kHz W 63 66 220 290 480 63 66 220 290 480 Pos ve 0 8kHz W 63 66 220 290 480 63 66 220 290 480 Ban 8 0amps M 30 30 130 30 30 30 30 30 30 30 24 VDC Supply Input rated voltage Voc 24 Tolerance Vocl 19 2 30 0 4 typical input current A 0 8 5 max input current A 1 0 5 Switch on current A 2 5 Note 1 Operation of a SAM Drive at DC Bus voltages down to zero VDC does not consti tute an error However maximum achievable motor speed decreases with de creasing DC Bus voltage Note 2 X All SAM Drives are capable of operating at peak current for at least two sec onds If the operating average RMS current is less than rated current konr or the ambient tem perature is less than max permitted value the overload condition is permitted for a much longer time Thermal modell
16. 9032011852 Rev April 8 1999 Page 67 ABOUT THE SAM DRIVE Notes About PAM with SAM Page 68 DOC 9032011852 Rev April 8 1999 About the SAM Supply Introduction The SAM Supply converts power from the three phase AC Supply to DC power for distribution to one or more SAM Drives A secondary function of the SAM supply is to manage energy returned to the DC Bus by motors operating in regeneration mode Figure40 The SAM Supply About PAM with SAM DOC 9032011852 Rev 8 1999 Page 69 GL THE SAM SUPPLY AC TO DC CONVERSION COOLING EXTERNALLY MOUNTED DB RESISTOR Functional Description The following paragraphs which present a functional description of the SAM Supply make reference to the functional diagram in Figure 41 gt Fatal Error Delay Delay 0 5s 0 5s gt OverTemp gt DBR Overload gt OverVoltage Latch Latch Latch DC Bus Low Reset Eee 24 VDC DC D Logic s AAA Heat AN 5 L2 SCH L3 A PE j ES p gt DC Bus Y p gt DC Filter Figure41 SAM Supply Functional Diagram Power Conversion The three phase AC supply is converted to DC by the rectifier As usual with three phase power distr
17. Motion Superimposed upon Pipe Motion UO Control Tightly Integrated with Motion In modern high speed machinery actuation of certain machine components must be closely synchronized with machine motion Two pipe blocks the Comparator and Multi Comparator see Comparator and Multi Comparator on page 21 provide this capability The Comparator Multi Comparator may be programmed to immediately set or reset an output when the value at it s input crosses a specified trigger point Similarly when the machine control must immediately respond to a change of state of a discrete input the condition of interest may be defined as an event in the application program Upon occurrence of the event the PAM operating system immediately initiates execution of a specified set of instructions sequence About PAM with SAM Page 26 DOC 9032011852 Rev April 8 1999 A HIGH LEVEL DISTRIBUTED CONTROLLER PAM FUNCTIONS SHARED FUNCTIONS SAM FUNCTIONS ABOUT THE PAM WITH SAM SYSTEM NE PAM with SAM System Architecture Distributed Control for Optimum Performance PAM in combination with SAM Drives linked by a high speed fiber optic bus forms a high level distributed controller providing coordinated motion I O and overall application program flow among a small or large number of axes Figure 14 illustrates the distribution of system functions between PAM and SAM Drives PAM SAM Safety Discrete I O E Application Pr
18. a speed greater than 8 000 RPM With standard encoders sine cosine interpolation is not used A resolver or encoder providing position feedback from a remote apparatus or directly measuring product position may be interfaced to the second position measurement port Refer to Axis Configurations on page 60 for examples of position feedback configuration options Motion Generator The Motion Generator executes those portions of various pipe block functions which are implemented at the axis level Secondly it generates independent motion profiles including point to point and continuous motions in response to commands and parameters from the application program As illustrated in Figure 35 motion profiles produced by the TMP Generator and pipe motions may be superimposed A Limiter compares the flow of motion data against limiting values of positive and negative travel speed acceleration deceleration torque and direction imposed by the application Whenever a trajectory values exceeds a limit the Limiter sets an appropriate status bit which is normally used to stop the motion Limiter parameters are normally established by the user based on the application s requirements Standard User I O SAM Drives with model numbers ending in i e SAM DA 400 07N P1N A have no digital I O and one analog input with 5V range These models which were supplied prior to mid 1998 are available for maintenance purposes only All S
19. which occurs upon power up PAM verifies readiness of the entire PAM Ring by transmitting a series of test messages at reduced optical power level Any marginal or defective component in the ring is thereby detected and identified before the system progresses to the operational state Three Types of Fiber Optic Cable Available ACC supplies three types of fiber optic cable assemblies including alow cost standard duty plastic fiber cable assembly for use within protected areas equipment enclosures where the cable length is less than 20 meters a heavy duty plastic fiber cable assembly with protective jacket for applications where the fiber cable must be routed through conduits or cable trays with length up to 20 meters along distance fiber optic cable for use where cable lengths up to 100 meters is required Fiber optic cable assemblies are available in a number of standard lengths About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 29 DM THE PAM WITH SAM SYSTEM Operating Stand Alone or in a Network As a Stand Alone Machine Controller WHEN THE When machine or process control requirements do not warrant inclusion of a NOT WARRANT A separate host a PAM with SAM system may be configured to operate as a SEPARATE HOST stand alone machine controller In this configuration see Figure 16 discrete I O available as a SAM Drive option monitor and control machine functions and interface to simple operator
20. 3 25 Fax 44 0 1484 68 83 26 Atlas Copco Controls AB Solkraftsvagen 13 13570 Stockolm Sweden Tel 46 0 8 682 64 00 Fax 46 0 8 682 65 80 Atlas Copco Controls Inc 211 Overlook Drive Sewickley PA 15143 2305 USA Phone 1 412 749 07 10 Fax 1 412 749 07 05 Internet http www atlascopo com controls Wehntalerstrasse 6 CH 8154 Oberglatt Switzerland Tel 41 0 1 851 50 10 Fax 41 0 1 851 50 20 Langermarckstr 35 D 45141 Essen Germany Tel 49 0 201 855 52 96 Fax 49 0 201 855 52 94 Box 195 5 23423 Lomma Sweden Tel 46 0 40 41 48 50 Fax 46 0 40 41 48 55 About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 3 Notes About PAM with SAM Page 4 DOC 9032011852 Rev April 8 1999 Table of Contents Acknowledgements Introduction About PAM with SAM Documentation Scope of this Manual Related Documents Technical Support About PAM with SAM Products Intended Use of PAM with SAM Products Personnel Safety Compliance with International Standards About the PAM with SAM System Introduction liess Overview Important Features and Capabilities Machine Control Capabilities Motion Application Versatility Extensive Set of Co
21. 777216 IWV_ErrAxe2 0 0 0x0 IWV Speed 36 36 0x24 IRV PosLag 0 2 2 ms SEQ Start TSK MI 0 SUSPENDED on CONDITION BEQ T AXSET AGL L284 C21 Started by CONDITION BEG T AXSET AGL L284 C21 TIMEOUT NOT OCCURED IWV ErrAxel 16777216 116777216 0x1000000 IWV 2 0 0 0x0 IWV Speed 36 36 0x24 IRV PosLag 0 3 5000 ms SEQ Start TSK_M1 0 ALIVE Started by CONDITION BEQ_T_AXSET_AGL_L284_C21 TIMEOUT NOT OCCURED IWV ErrAxel 16777216 16777216 0x1000000 IWV ErrAxe2 0 0 0x0 IWV Speed 36 36 0x24 IRV_PosLag 0 4 Read EPROM V3 0 22 T_axset V1 00 RUNNING Figure 51 The Trace Tool Display About PAM with SAM Page 86 DOC 9032011852 Rev April 8 1999 SOFTWARE TOOLS FOR PAM AND SAM EE Monitoring Application Inputs Outputs and Variables The Scanning Tool see Figure 52 provides a real time display of selected application variables discrete inputs and discrete outputs on the PC monitor For test and debugging purposes inputs and outputs may be set and reset using the Scanning Tool IRV_PosLag x Figure52 Scanning Tool Display with four Application Variables Selected Logging PAM Activity The PAM Activity Log see Figure 53 provides a running display of activity related to execution of an application Items displayed include application startup and initialization information During application program execution error and war
22. A NETWORK ON PAGE 30 SEE SOFTWARE TOOLS FOR PAM AND SAM ON PAGE 79 SEE COMPLIANCE WITH INTERNATIONAL STANDARDS ON PAGE 12 ABOUT THE PAM WITH SAM SYSTEM NE Upstream Communications Capability for Hierarchical Control The PAM with SAM system operates stand alone or as a component in a wider network PAM interfaces with PCs PLCs industrial field busses including Profi bus DP CAN DeviceNet FIP I O Ethernet RS422 and others and MMI soft ware packages Powerful Tools for Application Development Test and Monitoring An extensive set of Windows 95 based PAM and SAM software tools support ap plication development testing and maintenance Efficient and Cost effective Solution for any Number of Axes The modularity of the hardware along with ratings and options choices provides an optimized solution for each application Full Compliance with International Standards The PAM with SAM system is recognized to be in compliance with a number of important international standards a significant advantage to machine manufactur ers building machines for a worldwide market About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 15 DM THE PAM WITH SAM SYSTEM Machine Control Capabilities Motion Application Versatility Pipes and Pipe Blocks The designers of PAM and SAM set a design goal that the PAM with SAM system should be able to handle any machine control application requiring multi axis coo
23. AM Drives are supplied with the following user inputs and outputs for controlling machine functions 2 isolated 24 VDC PLC type digital inputs 1 isolated 24 VDC 0 5A PLC type digital output 1 high speed 5 VDC differential digital input 1 10 V PLC CNC type analog input with 12 bit resolution In addition to these standard User I O SAM Drives can be supplied with additional user I O as options Refer to User I O on page 58 for a description of optional user UO configurations About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 55 UM THE SAM DRIVE FOUR LEVELS OF ERROR FAULT RESPONSE DEFINING THE RESPONSE TO A GIVEN ERROR FAULT CONDITION SECONDARY PROTECTION FOR SITUATIONS WHERE NORMAL CONVECTION COOLING MAY BE IMPEDED Safety Stop Functions Dedicated hardware in conjunction with extensive error fault monitoring by the SAM Drive firmware detect and respond to error fault conditions occurring within the drive Four levels of fault error response are defined STOP 0 immediate deactivation of the drive Power Stage STOP 1 controlled stop constant deceleration ramp followed by Power Stage deactivation after a delay STOP 2 controlled stop as in STOP 1 but no Power Stage deactivation USER SIGNAL additional controlled stop similiar to STOP 2 for non error fault conditions as defined by the application An application program can define the le
24. C PLC type outputs provided for a host PLC or similar system monitoring status at the machine level The status outputs except pc Bus Low are applied as inputs to logic controlling the fatal error relay The FATAL ERROR output is disabled contact open whenever one or more of the error outputs is set FATAL ERROR is a component of the system level Safety and Protective Interlocks network A PLC type 24 VDC RESET input is used by the host system for resetting the error latches and fatal error condition when restarting following a fatal error About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 71 GL THE SAM SUPPLY Sizes and Ratings AC Supply Voltage and Output Power Ratings AC Supply Voltage SAM SUPPLIES FOR ACC manufacturers two separate families of SAM Supplies for operation at AC 240 400 AND 490 VAC Supply voltages of 400 and 480 VAC respectively and frequencies of 50 to 60 Hz The Supply Unit Specifications on page 73 lists the AC supply voltage range for each SAM Supply voltage family OPERATION AT LOW Operation at AC supply voltages below the lower limit specified in the Supply Unit AC SUPPLY VOLTAGE specifications is permitted however the corresponding reduction in DC Bus voltage may limit the maximum speed achievable with some SAM Drive motor combinations Operation at voltages above the specified AC Supply upper limit is not permitted NO TRANSFORMER SAM Supplies do not require a transformer when
25. C synchronous motors AC Servo motors and asynchronous motors AC induction motors are built in and selectable by parameter A downloadable parameters file which correctly configures the Current Regulator and Power Stage is available for every model Atlas Copco servo motor Configuration files for other types of motors are also available Built in thermal load modelling of the axis motor utilizing motor and drive parameters provides reliable and responsive motor overload protection under all operating conditions Position Regulator The Position Regulator see Figure 36 provides field proven closed loop PID control with enhanced feed forward compensation technology for stable overshoot free yet very dynamic performance Virtually lag free positioning is About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 53 UA THE SAM DRIVE DIGITAL TECHNIQUES PROVIDE PRECISE REPEATABLE PERFORMANCE achievable A notch filter which can be activated and tuned by parameter may be utilized to improve system performance in the presence of strong torque disturbances when a mechanical resonance frequency might otherwise limit the closed loop passband The Regulator a firmware algorithm employing totally digital techniques provides the benefits of precision and repeatability Two SAM Drives with identical tuning parameters respond identically in the same axis environment Other Regulator operating modes including speed regulator
26. M CONVERTER AXIS CN NS E _ 6 rg Su IT gt b Pipes Network Reconfigured Mechanical lag Axis2 Axis SAMPLER CAM CONVERTER AXIS at og B 62 gt Figure 11 The Flying Master concept If the vertical axis becomes unsychronized and a mechanical lag develops a collision might occur middle picture because the horizontal axis is still synchronized to the TMP Generator When mechanical lag is detected in axis 2 the Page 24 About PAM with SAM DOC 9032011852 Rev April 8 1999 ABOUT THE PAM WITH SAM SYSTEM NE pipe structure is reconfigured within milliseconds as shown in the lower picture Now axis 2 is the master and axis 1 follows it As Axis 2 is brought to a stop Axis 1 maintains proper synchronization enabling it to continue transferring products and avoid a collision Independent Motion Capability PAM supports axes functioning independently motion not continuously coordinated with other axes and the capability to synchronize independent axes to other machine activities Figure 12 illustrates an example the carton conveyor positions a box which is filled with products conveyed by the transfer belt the transfer conveyor transfers product into the box the Comparator triggers when a preset amount of product has been transferre
27. Machine The Problem Filling containers of various sizes with liquids of varying properties requires a machine with great versatility Furthermore the machine must fill the containers precisely and at high production rates As with the packaging machine changeover from product to product must be accomplished quickly and easily The Solution This filling machine manufacturer selected a PAM with SAM system to drive the critical processes in their container filling machine The application makes extensive use of the profiled motion capabilities of the PAM with SAM system that is the capability to electronically duplicate the motions produced by cams and cam followers Each axis may execute a separate motion profile however the motions of all axes are continuously coordinated thereby providing the synchronization necessary among all axes The basic machine employs a PAM and nine SAM drives which operate two parallel lines each with a dual filling station A second version of the machine with capability to blend two liquids employs a PAM and thirteen SAM Drives The configuration for one line is illustrated in Figure 24 Axes six through nine not shown control a second conveyor dual filling station and lifting mechanism parallel to and behind the first conveyor Axis 5 drives the conveyor chain which indexes containers into position under the dual filling station Axis 3 raises the containers under the filling heads Gripper mechanisms con
28. N POSITION_PERIOD POSITION RANGE END NOD 11930464 7111 2 32 360 3600 0 77 10 t s 36000 0 100 t s 2 36000 0 0 0 360 0 VR E 0 0 360 0 TMP GENERATOR TMP_ TRAUEL SPEED ACCELERATION DECELERATION INITIAL_POSITION POSITION_PERIOD POSITION_RANGE PERIOD ANTI_DELAY 60 0 360 0 6 001 VES VYES2NO END CONVERTER CNU_ DESTINATION MODE POSITION POSITIONSSPEED2TORQUESURLUE END 4 14 File PASCRAPADESSINITST AGL Mod Ins Line 10 Col 1 Figure 44 Application Program Creation using Codewright About PAM with SAM Page 80 DOC 9032011852 Rev April 8 1999 SOFTWARE TOOLS FOR PAM AND SAM EE Creating and Editing Cam Profiles CamMaker the cam profile creation and editing tool is used to create and edit motion profiles which define the transfer function of Cam pipe blocks CamMaker converts raw profile data from Excel or other common spreadsheet programs to a file which is downloaded to PAM along with the application CamMaker s graphical display capability permits a profile and it s first three derivatives to be viewed on a PC monitor see Figure 45 Using CamMaker a machine designer may adjust a cam profile selecting linear quadratic or third order spline function for each segment then immediately view the result 7 CamMaker POLY 1 IFC Elz els j 2
29. OC 9032011852 Rev April 8 1999 Page 45 The set of programming language statements may be broadly grouped into the following categories flow control statements object access statements mathematical statements and logical statements The language includes a comprehensive set of mathematical and logical operators and mathematical functions Program objects may be assigned symbolic names relevant to the application A built in units conversion capability permits application programs to be written using units relevant to the application To simplify application program creation a Smart editor is available See Writing the Program Statements on page 80 Axis 1 Control Task Axis 2 Control Task PAM HOST Communication Task Axis Set Control Task Machine Control Task Jog Sequence Sequence Power On Sequence Fast Sequence Cur Spd TMP MastITRAVEL SPEED IF Cur Spd 0 THEN Run Alarm on WAIT TIME 1000 Run Alarm off ENDIF TMP Mast TRAVEL SPEED Slow God CASE CONDITION Run Fast XEQ SEQUENCE Fast CONDITION Run Slow XEQ SEQUENCE Slow CONDITION Stop XEQ SEQUENCE Idle END SEQUENCE Figure 29 Application Structure illustrating relationship among Statements Sequences and Tasks About PAM with SAM Page 46 DOC 9032011852 Rev April 8 1999 PAM Hardware PAM Electronics The PAM hardware configuration see Figure 30 is bu
30. OM2 TRACE404 TRC pO E View Window E POS LAG MEM DSP INT 0 01 1 INTIG PS TORO FLOW MEM DSP INT OxOtae INTIG 4000 3000 1000 I Ready Figure48 Trace showing an axis response to a torque step input Once tuning parameter values are established SAM Tools provides the capability to upload archive and download them About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 83 ul TOOLS FOR PAM AND SAM Replicating a SAM Drive Setup SAM Tools provides a set of menu commands see Figure 49 for uploading archiving and downloading a complete set of parameters which establish the operating characteristics of a SAM Drive SAM Tools COM2 Log SAMT0009 LO0G DI File Device Bootware Firmware Advanced Log View Window Help Lei c 2 2 E from file 5 Uploa Save Use Default Modify BOOT RS V1 2 18 SFGZ 1 2 29 CONFIGURING Figure 49 SAM Tools Parameters Menu About PAM with SAM Page 84 DOC 9032011852 Rev April 8 1999 SOFTWARE TOOLS FOR PAM AND SAM Low Tools for Machine Testing and Monitoring During machine system checkout and validation it is essential to have tools capable of monitoring application program execution and capturing critical events and data when abnormalities occur These tools must operate in harmony with the application and not impede application program execution The follow
31. OS 622 Figure 46 Selecting the Configuration File for an ACC Motor Tuning an Axis Since SAM Drives are totally digital tuning is a matter of establishing the optimum value of a set of gain and feed forward parameters in the SAM firmware Utilizing two of SAM Tools most powerful features Traces and Panels and a fully documented procedure axis tuning is a straight forward procedure requiring no special equipment beyond a PC running SAM Tools A Tuning Panel see Figure 47 included in the ProMotion software provides all the controls and indicators necessary for tuning an axis About PAM with SAM Page 82 DOC 9032011852 Rev April 8 1999 SOFTWARE TOOLS FOR PAM AND SAM EE SAM Tools COM TLIMING PAN Die Edi Window Help M_StallTore Diego 1500 S AB he 59101 MexTarq 8 42 5 Dese STATUS Status 00000000 _ 500 caa Sg D 1 R Dem 220 de sews 10 RP viscFne Tong mf mE 00 Pel E Travel Spaed Hentz 3501 inertia 1 5 karn 2 Acceleration degia 2 dE eg e H H Staten mhm Deceleration 2 Em Fi Regna ERAI REG MODE PDPOS SAVE Parsmeters BOOT LAS Vi 218 wv 2 29 Figure47 Panel for Axis Tuning Utilizing a trace setup file supplied with ProMotion software the axis response see Figure 48 may be viewed as adjustments to tuning parameters are made on the Tuning Panel SAM Tools C
32. This version replaces all previous versions of this document Atlas Copco Controls has made every effort to insure this document is complete and accurate at the time of printing In accordance with our policy of continuing product improvement all data in this document is subject to change or correction without prior notice Atlas Copco Controls SA 2 1 La Rippe CH 1303 Penthaz Switzerland Socapel SAM A Smart Axis Manager About the PAM amp SAM System Ordering Number 9032011852 Rev April 8 1999 Ordering No 9032011852 Old Number 025 8012 G Rev April 8 1999 1997 1998 1999 by Atlas Copco Controls SA All rights reserved Notes About PAM with SAM Page 2 DOC 025 8012 F Rev April 8 1999 Application Centers E mail cspinfo atlascopco com Atlas Copco Controls SA 2 La Rippe CH 1303 Penthaz Switzerland Tel 41 0 21 863 63 63 Fax 41 0 21 863 63 99 Atlas Copco Controls GmbH Z hringerstrasse 23 D 77652 Offenburg Germany Tel 49 0 781 919 080 Fax 449 0 781 919 08 29 Atlas Copco Controls SA 190 avenue Franklin Roosevelt F 69516 Vaulx en Velin France Tel 33 0 472 47 09 17 Fax 33 0 472 47 06 73 Atlas Copco Controls Via Fratelli Gracchi 39 20092 Cinisello Balsamo Italy Tel 39 02 61 79 91 Fax 39 02 6601 4699 Atlas Copco Controls Bridge Mills Holmfirth Huddersfield W Yorkshire HD7 2 TW Great Britain Tel 44 0 1484 68 8
33. a for the entire pipe network ww MASTER Figure 2 Mechanical System About PAM with SAM Page 16 DOC 9032011852 Rev April 8 1999 PIPE NETWORKS ARE DEFINED BY THE APPLICATION PROGRAM PIPE NETWORKS CAN BE RECONFIGURED ON THE FLY A VIRTUAL MASTER FOR MACHINES ABOUT THE PAM WITH SAM SYSTEM NE GENERATOR AMPLIFIER CONVERTER Master Gear1 Conv1 Axis1 AMPLIFIER CAM CONVERTER AXIS Gear2 Cam2 Conv2 Axis2 AMPLIFIER CONVERTER AXIS D no um Gear3 Conv3 Axis3 Figure 3 Analogous System Constructed of Pipes and Pipe Blocks The topology of a pipe network is defined by the application program usually during the initialization phase of the application However pipe networks may be modified or completely reconfigured during application execution This capability proves useful in applications where multiple products are produced on a machine for threading a machine or for instant changeover to a redundant backup station on machines so equipped The capability to reconfigure a pipes network on the fly within a few milliseconds and without loss of coordination enables the machine designer to program in collision avoidance and product loss prevention measures see The Flying Master on page 24 Extensive S
34. accuracy 2 of reading input impedance ohms 10 000 sampling rate kHz 2 0 Brake Conirol Output optional type isolated 24 VDC output short circuit over voltage and polar ity reversal protected lore mA 1 lon 2 0 rated 2 4 max voltage drop 2 V About PAM with SAM Page 64 DOC 9032011852 Rev April 8 1999 ABOUT THE SAM DRIVE NES SAM DA 400 SAM DA 480 14 28 50 o7 14 28 50 delay Motor Overtemp Fatal Error type floating contact normally open closed if no fatal error max current A 1 0 max voltage 60 VDC or 125 VAC switch on switch off ms 2 0 typical thermal switch or PTC on off transition 0 900 1800 typ 1300 hysteresis 0 Position Measurement 100 Contact ACC for list of compatible position mea Port A surement devices Position Measurement Contact ACC for list of compatible position mea Port B surement devices Service Port type RS 422 full duplex baud rate baud 19 200 About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 65 UM THE SAM DRIVE Environmental Specifications all units SAM DA 400 SAM DA 480 04 o 14 28 50 M o7 14 28 50 Protection protection degree Ambient Temperature IP20 IEC 529 operating 5 40 C air temperature below unit extended range 5 55 C wit
35. active are granted slices of processing time by the operating system Once the sequence of instructions linked to an event have been executed the task returns to the inactive state Inactive tasks consume no processor time Tasks may be assigned a priority At times of heavy demand for processing time the operating system services higher priority tasks first As illustrated in Figure 28 a portion of the total processing time is used by the PAM operating system which periodically performs key operating system functions including pipe and pipe block computations communications and events management The interval at which these functions are performed the PAM cycle may be adjusted to meet the requirement of the application PAM Functions n PAM Cycle Cycle Event Vig Event reactivation Ms Suspended V Delay from external Executing event to scheduling Figure 28 Program execution under multi tasking operating system Inactive Event management Page 44 About PAM with SAM DOC 9032011852 Rev April 8 1999 APPLICATIONS ARE ORGANIZED INTO TASKS SEQUENCES ARE SETS OF STATEMENTS EXECUTED SEQUENTIALLY EVENTS CONTROL PROGRAM FLOW ORIENTED FOR MACHINE CONTROL PEOPLE With PAM s operating system handling the above mentioned functions the application program statements focus mainly on defining machine behavior in response to events The princi
36. asks for this application About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 41 ABOUT THE PAM WITH SAM SYSTEM peen Josuas uoisue Jeoueq uoneis WU Josueg Jud Josueg Jeoueq Indu OY no 8 9 fe e SE SI E E gia 2 Ej r Mamm I ER E z A 8 x A z 1 8 x T B GG AE e E AXIS CONVERTER CORRECTOR AMPLIFIER AMPLIFIER AMPLIFIER e 5 5 E E N e lt 2d o d Gr 5 F S o Figure 26 Printing Section Main Control Components About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 42 About PAM Introduction PAM the Programmable Axes Manager is one of the most advanced motion co ordination and machine control products available It offers the highest performance levels and employs the most advanced hardware and software techn
37. ator Derivator H The Derivator is a general purpose pipe block whose output is the derivative of it s input Phaser Phaser A Phaser produces a flow of output values which are offset phase shifted a specified amount from it s input A slew rate parameter is provided to limit the implementation of step changes of phase A typical application of a Phaser is to provide independent phase adjustment capability on an axis About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 23 DM THE PAM WITH SAM SYSTEM IMPLEMENT COLLISION AVOIDANCE MEASURES The Flying Master The ability to reconfigure a pipe network within a time span of several milliseconds while the axes involved are in motion and without loss of coordination is of great benefit in multi axis web handling machines or machinery with intersecting axes Consider the scenario illustrated in Figure 11 where axis 2 drives a vertical conveyor and axis 1 transfers products onto a horizontal conveyor During normal operation top picture both axes follow the TMP Generator Original Configuration GENERATOR CONVERTER AXIS S an EX li VW Axis CAM CONVERTER AXIS 1f Qum o Lad d pus d CONVERTER me Mechanical lag Axis2 di rg ZA Dm Axis1 CA
38. ause it is widely used the resolver is a standard motor feedback device An advanced resolver to digital conversion algorithm provides dynamic response and 200 000 counts turn resolution at speeds up to 8 000 RPM The position is sampled and calculated every 125 usec The interface includes a resolver excitation signal source and built in error checking for loss and degradation of signal Page 54 About PAM with SAM DOC 9032011852 Rev April 8 1999 SINE COSINE ENCODER INTERFACE INCREMENTAL ENCODERS SECOND POSITION MEASUREMENT PORT PERFORMS PIPE BLOCK FUNCTIONS amp INDEPENDENT MOTIONS DETECTS EXCURSIONS BEYOND LIMITS SET BY THE APPLICATION NOTE ABOUT THE SAM DRIVE The sine cosine encoder conversion process provides 12 000 counts per encoder period gt 20 000 000 counts turn with a 2048 period encoder at a 125 usec sampling interval The interface supports absolute position readout for encoders possessing this feature using a number of techniques including serial readout second sine cosine readout and reference mark readout The interface includes a regulated four wire 2 wires for current two wires for voltage sensing 5 VDC power source and 12 VDC power source for powering the encoder Standard quadrature output incremental encoders with input pulse rates before quadrature up to 300 kHz may be directly interfaced to the sine cosine encoder interface This means 2048 line encoders can be operated at
39. capabilities Axis position is usually the profiled variable however velocity or torque profiles may be generated as well Profiles are created by any method capable of producing tabular x y output a spreadsheet program is frequently utilized to create profiles The CamMaker software tool see Creating and Editing Cam Profiles on page 81 provides the capability to visualize analyze edit and smooth profiles Figure 7 illustrates use of the Cam blocks in a three axis container filler mechanism The cam profile for axis 1 controls the volume of liquid dispensed and the fill rate Axis 2 raises and lowers the container Axis 3 indexes containers under the filling mechanism All three axes track the main machine motion profile produced by a TMP Generator About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 19 ABOUT THE PAM WITH SAM SYSTEM Axis1 min Axis2 Axis3 gs max o gt d a UN 5 AXIS AXIS AXIS KE min MU maxi a 0 S CONVERTER CONVERTER CONVERTER 2 N No a min 3 d 360 s CAM CAM CAM Ex Co EY 3 if I d 0 Kaf GENERATOR TMP Pos Figure 7 CAM Blocks control operation of a Three Axis Fi
40. control buttons and indicators Once configured and loaded with the application program the system is self starting Front panel displays on the PAM and each SAM Drive provide an indication of system status and of existing fault warning conditions eoe Operator Controls Figure 16 with SAM as a Stand alone Controller About PAM with SAM Page 30 DOC 9032011852 Rev April 8 1999 ABOUT THE PAM WITH SAM SYSTEM NE Under Control of PC or PLC Host PAM amp Host Linked by RS 422 Communications Channel LOW COST AND For applications where communications data rates are not severe a low cost EASILY IMPLEMENTED oagily implemented RS 422 serial communications interface provides a good solution A typical configuration see Figure 17 places motion functions and machine functions which require close synchronization with motion under direct control of the PAM with SAM system while machine functions not closely linked to motion are managed directly by the host The host has read write access to PAM with SAM system operating parameters and variables through which it controls system operation A set of C language utilities for implementing the RS 422 interface protocol on the user s side are available FEEF
41. corporated into most motors provides for a secondary level of motor overload protection for situations where normal convection cooling of the motor may be impeded When loss of convection cooling capacity is not a concern primary motor overload protection provided by the Current Regulator is ample Page 56 About PAM with SAM DOC 9032011852 Rev April 8 1999 ABOUT THE SAM DRIVE ER STOPO User Mask STOPOForcedMask llfaultsignals 64 Default AB 0x59F 18401 AB 0x59F10000 Default CD 0x004F2183 CD 0x00440080 Fault Status unlatched 64 64 m 64 64 64 Q D D 64 62 all except Stop 0 input and Reset Stop 0 command 1 Y Latched STOPO ABCD first StopO cause d StopO latched for Fatal Error actions diagnosis Figure 37 STOP 0 and Fatal Error Logical Structure Other Functions Commands Manager The Commands Manager handles communications with PAM application program execution and coordinates activities within the SAM Using a dedicated RS 232 port it communicates with a PC running SAM Tools and a Test Device accessory Front Panel Status Indicator This seven segment display mounted in the SAM Drive front panel provides a continuous indication of the unit s operational state When an error fault condition has been detected it alternatively displays corresponding error codes Fiber Optic Bus Interface Bi
42. d into the acrton the carton conveyor moves an empty carton into the filling position in full synchronization with arrival of product from the transfer conveyor THE AXIS OBJECT The independent motion capabilities of the AXIS object include relative or absolute GENERATOR MP movements and continuous motion at specified acceleration deceleration and maximum travel speed Feed Rolls Rotary Knife Transfer Carton Conveyor Conveyor i T T T AXIS AXIS AXIS T wy DJ Vu s Dm T 1 CONVERTER CONVERTER CONVERTER Carton Conveyor Task AMPLIFIER ICOMPARATOR Routine gt 08 AMPLIFIER MN gt Figure 12 Independent Motion synchronized with coordinated motion About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 25 DM THE PAM WITH SAM SYSTEM Independent Motion in Combination with Coordinated Motion Each AXIS object is capable of producing independent motions as well as implementing coordinated motion trajectories produced by pipe blocks Furthermore independent motions may be superimposed upon pipe motion as illustrated in Figure 13 thereby providing another level of motion flexibility commands Trapezoidal Motion Profile functions Arbitrary Motion Profile Figure 13 Independent
43. d the machine control tasks structure Once these are defined writing sequences of program statements which define a machine s behavior in detail can begin Developing the Application Program Structure Utilizing a field proven generalized machine control application shell developed by ACC as a model an appropriate structure for the subject machine control application may be quickly implemented A collection of sample machine control programs and routines are available for use as templates by users developing application programs Writing the Program Statements ACC has adapted Codewright a customizable programming language editor for creating and editing PAM application programs When customized with dictionary and configuration files available from ACC Codewright becomes an intelligent editor which recognizes statement syntax and form As the programmer enters the first keyword of a program statement or declaration the editor supplies the remainder of the statement components with mandatory and optional arguments designated and placeholders for argument values In Figure 44 all of the text in the window was supplied by the PAM editor significantly reducing the requirement for manual entry along with probability of error and omissions RA Codewright P SCRAP DESSIN TST AGL Eile Edit Search Project Text Document Tools Window Help AXIS AXI NODE PULSES_PER_UNIT TRAVEL_SPEED ACCELERATION DECELERATION INITIAL_POSITIO
44. des 90 PAM and SAM Tools Operating Platform 91 Configuration Requirements 91 About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 7 TOC OF CONTENTS Appendix A Declaration of Conformity PAM 93 Declaration of Conformity 94 About PAM with SAM Page 8 DOC 9032011852 Rev April 8 1999 Acknowledgements ACK Atlas Copco Controls has made every effort to supply trademark information about company names products and services mentioned in this book Trademarks indicated below were obtained from various sources Windows NT Windows 95 and Excel are registered trademarks of the Microsoft Corporation Wonderware is a registered trademark of the Wonderware Corporation Wonderware InTouch is a trademark of the Wonderware Corporation Intel and Pentium are registered trademarks of the Intel Corporation SIMATIC is a registered trademark of Siemens Gmbh About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 9 ACKNOWLEDGEMENTS Notes About PAM with SAM Page 10 DOC 9032011852 Rev April 8 1999 SAM SYSTEM DESIGNERS GUIDE AC SERVOMOTORS MANUAL SAM SYSTEM USERS HANDBOOK SAM SYSTEM USERS MANUAL PAM SYSTEM REFERENCE MANUAL Introduction About PAM with SAM Documentatio
45. directional communications with PAM as well as the physical interface to the fiber optic bus are tasks performed by the Fiber Optic Bus Interface About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 57 UA THE SAM DRIVE DC to DC Converter An electrically isolated DC DC converter not shown produces all SAM internal voltages from an external 24 VDC supply and monitors these internal voltages for overvoltage and undervoltage conditions Optional Functions Brake Control Output The Brake Control Option is used for controlling an electro mechanical brake on a motor so equipped This isolated 24 VDC 2A output is on conducting when the Power Stage is enabled and off not conducting when the Power Stage is disabled The brake control output may be switched off by the application program prior to disabling the power stage to compensate for actuation time of an electro mechanical brake This brake specific output is both short circuit and open circuit protected The condition of no current flowing when the output is on as would occur with an open brake circuit is recognized and treated as an error condition This same option may be used to operate the contactor in a motor short circuit braking circuit User I O A SAM Drive may be equipped with additional user inputs and outputs for controlling machine functions User I O are housed on a daughter board installed in the drive Inputs and outputs are optically coupled
46. document or for additional information or applications assistance on any Atlas Copco Controls product contact an Atlas Copco Applications Center listed in the front of this manual About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 11 About PAM with SAM Products Intended Use of PAM with SAM Products Atlas Copco Controls PAM with SAM product line constitutes a Power Drive System according to international standard IEC 1803 and Power Conversion Equipment according to UL standard 508C It s intended use is for powering and controlling moving parts within industrial machines PAM and SAM products are supplied as subassemblies to professional assemblers for incorporation into machines apparatuses and systems Assemblers are responsible for insuring that these products are used for their intended purpose only and for compliance with all applicable regulations According to the European Directive 89 392 EEC regarding machinery putting a Power Drive System into service is prohibited until the machinery into which it is to be incorporated has been declared in conformity with the provisions of this Directive Personnel Safety The PAM with SAM product line is intended for connection to standard main voltages up to 480 VAC and for running motors up to 8000 RPM High voltage and moving parts can cause severe or fatal injury Atlas Copco Controls provides this and other manuals for assisting assemblers in using these products in a co
47. e Figure 15 with SAM system fieldbus arrangement PAM s Event based Data Throughput Compared to Cyclic Systems PAM as the bus master creates 68 bit frames at the continuous rate of 30 frames per millisecond providing a data throughput of up to 2 04 Mbits s Communications on the PAM Ring is purely event based which means bandwidth is used only to send relevant information Compared with cyclic fieldbus communications systems which send all information new as well as non changing each communications cycle studies have shown that the event based PAM communications bus uses available bandwidth up to four times more efficiently than cyclic buses Communications Reliability Starting with superior electrical noise immunity and the simple rugged interconnection means offered by fiber optic cable reliability has been designed into PAM s fiber optic fieldbus A CRC Cyclic Redundancy Check frame built into Page 28 About PAM with SAM DOC 9032011852 Rev April 8 1999 REDUCED POWER LEVEL TESTING DETECTS MARGINAL COMPONENTS ABOUT THE PAM WITH SAM SYSTEM Low each message further insures message integrity Should a fault occur in the PAM Ring PAM immediately detects the loss of returned signal permitting implementation of necessary actions to facilitate prompt restoration of communications built in diagnostic routines identify the defective bus segment when a fault occurs During system self testing
48. e Machine Control task The labeled connecting lines between sequences represent events that trigger corresponding sequences e g RunFast triggers Fast Sequence In a basic implementation events may be signals from pushbuttons The POWER ON sequence executed automatically upon power up or reset of the PAM provides a mechanism for initialization The user constructs compact intuitive sequences using programming language statements which correspond closely with individual steps in a machine control flow diagram For example Figure 29 illustrates the program statement complement and corresponding process flow diagram for the SLOW sequence The PAM Programming Language The PAM application programming language is a literal language with natural syntax oriented for machine process control people The language has been organized in accordance with IEC Standard 848 Preparation of Function Charts for Control Systems utilizing terminology and structures which simplify creation of application programs from process function charts prepared according to IEC 848 The basic language concept is very similar to the well Inown programming language C C The libraries are extended with special structures and commands for axis control and management In contrast to graphic oriented programming languages the user has full access to the full versatility and flexibility of this 4th generation literal high level language About PAM with SAM D
49. e feeding rate while SAM 2 operating as a torque controller supplies constant tension At the beginning of a material feeding cycle axis 2 applies a predefined initial torque in a direction opposite to the direction of material feeding SAM 1 is then commanded to run continuously at the desired material feeding speed During unwinding the application program periodically interrogates SAM 1 and SAM 2 to obtain current axis 1 and 2 speeds from which it calculates the current diameter of the roll of material on axis 2 then adjusts the axis 2 torque to maintain constant tension on the material Axis with Direct Product Position Measurement Here the lower drive belt powered by an AC servo motor with integral resolver provides the force required to feed the material and the upper idler belt holds the material against the lower drive belt Due to slippage between the drive belt and material as well as stretching of the drive belt during feeding the length of material fed cannot be inferred from motor rotation PRODUCT POSITION MEASURED SEPARATELY FROM MOTOR POSITION The upper belt which always tracks material movement without slippage has been outfitted with a resolver or encoder which is connected to the second position measurement port on the SAM Drive This second resolver which provides an accurate measure of actual length of material fed through the belts is the primary position measurement transduce
50. ervomotors includes more than 80 different standard models For most torque ratings the selection includes a longer motor with lower inertia and a shorter motor with larger diameter but lower cost Different winding dependent s for low speed or high speed operation are available Each model is optimized characterized and pre configured for use with SAM Drives The complete family of AC Servomotors is fully described in the Atlas Copco AC Servomotors Manual Most Atlas Copco AC Servomotors can be fitted with planetary gear boxes from Alpha and other manufacturers For additional information or assistance contact an Atlas Copco Applications Center Special Motors Other types of motors such as induction motors and gear motors water cooled motors low speed direct drive motors and linear motors may also be used in PAM About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 77 MM SYSTEM COMPONENTS PROTECTIVE COMPONENTS with SAM systems For additional information or assistance in using other types of motors contact an Atlas Copco Applications Center Protective Components and Safety Interlocks SAM Supply Units do not include protective components such as fuses circuit breaker in rush current limiters etc Components for these protective functions must be supplied by the user Additionally the SAM System Designer s Guide provides comprehensive information on selecting cables fuses breakers etc
51. et of Coordinated Motion Functions Introduction PAM with SAM s versatility as a multi axis machine controller results largely from the flexibility and functionality of it s pipe blocks Pipe blocks duplicate and expand the functions of mechanical and electro mechanical components Additionally number of pipe blocks with no direct electro mechanical counterpart have been developed to enhance PAM with SAM s unique capabilities as a machine controller Application programs setup and dynamically modify the behavior of pipe blocks by adjusting the value parameters which input to the pipe block s transfer function Descriptions of and typical uses for each pipe block type are presented in the following paragraphs TMP GENERATOR TMP Generator A The TMP Trapezoidal Motion Profile Generator is a virtual master for a machine or segment of a machine see Figure 3 It provides linear acceleration and deceleration also constant speed operation A TMP Generator may be commanded to produce a movement of specified length distance or to accelerate to setpoint rate and operate at that rate until commanded to operate at a different rate Acceleration and deceleration rates are also specified by the application About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 17 DM THE PAM WITH SAM SYSTEM PRODUCES JERK LIMITED MOTION THE CONNECTION PMP Generator PMP Generator The PMP Parabolic Moti
52. following fieldbusses CAN implements the CAL standard protocol using a special in terface DeviceNet Group 2 Slave only 2 masters using a special interface FIPIO using a standard external adapter and extended protocol ProfiBus using PC 104 interface Ethernet using PC 104 interface 9 EH eem D E Fieldbus Interface Interface Driver gt 69 Figure 21 with SAM system on Industrial Network About PAM with SAM Page 34 DOC 9032011852 Rev April 8 1999 ABOUT THE PAM WITH SAM SYSTEM NE Implementing a MMI with Intouch Software Using DDE server software a PAM with SAM system interfaces to Intouch Man Machine interface software running on a standard PC Figure 22 illustrates the configuration The DDE Server software is available from ACC Intouch software may be purchased from a commercial software distributor The PAM RS 422 port and a COM port on the PC are used for communications PC and MMI Display Intouchr Software es LZ PAM DDE Server 15422 Link IUS P Figure 22 Configuration for Implementing a Man Machine Interface About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 35 DM THE PAM WITH SAM SYSTEM System Solutions Introduction This section presents hist
53. ge 92 DOC 9032011852 Rev April 8 1999 Appendix A Declaration of Conformity PAM according to the EMC Directive 89 336 EEC Type of equipment Programmable controller Brand name or trade mark SOCAPEL PAM Type designation Part number Socapel PAM 006 77xxxx Manufacturer s name address telephone amp fax no Atlas Copco Controls SA En Montillier 4 telephone 41 0 21 863 63 63 CH 1303 Penthaz telefax 41 0 21 863 63 99 Switzerland European representative address telephone amp fax no Atlas Copco Controls AB Solkraftsvagen 13 telephone 46 0 8 682 64 00 135 70 Stockholm telefax 46 0 8 682 65 80 Sweden Conformity with the Directives stated above relates to the following standards and oth er normative documents Standard and other normative documents EN 61131 2 Programmable controllers Part 2 Equipment requirements and test August 1994 Installation and use documentation Socapel PAM Simatic S5 Technical Manual May 1996 part number 006 8006 B As manufacturer we declare under our sole responsibility that the products to which this declaration relates follow the provisions ofthe EMC Directive stated above as long as they are used as described in the PAM Simatic S5 Technical Manual 006 8006 B Stockholm December 19 1997 Atlas Copco Controls SA Atlas Copco Controls AB Patrick Burnand Mats Onner General Manager General Manager About PAM with SAM DOC 9032011852 Rev 8 1999 Page 93
54. ge monitoring circuit which immediately shuts down the Power Stage Power components are mounted and thermally bonded to a heat sink at the back mounting end of the SAM Drive Air circulated over the heat sink by an integral fan on most models transfers heat by convection from the heat sink into the enclosure in which the SAM Drive is mounted The heat sink mounting surface temperature is monitored and together with a software based power stage thermal model used to provide a warning when the computed transistor temperature approaches the upper limit for reliable operation Should the temperature continue increasing i e due to failure to stop the machine after a warning the power stage is immediately shut down Motor faults including phase to phase shorts and shorts to ground are automatically detected initiating an immediate power stage shutdown Disabling of the power stage as a result of error fault conditions is accomplished by removing the current source to each IGBT pre amplification circuit Current Regulator The Current Regulator is a closed loop controller which supplies a three phase pulse width and sine wave modulated current command to the Power Stage It monitors the output currents and regulates the direct Ip and transverse Ic current components The Current Regulator employs totally digital control which provides improved performance and repeatability compared to standard analog technology Control algorithms for A
55. gorithm which may include a time delay slope parameters and multiple trigger points Figure 9 illustrates an application of the Comparator In this example an output valve controlled by a Comparator is added to the filling mechanism from Figure 7 When cam position crosses the value Trigger 1 the Comparator initiates the Open Routine which in turn opens the output valve Next the Comparator is set to the value Trigger 2 When cam position crosses the Trigger 2 value the Comparator initiates the Close Routine and the valve is closed The Comparator is again set to the value of Trigger 1 and the cycle restarts A user output resident in the SAM Drive operates the valve max M A Ni Y min CONVERTER a Gan Trigger2 Close S Routine dig UD EAS _ 4 COMPARATOR Trigger Open n lt gt Routine _ SNo zo max 5 Trigger 2 g 3 J 5 N W Ip Trigger2 GENERATOR min Figure 9 Comparator used to Control a Valve on a Filler Mechanism About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 21 DM THE PAM WITH SAM SYSTEM Corrector IMPLEMENTS AN The Corrector is a special purpose pipe block which implements an automatic DENTON registration function on an axis Figure 10 illustrates the concept In this application FUNCTION one axis drive
56. gure 24 Container Filling Machine About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 39 DM THE PAM WITH SAM SYSTEM Label Printing Machine The Problem This manufacturer builds machines which print elegant product labels of different sizes in up to eight colors The same machine can emboss apply special foils die cut and laminate all in a continuous process The manufacturer required a highly modular motion control system to compliment the modular design of the machine components Up to twenty coordinated axes were required for a fully configured eight color machine The label stock used by many customers is quite expensive so the requirement to minimize scrap was a principal design criteria High accuracy stability and repeatability at all operating speeds were required of all axes involved in moving the web The Solution A PAM with SAM system controls all axes directly involved in printing and moving the web SAM Drives provide the required accuracy stability and repeatability With only seven system connections per drive 2 fiber optic bus cables 3 power 2 safety SAM Drives are easily integrated into a modular machine design A feature of the system software enables the PAM with SAM system to detect which axes are physically present at power up and disconnect the software for non existent axes This permits a single control program to be used for all machines regardless of the number of print stations em
57. h derating of power outputs and forced air circulation within cubicle daily avg op temp lt 30 C transport and storage Relative Humidity 25 70 C operating 5 95 occasional condensation transport and storage Altitude 5 95 occasional condensation except at low temperature in order to prevent the risk of damage by freezing operating lt 1000m extended range lt 2000m with derating of power outputs and forced air circulation within cubicle transport and storage lt 3000m Climate pollution degree 2 operating Class B3 IEC 654 1 3K4 721 3 transport and storage Shock and Vibration Class n a IEC 654 1 2K4 721 3 high freq vibrations class V H 4 IEC 68 2 6 operating 0 15mm constant amplitude 10 lt f lt 57 2 0 g constant acceleration 57 lt f lt 150 vibration severity Class V S 2 IEC 68 2 6 lt 10mm s shocks 25 g 10ms XYZ occasional IEC 68 2 27 op erating free falls 1 0m 5 times in 5 min IEC68 2 32 during transport Physical Characteristics SAM DA 400 SAM DA 480 04 07 14 28 50 04 07 14 28 50 weight kg 3 8 3 8 6 9 7 1 139 3 8 3 8 69 7 1 13 9 Page 66 About PAM with SAM DOC 9032011852 Rev April 8 1999 ABOUT THE SAM DRIVE
58. ibution networks the AC Supply s neutral or star point must be grounded Therefore the DC Bus output terminals are at symmetrical voltages typically 280 and 280 VDC respectively for a 400 VAC supply Power dissipating components are mounted on a heat sink Ambient temperature air circulated over the heat sink by an integral fan transfers heat into the enclosure in which the SAM Supply is mounted Dynamic Braking The Dynamic Braking circuit including an internal or externally mounted DB Resistor handles kinetic energy returned by motors while braking if it cannot be immediately reused for powering other motors When DC Bus voltage reaches a predetermined threshold level the Dynamic Braking circuit allows current flow through the DB resistor where excess energy is dissipated In most applications the amount of power which must be dissipated in the Dynamic Braking circuit is considerable In this situation ACC recommends an externally Page 70 About PAM with SAM DOC 9032011852 Rev April 8 1999 OVERVOLTAGE ON DC BUS LOW DC BUS VOLTAGE EXCESSIVE POWER DISSIPATION IN DB RESISTOR POWER COMPONENTS TEMPERATURE TOO HIGH STATUS OUTPUTS FATAL ERROR RESET INPUT ABOUT THE SAM SUPPLY LOS mounted DB resistor suitably located and protected to alleviate the cooling problems associated with dissipating hundreds or thousands of watts in the system enclosure ACC supplies a complete range of DB resistors for ex
59. ilt around a 32 bit RISC processor Intel i960 which performs all PAM functions The application program and PAM firmware along with data reside in DRAM during execution Two memory size options are available depending on the application s memory requirement PAM firmware and application program are stored compressed in flash EEPROM Parameters are stored in non volatile SRAM The RS 232 interface is a service port reserved for use with PAM Tools An optional RS 422 port is for communications with a host PC PLC when using the RS 422 communications option Modem Internet JC Ethernet COM Profibus SVGA MMI Industrial UO Soft PLC z Any PC compatible PC104 VxWorks RT OS Windows 4EC1131 Run PC104 Slot ISA Signals Fatal Error Reset CPU i960 Dualport Memory Display Communication Interface Connector RS232 Interface To CAN Board or Simatic S5 Bus Dynamic RAM up to 16Mb 2 28 be or Wi FLASH Non volatile EEPROM SRAM 2Mb 8kb Option RS422 Interface Figure 30 PAM block diagram About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 47 The PAM includes a fiber optic bus interface for the PAM Ring and components for test monitoring and maintenance purposes An 8 digit alphanumeric display see Figure 31 serve as a simple operator interface for diagnostic and maintenance purposes A RESET button provides hardware reset ca
60. ing paragraphs illustrate how PAM Tools and SAM Tools support these tasks At the Application Level Displaying the State of an Application Program The Snapshot tool see Figure 50 provides a report on the state of an application program under execution which includes the status of all tasks and sequences and their triggering events PAM Sequences Snapshot Application T_axset Version 1 00 SEQ Zero TSK MI 0 DEAD SEQ Start TSK MII SUSPENDED an CONDITION BEG T AXSET AGL Le Cl Started by CONDITION T AXSET AGL L284 C21 TIMEOUT NOT OCCURED SE M1 POWERON T5K MI 0 DEAD SEQ_Power Off TSK_Stop 0 DEAD GEO ErmAxe T5K 0 ALIVE Started by ON EVENT T AXSET AL L3651 217 Figure 50 Application Snapshot provided by PAM Tools About PAM with SAM DOC 9032011852 Rev 8 1999 85 ul TOOLS FOR PAM AND SAM Tracking the History of Application Program Execution The Trace tool see Figure 51 displays the history of a specified task or sequence beginning at a defined trigger point A Trace may also be setup to include the history of a number of application variables W Tools COM1 TRACE002 PET _ x Trace View Window x 212 2212 EVENTS 1 0 ms SEQ Start TSK_M1 0 ALIVE Started by CONDITION T AXSET AGL L284 C21 TIMEOUT NOT OCCURED IWV ErrAxel 16777216 416
61. ing performed by the SAM Drive provides full protection Note 3 4 KHz and 8 KHz refer to the PWM frequency selected Operation at the 8 Khz PWM frequency with it s higher pass band and lower acoustic noise is rec ommended In applications where lower pass band and a higher acoustic noise level are acceptable the higher output power ratings at 4 kHz PWM frequency may permit selection of a smaller and lower cost drive A SAM Drive s PWM frequency is user selectable by parameter Note 4 Includes all components Note 5 Depends on the option s included in the unit About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 63 UA THE SAM DRIVE Other Electrical Inputs and Outputs SAM DA 400 SAM DA 480 4 o7 14 28 50 o o 14 20 50 User digital Inputs amp standard and high speed user inputs Safety Inputs STOP 0 amp STOP 1 Safety inputs type isolated 24 VDC input type 2 IEC1131 2 Vorr Voc 0 3 5 0 1 mA max Von Mod 15 30 10 mA typ on off and off on delay ms 0 3 typical for high speed input 10 0 typical for other inputs User Digital Outputs type isolated 24 VDC output protected against short circuit over voltage and polarity reversal lorr max mA 0 4 lon Max mA 600 voltage drop 2 V on off and off on delay ms 10 0 typical User Analog Input type differential input 12 bit resolution input range volts 10 0
62. ith SAM Power Drive System comprised of a PAM SAM Drives a SAM Supply and motors with or without integral position feedback transducers P WM S Jr Int TIT gt e e gt Fieldbus Fiber Optic Ring Actuators AC Supply Servo Motors Figure 1 PAM with SAM System Block Diagram PAM is the system s control and motion coordination center It controls motion I O and program flow as dictated by the application program under execution PAM MOTION COORDINATION may be linked to a host PC PLC or factory automation system for hierarchical CENTER control and reporting using one of a number of industry standard communications interfaces About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 13 DM THE PAM WITH SAM SYSTEM SAM DRIVES EXECUTE MOTION I O AND PROGRAM TASKS SAM SUPPLY PROVIDES RECTIFIED DC POWER TO SAM DRIVES FEEDING SECTION INCLUDES SAFETY AND PROTECTIVE COMPONENTS MOTORS SEE MOTION APPLICATION VERSATILITY ON PAGE 16 SEE EXTENSIVE SET OF COORDINATED MOTION FUNCTIONS ON PAGE 17 SEE MACHINE CONTROL PROGRAMMING ENVIRONMENT ON PAGE 44 SEE ABOUT THE SAM DRIVE
63. ition Transducers 62 SAM Drive Specifications 63 Power Input Output 1 63 Other Electrical Inputs and Outputs 64 Environmental Specifications all units 66 Physical Characteristics 000 ec cece eee eens 66 see eek ete ee a he ohne da eid eta cadets 67 SAM Drive Ordering 67 About the SAM Supply 69 MEUM 69 Functional Description 70 Power Conversion 70 About PAM with SAM Page 6 DOC 9032011852 Rev April 8 1999 TABLE OF CONTENTS TOC Dynamic Braking isset ded Re dvd Are MY 70 Fault and Error Monitoring 71 Status Inputs and Outputs 006 eee eee 71 Sizes and 5 cence nnne 72 AC Supply Voltage and Output Power 72 Supply Unit 73 Power Input output Ratings 73 Electrical Inputs and Outputs all units 74 Environmental Limits all units 75 Physical Characteristics 0 eee eee 75 lu Ee EE NE 76 SAM Supply Ordering Key 76 Other System Components 77 General Information
64. ives may be operated with reduced AC supply voltage and correspondingly reduced DC Bus voltage down to zero VAC without error However maximum achievable motor speed decreases with decreasing DC Bus voltage Continuous and Peak Current Within each SAM voltage family are four or five separate drive models each with different continuous and peak current ratings With five different ratings to select from the user may assemble an optimum cost effective configuration closely matched to the machine requirement on an axis by axis basis Refer to Voltage and Current Output Ratings on page 63 for the continuous and peak current ratings for all models Two sets of ratings 4 KHz and 8 KHz refer to the PWM frequency selected Operation at the 8 Khz PWM frequency with it s higher pass band and lower acoustic noise is recommended In some applications where lower pass band and a higher acoustic noise level are acceptable the higher output power ratings at 4 kHz PWM frequency may permit selection of a smaller and lower cost drive A SAM Drive s PWM frequency is a user selectable parameter Drives can supply their rated peak current for at least two seconds after which the SAM issues an overcurrent warning If a SAM Drive is operating at below it s continuous current output rating peak current is available for as long as heatsink temperature remains below it s operating limit This interval can approach several minutes especially when the coo
65. kaging 48 PAM Specifications 50 PAM Ordering Key access shea lE vg tacos nace EN 50 About the SAM Drive 51 Introd clion 22cm ee ee eden Ber Ae SNE eee 51 Functional Description 52 Block Diagrami i ius Deed x oe ee eet 52 Stage ert eu Ded EZ prO E ed bet re 53 Current Regulator 53 Position Regulator 53 Position Measurement 54 Motion Generator 55 Standard Wser O s icc np etna ance See diane bce acetal ace 55 Safely d n aol estere hate eterna 56 Other Funcions RES atu rece HER RR 57 Optional Functions 58 Voltage and Current Ratings 59 AC Supply Voltage 59 Continuous and Peak Current 59 Axis Configurations 60 ocr due tope 60 AC Servo Motor with Integral Resolver 60 AC Servo Motor with Integral Sine Cosine Encoder 60 Induction Motors with Resolver or Encoder Feedback 61 Axis with Direct Product Position Measurement 61 Axis or Axes Slaved to a Remote Apparatus 62 Linear Motors with Linear Pos
66. l Option E Safety User 3 IN safety Stop0 Stop1 circuits DSP Pos Vel Pos Vel Acc Reference Position Regulator Y Position Position Measurement a Position T Magn Pos i Power Stage Current Torque Regulator Reference DC Bus Figure 35 SAM Drive Functional Diagram Page 52 About PAM with SAM DOC 9032011852 Rev April 8 1999 THREE PHASE IGBT OUTPUT CONVERTER POWER FOR DRIVING AXIS MOTORS DC BUS OVERVOLTAGE PROTECTION COOLING POWER COMPONENTS OVER TEMPERATURE PROTECTION FAULT DETECTION CONTROLS BOTH AC SERVO MOTORS AND INDUCTION MOTORS CORRECTLY CONFIGURED FOR THE MATING MOTOR RELIABLE MOTOR OVERLOAD PROTECTION CLOSED LOOP PID CONTROL FEED FORWARD NOTCH FILTER ABOUT THE SAM DRIVE Power Stage The Power Stage employs an efficient three phase four quadrant IGBT output converter with ratings dependent on the model together with pre amplification and protection circuitry and filtering capacitors Power for driving the axis motor is drawn from the DC Bus During braking kinetic energy is fed back to the DC Bus where it is available for simultaneous acceleration of other motors Each voltage family of SAM Drives is designed for a specific maximum DC Bus voltage DC Bus voltage in excess of this limit is detected by a volta
67. ling air temperature is significantly below 40 degrees C Drive width varies depending on the current rating Figure 39 shows the dimensions of the various models About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 59 UM THE SAM DRIVE NOTE COST EFFECTIVE SOLUTION FOR MOST APPLICATIONS SOLUTION WHERE HIGH ACCURACY OR HIGH STIFFNESS IS REQUIRED Axis Configurations Introduction This section presents some axis configuration possibilities using SAM Drives along with various type motors and position feedback options Other arrangements are possible For all configurations motor and feedback cable lengths up to 100 meters may be used AC Servo Motor with Integral Resolver This is the most widely used configuration AC Servo motors offer high torque to inertia ratios high electrical efficiency and speeds up to 8000 RPM A single resolver integral to the motor provides position feedback for commutating the motor and positioning the axis A resolver with 6 arc minutes accuracy mounted on the motor shaft is supplied as standard in Atlas Copco AC servo motors With resolver feedback the SAM Drive provides position measurement resolution greater than 200 000 counts turn This is the most cost effective solution for applications such as pick and place or cam functions where high dynamic performance is required AC Servo Motor with Integral Sine Cosine E
68. lling Mechanism SYNCHRO X Synchronizer WHEN A SLAVE AXIS The Synchronizer provides the capability to desynchronize and resynchronize an ES AICHBONOGER axis to an internal or external master It is used where a slave axis must be stopped WITH A MASTER AXIS and when restarted achieve perfect jerk free resynchronization with the master The ramping distance increment of slave axis motion within which ramp up or ramp down occurs and the slave axis resting position are adjustable Figure 8 illustrates the application of a Synchronizer which enables a slave axis to be stopped started and resynchronized to an external master About PAM with SAM Page 20 DOC 9032011852 Rev April 8 1999 SYNCHRONIZE OPERATION OF INPUTS AND OUTPUTS TO MOTION ABOUT THE PAM WITH SAM SYSTEM Encoder SAMPLER CONVERTER SYNCHRO ARIS mi mp 9 Figure 8 Synchronizer Provides the Capability to Start Stop and Resynchronize a Slave axis COMPARATOR Lr 52 Comparator Multi Comparator A Comparator monitors the flow of pipe data and causes a specified action when the flow of values at it s input crosses a specified reference value A Comparator is often used for synchronizing the operation of an actuator to the position of a product or axis in a machine cycle A Multi Comparator is similar to a Comparator but provides a more sophisticated triggering al
69. n Scope of this Manual This manual About PAM with SAM provides a description of the functions and applications of PAM and SAM products when applied as a multi axis motion controller providing coordinated motion and I O sequencing functions Related Documents For comprehensive information on designing motion systems using SAM products refer to the SAM System Designer s Guide This manual provides important information on configuring power drive systems using SAM products as well as details on the sizing and selection of system components options and accessories The Atlas Copco AC Servomotors Manual provides complete electrical and mechanical performance data on more than eighty 80 different AC Brushless motors designed optimized and characterized for use in SAM systems This manual About PAM with SAM together with the SAM System Users Manual SAM System Designer s Guide and the Atlas Copco AC Servomotors manual comprise the SAM System Users Handbook For more detailed information on topics including integration start up programming maintenance and trouble shooting of SAM products please refer to the SAM System User s Manual This manual also contains information which may be helpful to the assembler in preparing his own documentation for the end users This manual provides extensive information on PAM system concepts design and programming Technical Support For additional information on any topic covered in this
70. ncoder When axis positioning accuracy requirements are severe or when high stiffness in the presence of strong torque disturbances is required i e printing applications Atlas Copco AC servo motors may be equipped with with an integral high resolution sine cosine encoder in place of a standard resolver Sine cosine encoders with accuracies down to 20 arc seconds are standard and provide in combination with a SAM Drive position measurement resolution up to 20 000 000 counts turn The SAM Drive is compatible with Heidenhain Stegman Huebner and other sine cosine encoders providing the necessary power control conversion hardware and software SSI and Hyperface interfaces available mid 1998 Thanks to an integral four wire 5 VDC regulated power source 5 volt sine cosine encoders may be used with cables up to 100 meters in length Page 60 About PAM with SAM DOC 9032011852 Rev April 8 1999 ABOUT THE SAM DRIVE Induction Motors with Resolver or Encoder Feedback COST EFFECTIVE Induction motors are cost effective choices for applications where high power is POWER needed They provide a cost efficient solution for winding unwinding axes and APPLICATIONS applications where simple gear motors are mechanically acceptable Either a resolver or incremental encoder is a suitable position feedback device for this type of application This two axis system feeds material from a supply spool SAM 1 controls th
71. nd optimized for use with SAM Drives Other motor types including linear direct drive and AC induction motors are readily interfaced with SAM Drives Important Features and Capabilities PAM with SAM incorporates a number of features and capabilities important to the machine designer including Total Flexibility when defining Motion Relationships The system s motion relationships are totally defined by the user s program and may be redefined on the fly thereby providing unsurpassed flexibility to support the demand for increasingly more flexible machines Comprehensive set of Motion Functions A competitive advantage of the PAM with SAM system is it s capability to continu ously coordinate the motions of a few or many up to 127 axes performing varied motions An extensive set of motion functions satisfies almost every machine mo tion requirement Optimized Machine Control Programming Environment With the details of motion NO and program flow managed by the PAM operating system the user s program concentrates on describing machine behavior Precise Position Control SAM Drives provide closed loop PID position control with enhanced feed for ward technology for stable overshoot free yet very dynamic performance With a number of position feedback device options each axis may configured for the accuracy needed Page 14 About PAM with SAM DOC 9032011852 Rev April 8 1999 SEE OPERATING STAND ALONE OR IN
72. ning messages from the PAM operating system are are placed on the Activity Log E PAM Tools COM PAMTODIS LOC Appicebon Objects Advenced Log View With Help COMI D TOD44OD 1 Attateh s completed COM DBOONMTOT No Channel definition COM Starting Init COMI 0700 004 Ring configuration checked COM D 780 MODS n duaiport declared COM 0TH MODA Gesases Im Initialieiest COM 0 FBIO MOU B Ring peripherics CONT OTROMODF Geszboes is running COM D 730 MOZ5 All SAM io are configured COMT 0 TO MO 5 Equations with linked aut Installed COMI 0 16 Starting power ON actions COM OTRO MD Working in main hemp COMI 0780 MOT5 Evaluator process started COMI Power ON actions completed Ur MU 20121 yap Parati OGUDOUCU 1 Heady EPROM Wa Tasset VLDE Figure 53 PAM Tools Main Window with Activity Log Displayed About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 87 ul TOOLS FOR PAM AND SAM At the Axis Level Capturing and Displaying SAM Drive Response The history of up to four SAM variables as functions of time see Figure 54 may be captured and displayed using the SAM Tools Trace feature The trace trigger point is set by an expression which may be a combination of numerical and logical values and operators Trace data is captured and saved in a reserved segment of SAM s RAM memory for subsequent upl
73. oad to a PC where it is displayed in oscilloscope format As with most digital storage oscilloscopes the trace tool may be configured to display data before and after the trigger point The sampling rate is adjustable over a wide range of values from 8 kHz to 1 one Hz Trace data along with setup information may be saved in PC files for archiving purposes or for subsequent use as benchmarks or references SAM Tools COM1 TRACE333 TRC File Trace View Window Help es esi Ej os 8 ESI Haga COM Parameters restored torqflow MEM DSP INT OxO1ab INT16 5000 4000 3000 2000 1000 poslag MEM_DSP_INT Ox01a0 INT16 500 750 1000 T I I 0 0 05 0 1 O16 032 0 25 Ready SBEZ V1 3 03 SFEB V1 3 00 RUNNING Figure54 Example Trace showing two variables verses time Testing and Evaluating Machine Performance Custom control panels for directly exercising and monitoring a SAM Drive may be created in a window using the Panels tool As illustrated in Figure 55 control panels employ standard Windows components including buttons display boxes and lists Buttons and boxes may be custom labeled in any language The Panels tool uses familiar Windows dialog boxes menus and prompting in the control panel design process so no special training beyond familiarity with Windows is required to design custom control panels Control panels may be saved in files for use at any time by simply recalling the desired file
74. ogram vents Management Brake Control Option Position Measurement Motion Trajectories Generation Position Velocity 9 O Ex o Fieldbus Interface Figure 14 Distribution of system functions PAM controls execution and flow of the application program and manages the pipes network If the system is under control of a host PAM manages communications with the host utilizing the hardware and software protocols of the communications interface selected Finally PAM manages bidirectional communications with SAM Drives Some functions including motion trajectory generation events management and application execution are distributed between PAM and SAM drives The extent of processing load distribution depends upon the structure of the application Each SAM Drive executes it s pipe block functions and program tasks tracks its motion trajectory and manages communications with PAM A high performance PID Proportional Integral Derivative control algorithm and PWM Output Stage provides closed loop control of the axis motor Motor position for commutation and axis positioning purposes is computed by a position measurement system implemented in firmware using the output of a position feedback device such as a resolver or encoder integral to the axis motor When an application requires discrete inputs or outputs their physical hardware portion is housed within a SAM Drive s
75. ology available in an industrial product of it s type PAM incorporates a number of innovative concepts which make it especially well suited for applications where the motions of multiple axes must be precisely controlled and continuously coordinated with other machine functions PC104 Slot ISA Signals for PC and interfaces plug in Display Service Port Fatal Error Relay Comm Port i m amp Fiber Optic Ring gt Piggy back PMC format Figure27 The PAM About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 43 MULTI TASKING AND EVENT DRIVEN DEFINED Machine Control Programming Environment Multi tasking Event Driven Operating System PAM utilizes a multi tasking event driven operating system which simply means that PAM is able to perform a number of tasks seemingly at the same time The term task in this context means a series of application program instructions In actuality PAM as well as other single processor multi tasking systems devotes small amounts of time time slices to it s tasks switching in rapid succession among active tasks The term event driven means that some defined event i e an input changing state or occurrence of a time out etc causes the operating system to change a task s status to active and schedule it for execution or conversely terminate it Figure 28 illustrates how program execution might proceed in an application with three tasks Tasks 1 2 and 3 when
76. ols designed to aid in developing and supporting PAM with SAM systems Those software tools which interact with a PAM are called PAM Tools The set of software tools which interact with a SAM Drive are called SAM Tools PAM Tools and SAM Tools are easy to use With familiar Windows 95 menu driven operation see Figure 43 and extensive online help no specialized programming skills beyond familiarity with Windows are required to fully utilize these tools amp File Device Bootware Firmware Parameters Advanced Log View Window Help l uaga o Link ok IBOOT EB V1 2 19 ISFGZ V1 2 40 RUNNING Figure43 SAM Tools Main Window The PC hosting PAM Tools or SAM Tools connects to a PAM or SAM Drive respectively through a dedicated RS 232 Service Port A PAM or SAM remains fully connected to it s host and fully functional while interacting with the tools This chapter discusses how these software tools may be utilized in various phases of a project starting with creation of the application program through machine setup testing and ongoing support About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 79 ul TOOLS FOR PAM AND SAM Tools for Creating an Application Once the conceptual machine design is firm and process flow diagrams for the machine have been prepared creation of the machine control application program can begin The first steps are to define the motion relationships an
77. on Profile Generator is similar to the TMP Generator however it has the capability to produce jerk limited motions where the maximum instantaneous rate of change of acceleration is specified by parameter The PMP Generator is frequently utilized as a virtual master in machinery where large masses are being rotated or delicate webs are being processed The PMP Generator is also capable of producing forward backward motions with a non stop jerk free transition through zero speed see Figure 4 This feature is frequently useful for linear axes which must move back and forth with no requirement to pause at one endpoint position Backward speed Forward 0 time time Figure 4 PMP Generator Forward 8 backward Motion Profile SAMPLER Mm A Sampler implements a logical connection between an external master outside Sampler MASTER the PAM with SAM system and a pipe for the purpose of slaving the motion of the AND A PIPE PAM with SAM system to the external master Figure 5 illustrates the concept The NETWORK Sampler feeds motion trajectory data derived from an encoder or resolver coupled to the remote machine into the pipe network Remote machine Encoder md P Ba SAMPLER CONVERTER AXIS np mm e To other pipes Figure 5 Sampler Pipe Block used to track an External Master About PAM with SAM Page 18 DOC 9032011852 Rev April 8
78. open loop vector controlled operation and direct torque control can be selected A position feedback device typically a resolver or encoder provides velocity and position feedback to the Position Regulator Position Regulator Error Status PID notch filter torque limiter Position amp Velocity lag nek Torque actual values z E KE EI Reference A Proportional Gain Integral Gain Derivative Gain Position amp Velocity Feed set points Forward Inertia Static Friction Viscous Friction Torque set points O ACCEPTS RESOLVERS INCREMENTAL ENCODERS AND SIN COSINE ENCODERS ADVANCED RESOLVER TO DIGITAL CONVERSION ALGORITHM Figure 36 Position Regulator functional diagram Position Measurement The Position Measurement function converts the output of one or two position measurement devices to digital position for use by other drive functions One of these is normally the position measurement device associated with the axis motor while the second may be an auxiliary position measurement device The devices supported include resolvers high resolution sine cosine encoders and standard incremental encoders Device specific Interface circuitry is factory installed and reflected in the specific model number of the drive All position information known to the SAM is accessible to PAM for use by the application Bec
79. ordinated Motion Functions The Flying Master Independent Motion Capability IO Control Tightly Integrated with Motion PAM with SAM System Architecture Distributed Control for Optimum Performance High Speed Event based Fiber Optic Fieldbus Operating Stand Alone or in a Network As a Stand Alone Machine Controller Under Control of PC or PLC Host As a Fieldbus Node in a Wider Network Implementing a MMI with Intouch Software System Solutions Introduction eee eee eee Multi Product Packaging machine Container Filling Machine Label Printing Machine The Problem The Solution About PAM Introduction een n nnn m nnn TOC 11 11 11 11 12 12 12 12 13 13 14 16 16 17 24 25 26 27 27 28 30 30 31 34 35 36 36 36 38 40 40 40 About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 5 TABLE OF CONTENTS Machine Control Programming Environment 44 Multi tasking Event Driven Operating System 44 Creating Application Programs 45 PAM Hardware ene eee nde aca ee 47 PAM Electronics 2 ete teenies 47 PAM Pac
80. ories of applications in different industries where motion control systems from Atlas Copco have provided effective machine control solutions Multi Product Packaging machine The Problem Today s packaging machines need to be highly versatile quickly and easily configured and capable of very high operating speeds High versatility or flexibility implies that machines must be capable of packaging many types and sizes of products with changeover from product to product accomplished without time consuming and skill demanding mechanical adjustments The interdependent movements demanded by modern packaging processes are too intricate for conventional drive linkages involving cams gears and belts so electronic systems are increasingly being utilized to perform these functions The Solution A prominent packaging machine builder has for several years relied on motion systems from Atlas Copco to control their high speed multi product packaging machines The design incorporates four servo driven axes controlled and coordinated by the array of electronically generated motion functions illustrated in Figure 23 Single products of the same or different types arrive on a feeding conveyor at a constant average rate but with some variation in product to product spacing With the help of two sensors the product rate is measured and the TMP Generator controlling packaging machine speed is adjusted to match A Corrector with input from a high s
81. pability and a RUN indicator illuminates when the firmware is executing The 4 Kbyte dualport memory serves as the focal point for exchange of data with a number of optional host communications interfaces The PC104 slave interface including connector provides direct 16 bit read write capability with other PC104 devices The base address is selected by a switch array in the PAM lib 8544 e Run Reset Figure 31 PAM Display and Operator Function keys PAM Packaging Options PAM Freestanding Module PAM is a stand alone module see Figure 32 designed for direct installation in an ACC PAM Rack an ACC Elesta Display or any 6U chassis PC104 cards by ACC and others may be plugged into the PAM s ISA Bus connector ISA Bus 40 5 S A VS n i e N g v6 e Figure 32 PAM Freestanding Module Page 48 About PAM with SAM DOC 9032011852 Rev April 8 1999 PAM is available with a mating backplane connector which permits direct installation in a Siemens Simatic S5 PLC chassis models 115U 135U and 155U In this configuration power for the PAM is supplied by the host PLC Simatic S5 Mountable Module Panel Mount Chassis for 24 VDC Input Power This stand alone PAM Rack see Figure 33 accommodates one PAM and contains a power supply module which furnishes the DC power required by the PAM from 24 VDC input power This panel mountable chassis i
82. pal benefit is a concise simply structured application with very little application code actually being executed when a machine is operating in a steady stable condition Creating Application Programs Program Structure At the top level application programs are organized into tasks which define the behavior of system components where a system component may be an axis a section of a machine an entire machine or a special process related operation In a task structure typically utilized in machine control applications one task handles PAM Host communications while a second task performs overall machine control A separate task is created for each axis with unique behavior When a machine contains several axes with identical behavior they are frequently controlled from a single task Task are partitioned into one or more sequences where a sequence is a set of statements which are executed sequentially upon occurrence of a specific event Figure 29 illustrates the breakdown of a simple application into tasks sequences and the program statements which comprise a sequence Within each task the PAM operating system controls program flow among sequences based on the occurrence of application defined events and imposes the restriction that only one sequence within a task may be active at any time In the Machine Control task sequence structure shown in Figure 29 the blocks labeled JOG IDLE SLOW FAST and POWER ON represent sequences of th
83. peed sensor detecting products passing a reference point adjusts the phasing of an intermediate conveyor axis 1 as necessary to insert products cleanly onto the collection chain controlled by axis 2 Movement ot the collection chain axis 2 is optimized with a Cam block Products are transferred to a gripping mechanism in the vertical part of collection chain The gripping mechanism axis 3 traverses the collection chain at a fourty five degree angle removing the required quantity of goods from the collection chain at position 2 After releasing the goods to a transfer arm at position 3 the gripping mechanism moves quiclky back to position 1 to begin another cycle A digital output closely synchronized with the position of the gripping mechanism controls in out positioning of the picking forks as they alternately move from front to back side of the collection chain During the gripping mechanism cycle filling of the collection chain continues without interruption At position 3 the products are taken by a transfer arm which places the stacks into trays or cartons It is controlled by a separate TMP Generator whose cycle is triggered by command from the application program Page 36 About PAM with SAM DOC 9032011852 Rev April 8 1999 ABOUT THE PAM WITH SAM SYSTEM
84. ployed Figure 25 illustrates the basic machine configuration for single color printing The main PLC an Elesta CRISP by ACC performs overall machine control A CAN bus labeled in the figure links the PLC to the PAM with SAM system A number of Atlas DMC axis controllers The Atlas DMC is an ACC product perform other motions not requiring direct coordination with the moving web A small local PLC with touch sensitive MMI at each station manages other control functions In the unwinding section web material is pulled from a roll and fed into a loop1 The infeed roll in combination with the outfeed roll feed the web through a printing unit at constant speed and under constant tension The input and output dancers operating as a complementary pair superimpose a back forth motion on the web segment between them During the portion of station rotation where the printing plate is not in contact with the web the web backs up a bit to remove what would otherwise be considerable whitespace wasted material between successive images then resumes forward motion at print station speed Downstream of printing units stamping units perform various operations such as embossing application of foils cutting perforating and laminating A winding unit rewinds the finished product onto rolls About PAM with SAM Page 40 DOC 9032011852 Rev April 8 1999 ABOUT THE PAM WITH SAM SYSTEM NE
85. ptures a history of task state and values of specified variables Data gathered by these tools may be saved as files for easy transmission storage or later recall Installing Revisions and Upgrades PAM Tools provides the capability to download application program revisions as well as firmware revisions to a PAM Similarly SAM Tools may be utilized to configure SAM Drive and install SAM firmware revisions For downloading firmware a PC running SAM Tools may be connected to one SAM Drive for downloading to that drive only or connected to the PAM from which the firmware may be broadcast to all SAM drives via the fiber optic bus With familiar menu driven operation and prompting no specialized training beyond familiarity with Windows is required to perform these operations About PAM with SAM Page 90 DOC 9032011852 Rev April 8 1999 SOFTWARE TOOLS FOR PAM AND SAM EE PAM and SAM Tools Operating Platform Configuration Requirements The following hardware software configuration is recommended for a PC running PAM or SAM Tools processor Intel 80486 DX or Pentium 8 MB RAM memory 16 colors SVGA graphics adapter 2 serial ports 10 MB disk space Windows 95 98 operating system Using ACC s specific RS232 cable is recommended for linking the PC to SAM or PAM About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 91 SOFTWARE TOOLS FOR PAM AND SAM Notes About PAM with SAM Pa
86. r This arrangement also allows detection of the situation where no material is present About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 61 UM THE SAM DRIVE Axis or Axes Slaved to a Remote Apparatus INTERFACES A A position measurement port may serve as the gateway to a pipes network in E applications where one or more axes are to be slaved to the motion of a remote machine Figure 38 illustrates the configuration In this arrangement the output of a resolver or encoder coupled to the remote machine is brought in to an unused position measurement port of a SAM Drive controlling an axis motor Internally the pipes network in place defines how trajectory data from the remote machine is distributed Figure 38 System Slaved to a Remote Machine Linear Motors with Linear Position Transducers Linear AC servo motors with linear position transducers are an attractive solution for linear positioning applications demanding high positioning accuracy or stiffness Either magnetic or optical transducers interface directly to SAM Drives SAM Drives may be configured to match the operating characteristics and limits of any linear AC servo motor About PAM with SAM Page 62 DOC 9032011852 Rev April 8 1999 ABOUT THE SAM DRIVE NES SAM Drive Specifications Power Input Output SAM DA 400 SAM DA 480 o7 14
87. rdinated motion regardless of the mix or configuration of motion functions required With the development of pipes and pipe blocks described in the following paragraphs this goal has been achieved PIPES ARE Pipes are software entities used by an application to define motion linkages MET MOTION between source object master and destination objects usually axes and serve LINKAGES as conduits for the flow of motion trajectory data Pipe blocks perform operations on motion data PIPE BLOCKS Consider the mechanical system shown Figure 2 and equivalent system DATA MOTION constructed of pipes and pipe blocks illustrated in Figure 3 Pipes represented by line segments with arrows indicating direction of flow are an analogous to the lineshaft segments in the mechanical system Pipe blocks are shown as boxes with shaded sides Some pipe blocks AMPLIFIER and CAM for example duplicate the function of their mechanical counterparts gears and cams The CONVERTER pipe block has no exact mechanical counterpart It s purpose is to convert incoming values to position speed or torque setpoints as required by the application The AXIS block physically implemented in a SAM Drive is not technically a pipe block It is the destination for pipe data and the interface between a pipe and the motion functions implemented by a SAM Drive The pipe block labeled MASTER a TMP Trapezoidal Motion Profile Generator is the source of motion dat
88. re used as described in the Socapel SAM User s Manual 025 8003 A Stockholm December 19 1997 Atlas Copco Controls AB Mats Onner General Manager Page 94 About PAM with SAM DOC 9032011852 Rev April 8 1999
89. rrect efficient and safe manner Assemblers must insure that all persons responsible for design test maintenance and use of PAM and SAM products have the proper professional skill and apparatus knowledge For compliance with the EC Directives and standards applicable to PAM and SAM products assemblers must read understand and apply the specified procedures and practices regarding safety set forth in the PAM with SAM System Designer s Handbook as well as in the PAM with SAM System User s Handbook Compliance with International Standards PAM and SAM products comply with the European EMC and Low Voltage directives applicable to power conversion equipment and motion controllers and carry the CE mark Copies of the manufacturer s Declaration of Conformity for PAM and SAM products are included in Appendix A of this document About PAM with SAM Page 12 DOC 9032011852 Rev April 8 1999 PAM THE SYSTEM S CONTROL AND About the PAM with SAM System Introduction Overview PAM with SAM is a Power Drive System optimized for applications where the motion of multiple axes must be precisely controlled and continuously coordinated with other machine functions With an extensive family of standard motion functions and unparalleled flexibility PAM with SAM provides cost competitive solutions for motion control machine control applications ranging from straight forward to the most demanding and highly complex Figure 1 illustrates a PAM w
90. s a conveyor moving bottles past a capping station and a second axis drives the capping mechanism The placement of bottles on the conveyor is not precise so the capping mechanism must be rephased for each bottle A sensor triggers the Corrector when a bottle reaches a known reference point The Corrector knowing where the capping mechanism must be at this trigger point computes and implements a phase correction to reposition the capping mechanism as required for proper engagement with the bottle To prevent the application of step corrections which may be harmful to the capping mechanism the dynamics of a correction movement are controlled by Corrector parameters Before correction _ Required capping mechanism at trigger point 180 GENERATOR 170 170 78 Oy E qj v9 CONVERTER 170 CONVERTER AXIS mmy e After correction 180 GENEHATOR 1 70 CORRECTOR 1 80 CONVERTER 180 AXIS E mm p E edt CONVERTER AXIS Figure 10 Using a Corrector to perform Automatic Registration on a Bottle Capping Mechanism e fap About PAM with SAM Page 22 DOC 9032011852 Rev April 8 1999 FOR INDEPENDENT PHASE ADJUSTMENT ABOUT THE PAM WITH SAM SYSTEM NR Deriv
91. s intended for applications where the PAM is not installed in the chassis of the host system The chassis includes a fuse for input power EMI filter and POWER on indicator This chassis provides space for up to three PC 104 cards and front panels 3U 3 free 2TE 3U ja Ln Front panels Tm CR e d Y SS 116 Power Supply Figure 33 PAM Panel Mount Chassis PAM in Enclosure for Integration into CRISP Display PAM can be supplied in a sheet metal enclosure designed for direct integration into an ACC Elesta CRISP PC Display see Figure 20 on page 33 About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 49 PAM Specifications PAM P H8F L8F CPU model intel i960 with floating point unit clock speed Mhz 25 25 Onboard Memory DRAM for application execution Mbyte 8 8 Flash EPROM for firmware amp application storage Mbyte 2 2 non volatile RAM for RT clock amp parameter retention Kbyte 8 8 PC 104 Bus specification version 2 1 memory operations 8 amp 16 bit read write operations base address switch selectable RS 422 Port optional baud rate basic cycle dependent Baud 9600 or 19 200 RS 232 Service Port baud rate Baud 19 200 Input Power supply voltage VDC 5 0 5 current ADC 2 5 typ 4 0 max Ambient Temperature operating deg C 5 40 transport and
92. solutions About PAM with SAM Page 32 DOC 9032011852 Rev April 8 1999 ABOUT THE PAM WITH SAM SYSTEM NE Industrial PC linked with PC104 A NNoSNes Machine functions Motion related I O PC PLC Operator Display and Motion Functions in a Single Module Atlas Copco offers a wide range of PC based PLCs and PC displays using PC 104 technology and IEC 1131 3 soft PLC languages PAM can be directly integrated into the ACC Elesta CRISP Display PC see Figure 20 providing operator display PLC and motion functions in a single module ISA signals CRISP Display PC Dese isplay PAM Enclosure CRISP Cover PC104 based PAM is an ISA slave Dual Port RAM Figure 20 PAM integrated into an ACC Elesta CRISP PC Display About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 33 DM THE PAM WITH SAM SYSTEM As a Fieldbus Node in a Wider Network INTERFACES TO PAM interfaces to a number of industrial fieldbusses enabling a PAM with SAM system to function as node a wider network see Figure 21 PAM s PC104 bus FIELDBUSSES interface is the gateway to network connectivity Utilizing commercially available bus interface boards and software drivers running on standard CPU boards PAM connects to the
93. storage deg C 25 to 70 PAM Ordering Key optional RS 422 interface R no RS 422 interface N Rack mounted R1 Simatic S5 115 version S1 Simatic S5 135 version S3 Simatic S5 155 version S5 PC104 P1 PC104 enclosure for P2 integration into CRISP L8 4 axes 8Mb DRAM H8 gt 4 axes 8Mb DRAM F 2Mb Flash EEPROM AG Glass Fiber Interface for ST1 AP Plastic Fiber Interface for SAM TE Page 50 About PAM with SAM DOC 9032011852 Rev April 8 1999 About the SAM Drive Introduction The SAM Drive is an intelligent high performance digital motion controller with an integral power stage SAM Drives execute motion I O and program tasks in response to the flow of data and commands from a PAM providing enhanced system performance through efficient distribution and sharing of system functions This chapter describes the SAM Drive functioning as a component of a PAM with SAM system Figure 34 SAM Drive About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 51 UM THE SAM DRIVE Functional Description Block Diagram This functional description make reference to the SAM Drive block diagram presented in Figure 35 Generator SAM Tools Display 0227 UO Option Command Manager standard 1 0 Fiber Opie Interface Beke Ctr
94. ternal mounting Consult the System Designer s Guide for details on selecting an external DB Resistor Fault and Error Monitoring DC Bus voltage amplitude is monitored continuously and the OVERVOLTAGE output set and latched if DC Bus voltage exceeds the maximum rated value This error condition triggrers a fatal error without delay The output Bus Low is set whenever DC Bus voltage is below 75 percent of its nominal value It is normally used for system disgnostic and status monitoring purposes Low DC Bus voltage is not an error condition therefore this output is not an input to the fatal error logic The ID Resistor Rp a component of each DB Resistor assembly forms a timing component of an integrator which monitors power dissipation in the DB Resistor When the DB Resistor power dissipation limit is exceeded the condition is detected and the output DBR OVERLOAD is set and latched This error condition triggers a fatal error after 0 5 seconds The rectifier internal DB Resistor and DB switching transistor IGBT are mounted and thermally bonded to a heat sink along with a temperature sensitive switch which monitors heat sink temperature If mounting surface temperature exceeds a predetermined level the switch opens setting and latching the OVERTEMP output This condition triggers a fatal error after 0 5 seconds Status Inputs and Outputs The four status outputs OVERTEMP DBR OVERLOAD OVERVOLTAGE nd DC BUS LOW are 24 VD
95. the AC Supply voltage is within NEEDED specifications If a transformer is used for voltage transformation a lower cost autotransformer may be used Should an isolation transformer be used the secondary neutral or star point must be grounded Output Current and Power HIGH CURRENT AND Current and power ratings for each model SAM Supply available for each AC LOW CURRENT MODELS Supply voltage range are listed in the Supply Unit Specifications on page 73 About PAM with SAM Page 72 DOC 9032011852 Rev April 8 1999 ABOUT THE SAM SUPPLY LOS Supply Unit Specifications Power Input output Ratings SAM PA 400 SAM PA 480 1 30E 80 304 30E 80E AC Supply Vaus 400 10 three phase 480 1096 three phase neutral grounded neutral grounded Rated Output DC 570 680 Bus voltage Output Current Continuous Acct 30 30 80 30 30 80 surge 10 ms sine 480 480 1500 480 480 1500 Output Power kei continuous power out kW 13 0 13 0 35 16 16 42 pu Dynamic Braking Built in DB resistor yes no no yes no no DB resistance 50 75 10 shunt current A 13 40 100 10 40 100 10 Peak braking power kW 13 26 65 8 0 31 77 Max average braking kW 007 3 3 007 3 3 power load dependent Losses Rectifier Lou IW 90 90 190 90 90 190 DBR switching circuit IW 8 31 40 6 31 40 2596 dut
96. thereby providing total electrical isolation of the SAM Drive electronics from the user inputs outputs All I Os are electrically isolated with shared power and common connections A LED indicator for each input and output provides a visual indication of it s state A SAM Drive may be ordered with either the standard or optional User I O configurations Table 1 shows the complements of User I O available with each configuration type standard optional I O Configuration SABRE mn see Note 1 user high speed digital input 1 0 user digital input 2 6 7 8 9 10 user digital output 1 8 7 6 5 4 user analog input 1 1 Table 1 Standard and Optional User I O Complements Note 1 With the optional I O configuration 4 ports are user program mable as either digital inputs or digital outputs Page 58 About PAM with SAM DOC 9032011852 Rev April 8 1999 DRIVES FOR 400 480 VAC AND 50 60 HZ FIVE RATINGS FOR AN OPTIMUM MATCH 4 OR 8 KHZ PWM FREQUENCY PEAK CURRENT ABOUT THE SAM DRIVE Voltage and Current Ratings AC Supply Voltage ACC manufactures two families of SAM Drives designed for operation with AC supply voltages of 400 and 480 VAC respectively These voltage ranges cover the standard three phase AC supply voltages found worldwide Refer to Power Input Output Ratings on page 63 where AC Supply voltage specifications for all SAM Drive families are listed SAM Dr
97. trolled by axis 3 keep the containers securely anchored to the lifting mechanism Axes 2 and 4 pump liquid into the containers while axis three simultaneously lowers the containers in a profile which maintains the desired relationship between liquid level in the container and the tip of the filling mechanism Axis 2 and axis 4 also control valves at the inlet and outlet of the pumping mechanism Axis 1 places empty containers onto the conveyor chain A PLC controls non critical machine functions and coordinates the filling system with other upstream and downstream operations A PC with touch sensitive display running Wonderware s Intouch MMI software provides operator control panel functions along with status reporting DDE server software available from ACC enables direct exchange of system parameters and variables between PAM and the PC over a RS 422 communications link To setup the filling machine for a particular product the operator simply presses a button The machine control software then selects the pertinent motion profiles and parameters About PAM with SAM Page 38 DOC 9032011852 Rev April 8 1999 ABOUT THE PAM WITH SAM SYSTEM oe a m E Machine H Functions To other Fiber Optic Ring optional axes 1 2 Axis3 Fi
98. ture below unit Extended range 5 55 C with derating of power outputs Daily avg op temp lt 30 C Transport and storage Relative Humidity 25 70 C Operating 5 95 occasional condensation Transport and storage 5 95 occasional condensation except at low tem perature in order to prevent the risk of damage by freez ing Altitude Operating m 1000 Extended range m 2000 with derating of power outputs Transport and storage m 3000 Shock and vibration High freq vibration class V H 4 IEC 68 2 6 operating 0 15 mm constant amplitude 10 lt f lt 57 2 0 g constant acceleration 57 lt f lt 150 Vibration severity Class V S 2 IEC 68 2 6 10 mm s Shocks 25 0110 ms XYZ occasional IEC 68 2 27 operating Free falls 1 0 m 5 times in 5 min IEC68 2 32 during transport Physical Characteristics SAM PA 400 SAM PA 480 30 1 30 80 30 1 30 80 Weight kg 36 34 6 2 3 6 34 6 2 About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 75 GL THE SAM SUPPLY Dimensions Supply width varies depending on the current rating Figure 42 shows dimensions for the various models SAM PA J 30 E SAM PA 80 E SAM PA 30 1 A 29 gt 8 vr A q E X Y Y mm mE n Y N N
99. vel of response to error fault conditions detected by SAM Drive firmware i e a STOP 0 STOP 1 STOP 2 or USER SIGNAL response however the responses to certain critical fault error conditions are defined by firmware and not user alterable Figure 37 illustrates the relationship among the various inputs to the STOP 0 function Stop 1 is similar User Safety Inputs On every SAM Drive discrete user inputs to the STOP 0 and STOP 1 functions are provided to permit initiation of a fault error response by external circuitry These discrete STOPO and STOP1 inputs are isolated 24 VDC PLC type user inputs They provide sufficient redundancy to satisfy the criteria for category Ill safe standstill per standard EN954 1 STOP 0 STOP 1 STOP 2 and USER SIGNAL conditions are treated as events by PAM and SAM which means their occurrence initiates a defined response at the application program level They are represented in the SAM Status and produce an indication on the Front Panel Status Indicator Fatal Error Output The FATAL ERROR relay contact see Figure 37 is closed whenever no STOP 0 or STOP 1 condition originating internal to the Drive exists The FATAL ERROR contact is normally used to open a contactor supplying AC power to the SAM system upon occurrence of a fatal error Motor Overtemperature Protection An isolated thermal sensor input compatible with thermal switches and PTC positive temperature coefficient resistors in
100. y cycle Internal DB resistance M 70 70 Additional no load losses WI 15 15 15 15 15 15 24 VDC Supply Rated voltage Vac 24 Tolerance Voc 19 2 30 0 Typical input current A 0 8 Max input current A 1 0 Switch on current A 2 5 About PAM with SAM DOC 9032011852 Rev April 8 1999 Page 73 EM THE SAM SUPPLY Electrical Inputs and Outputs all units SAM P 400 SAM P 480 341 30E 80 304 30E 80E Reset Input Type non isolated 24 VDC input type 1 IEC1131 2 0 3 5 0 9 1 mA Von 15 30 10 typ Impedance to ground kQ 20 Outputs overtemp overvoltage etc Type non isolated 24 VDC output type IEC1131 2 short circuit protected Rated voltage 24 OFF leakage current mA 0 4 ON continuous output cur mA 120 rent Max voltage drop 2 Fatal Error Type relay output floating contacts normally open closed if no fatal error Max current A 1 Max voltage 60 Vpc 125 Vac Max power IW About PAM with SAM Page 74 DOC 9032011852 Rev April 8 1999 ABOUT THE SAM SUPPLY LS Environmental Limits all units SAM P 400 SAM P 480 30 1 30 E 80 E 30 1 30 E 80 E Climate Pollution degree 2 Operating Class B3 IEC 654 1 3K4 721 3 Transport and storage Ambient Temperature Class n a IEC 654 1 2K4 721 3 Operating 5 40 C air tempera

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