TRANS-O1 TRANSFER LINE CONTROL USER'S MANUAL
Contents
1. mmm TRANS 01 N TRANSFER LINE CONTROL USER S MANUAL Jae Den O O M REXROTH INDRAMAT E IA 30058 Precision Control For Automation Rev D 2 90 COPYRIGHT C 1981 1982 1983 1985 1986 1990 BY INDRAMAT DIVISION THE REXROTH CORPORATION PUBLICATION NUMBER IA 30058 REVISION D FEBRUARY 1990 All rights reserved No part of this publication may be reproduced stored in a retrieval system e g in memory disk or core or be transmitted by any means electronic mechanical photocopy recording or otherwise without prior written permission from the publisher IA 30058 Rev D 2 90 RECORD OF REVISIONS Revision Level Date Description of Change 12 81 Preliminary Version A 05 82 Original Release B 02 83 Updated to reflect TRO4 amp TROS software changes C 06 86 Updated to reflect version TR1X 003 X and TR2X 003 X software changes optional rotary motion control description and optlonal feed adaption descriptions added in Chapter 9 D 02 90 Updated version NOTE A TRANS 01 control with earlier revision level software than TR1X 003 X or TR2X 003 X may not include all functions described in this manua and differences may be noted in certain other functions IA 30058 Rev D 2 90 FOREWORD SPECIAL NOTATIONS Special notations are used throughout this manual to assist the reader in identifying unique conditions or important information There are three categories of notation NOTE Used for im2. DSC1 MAC TRANS 01 DE 0629 D 5 KDV KDS MAC TRANS 01 DE 0627 D 6 SPINDLE AXIS INTERCONNECT BE 1110 D 7 TANDEM TRANS 01 E STOP CHAIN AE 1019 D 8 KDA RAC SERVO INTERCONNECT AE 1022 D 9 IEM 2 INTERCONNECT AE 1021 D 10 46 IEM 3 INTERCONNECT AE 1012 D 11 ROV 01 S INTERCONNECT 109 0584 3601 00 01A D 12 ROV 01 BLOCK DIAGRAM 109 0584 3701 00A D 13 Rev D 2 90 IA 30058 TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Paragraph Title Page Appendix E MECHANICAL DRAWINGS OF TRANS RELATED COMPONENTS DRAWING NAME DRAWING NUMBER IEM 2 109 0588 4001 00A E 2 IEM 3 109 0617 3001 00A E 3 ROV O1S 109 0584 3001 00 01A E 4 Appendix F PROGRAMMING WORKSHEETS Rev D 2 90 TA ANNARRA CHAPTER 1 GENERAL DESCRIPTION 11 INTRODUCTION 1 1 1 General The TRANS 01 is a microprocessor based programmable control designed for control of transfer lines and flexible machining systems The basic function of the TRANS 01 control is the numerical control of an INDRAMAT AC servo drive as a feed drive operating a slide as well as the control of program dependent switching functions It is supplied in a rigid compact sealed enclosure designed for wet machining environments and can be mounted directly on the machine for true distributed control The TRANS 01 is intended for remote operation where it is controlled by the customer s Line Control usually a computer or a programmable controller which controls the entire transfer line The fu
3. Programmed motions Single cycle Emergency home Operator Interface Operation using pushbuttons mounted on an operator control panel external to the TRANS 01 Functions Include Programmed forward motion via pushbutton Programmed reverse motion via pushbutton Move to toolchange position Set up Operation Operation using the keyboard of the TRANS 01 Functions Include Homing Continuous operation Single block operation Single cycle operation Jogging forward and reverse IA 30058 1 6 Rev D 2 90 1 3 DISPLAY MODES The TRANS 01 control provides the following display modes for programming program testing checking system status and operator and service support 1 Block display for Programming Program review Display of the current block during program execution 2 Display of actual position actual feedrate and actual auxiliary function status 3 Display of commanded position destination programmed feedrate and programmed auxiliary function status 4 Display of following error deviation feedrate override and existing discrepancies between commanded auxiliary functions and their respective expected acknowledgments 5 Display of current programmed feedrate feedrate override BCD output currently selected tool correction register number and current reverse vector block number 6 Status and fault diagnostics 7 Tool correction display mode 1 4 ENGLISH LANGUAGE PROGRAMMING T
4. special commands or software can be used to enable a second spindle axis adaptive feed adaptive depth or rotary programming see Chapter 9 for details 1 1 2 Programming The TRANS 01 control can be programmed using two methods 1 Its operator keyboard display panel 2 Via Indramat s optional Line Control Adaptor LCA a microprocessor based serial bus driver RS 422 1 1 2 1 Line Control Adaptor Indramat s Line Control Adaptor LCA is designed to communicate simultaneously over an RS 422 serial link with up to 30 TRANS 01 controls on a high production line The LCA receives data such as slide position diagnostics I O status etc from each connected TRANS 01 and buffers the information in its RAM memory An RS 232C port on the front of the LCA connects to a user supplied device used to manipulate the data This device can range from a dumb terminal to a large computer Once connected to the LCA this device called the Line Control can reguest and obtain status information from any or all TRANS 01 controls on the line It can upload complete part programs parameters and tool corrections Additionally the Line Control can transmit programs parameters and tool corrections to any TRANS 01 on the bus and transmit commands such as Start Enable and Homing Complete information on the Line Control Adaptor including instructions on how to transmit programs parameters and commands to the TRANS 01 over the RS422 serial channe
5. 3 8 4 Interaction of Drive Stalled Tach Fault and P wo n Encoder Fault CHAPTER 9 TRANS 01 OPTIONS 9 1 Parameter Selectable Options 9 3 9 1 1 Spindle Control 9 3 9 1 1 1 Spindle Control Associated Parameters 9 4 9 1 1 2 Spindle Control Programming 9 7 9 1 1 3 Spindle Control Associated Signais 9 7 9 1 1 4 Spindle Control Diagnostics 9 9 9 1 1 5 Spindle Control Examples 9 10 9 1 2 Jump On Event 9 12 9 1 2 1 Jump on Event Programming 9 12 IA 30058 Rev D 2 90 TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Paragraph Title Page 9 1 2 2 Resetting the Excessive Thrust Output with Jump on Event 9 17 9 1 2 3 Jump on Event Examples 9 17 9 1 3 External Tool Correction 9 22 9 1 3 1 Theory of Operation 9 22 9 1 3 2 Bit Values 9 23 9 1 3 3 Suggested Interconnection of External Correction Input Option 9 25 9 1 3 4 Parallel Interface Module I 9 27 9 1 3 4 1 Specifications 9 27 9 1 3 4 2 Input Circuit Block Diagram 9 27 9 1 3 4 3 Input Connections 9 27 9 1 3 4 4 Installing the PIM 9 28 9 1 4 Linear Scale 9 29 9 1 4 1 Pre TRxx 5 0 Formulas 9 29 9 1 4 2 Pulse Weight 9 29 9 1 4 3 Post 5 0 Procedures 9 30 9 2 Software Selectable Options 9 31 9 2 1 Rotary Motion Control TR23 9 33 9 2 1 1 Associated Parameters 9 33 9 2 1 2 Mechanical Considerations 9 34 9 2 1 3 Programming Rotary Motions 9 34 9 2 1 4 Homing and Zero Offset NC code GO 9 34 9 2 1 5 Positioning NC code G1 9 34 9 2 1 6 Clamping 9 35 9 2 2 f
6. logic An EPROM memory for the executive program and a RAM memory for user programs and data protected against power failure by lithium battery backup Numerical control interface for the axis with input circuitry for the incremental position encoder travel limit switches and homing switch Input output bus interface for the Line Control Signal interface for an Operator Station panel Control and monitoring for up to 8 auxiliary functions TA 30058 1 9 Rev D 2 90 1 8 TECHNICAL DATA Dimensions and Physical Specifications TRANS 01 cabinet specifications Height Width Depth Weight Power reguired Power consumption Maximum ambient temperature Control interconnections Scan X vm VS ah ta AY ey LeS pun Gms ge bieck Control Specifications Number of axes controlled Dimensioning system Programming resolution Maximum traverse distance Feedrate Rapid traverse rate Maximum system speed Maximum rapid traverse rate Jogging Number of program blocks Repetition cycles block Programmed tool position corr Dwell time Aux functions Adjustable machine parameters Subroutine nesting Self diagnostic conditions IA 30058 16 14 in 410 mm 12 60 in 320 mm 6 2 in 155 mm for plug in connectors 30 0 lb 13 6 kg 115 220 Vac 20 50 60 Hz approximately 60 watts 45 C 113 P via sealed plug in connectors JA V 104 t sv Lom one inch or metric 0 0001 inches 0 001 mm 838 8600
7. which are used to adapt the control to the characteristics of a particular machine To enter a control program to perform the reguired machine functions To enter tool correction values For operation of the control in Single Cycle Single Block and Hand Modes For display of diagnostic codes which indicate the nature of any problems detected in the machine control motor and feedback loop 1 6 USER ACCESS LEVELS Access to the TRANS 01 functions is for practical needs divided into 5 levels They are interlocked to provide the widest possible margin of safety to prevent misuse of the control These access levels are 1 Engineering Interface At this level the TRANS 01 control is adapted to the drive and machine via direct input of parameters using the TRANS 01 keyboard display panel Because the entry of incorrect data can result in damage to the machine access at this level is possible only by unlocking the TRANS 01 cover and using the Parameter Keyswitch to enable Parameter Entry Edit Mode Parameter entry is described in Chapter 4 Programmer Interface At this level the control program is entered and possibly edited in Dialog Mode This program must be protected from accidental or intentional alteration by unauthorized personnel Thus access to the user program can be made only by unlocking the TRANS 01 cover and utilizing the Programming Keyswitch to enable Programming Entry Edit Mode Programming is described in Chapte
8. Feed Adaption Control TR24 9 37 9 2 2 1 Associated Parameters 9 37 9 2 2 2 Programming Adaptive Feeds 9 38 9 2 2 3 Idle Detection 9 38 9 2 2 4 Feed Adaption 9 39 9 2 2 5 Associated Signals 9 43 9 2 2 6 Diagnostics 9 44 9 2 2 7 Required Hardware 9 45 9 2 2 8 Example 9 45 9 2 3 Adaptive Depth Control TR25 9 47 9 2 3 1 Associated Parameters 9 47 9 2 3 2 Assotiated Parameters 9 47 9 2 3 3 Installing the Adaptive Depth Control Option 9 48 9 2 3 4 Programming the Adaptive Depth Control Function 9 49 9 2 3 5 Linear Encoder Deflection 9 52 9 2 3 6 Typical Program Structure 9 53 9 2 3 7 Illustration 9 54 9 2 4 Feed Ramp Option TR22 9 57 9 2 4 1 General Description 9 57 IA 30058 Rev D 2 90 Paragraph 9 2 4 2 9 2 4 3 9 2 4 4 9 2 4 5 9 3 9 3 1 9 3 2 9 3 2 1 9 3 2 2 9 3 2 3 9 3 2 4 9 3 2 5 9 3 2 6 9 3 2 7 9 3 2 8 9 3 2 9 9 3 3 9 3 3 1 9 3 3 2 9 3 3 3 IA 30058 TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Title Installing the Option Parameter Programming the Feed Ramp Modified Auxiliary Output Functions Hardware Options The LCA TRANS 01 Eprom Programmer Introduction Available Functions Start up Programming the EPROMS Output write Data Into an EPROM Comparing EPROM contents with TRANS 01 Data Downloading Data into the TRANS from EPROM Installing EPROMs in the TRANS 01 Fault Indication and Diagnostics on the EPROM Programmer TRANS 01 Interface Modules General Description AC Input M
9. ameter Values 4 25 4 6 Parameter Entry 4 26 4 7 Parameter Error Checking 4 27 CHAPTER 5 PROGRAMMING 5 1 General 5 1 5 2 which can be Programmed 5 1 5 3 Application Programming Requirements 5 2 5 3 1 Start of the Program 5 2 5 3 2 End of the Program 5 3 5 3 3 Basic Homing Program 5 3 5 3 4 Too1 Change Program 5 4 5 3 5 Homing and Zero Offset NC Code GO 5 5 5 3 6 Positioning NC Code G1 5 5 5 3 7 Lag Finishing During Positioning 5 6 TA ANNARA Rav N 2 9N Paragraph 5 3 8 5 3 9 5 3 10 5 3 11 3 12 5 3 13 5 3 14 5 3 14 1 5 3 14 2 5 3 14 3 5 3 14 4 5 3 14 5 5 3 15 5 3 15 1 5 3 15 2 5 3 15 3 5 3 15 4 5 4 5 5 5 5 1 5 5 2 5 5 3 5 5 3 1 5 5 3 2 5 5 3 3 5 5 3 4 5 5 3 5 5 5 4 5 6 5 7 5 7 1 5 6 2 6 1 6 2 6 2 1 6 2 2 6 3 6 3 1 6 3 2 6 3 3 IA 30058 TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Title Feedrate NC Code F Dwell NC Code G4 Feed to Positive Stop NC Code G5 Tool Corrections NC Code T Auxiliary Functions BCD Output NC Code B Program Jumps Unconditional Jump NC Code JN Jump to Subroutine NC Code JU Conditional Jump NC Code JC Jump and Stop NC Code JS Reverse Vector NC Code JR Block Repeat NC Code E Programming the Jump on Event Program Block Repeat NC Code E Spindle Speed Control NC Code S Spindle Positioning NC Code P Program Data Programming Display Program Blocks Block Display Mode Program Block Function Homing Posi
10. amming Worksheet Adaptive Depth Control Interconnection EXE 602 pulse shaper dimensional drawing Example of Linear Encoder Deflection Profile of Operation Using Adaptive Depth Control Adaptive Depth Control Programming Worksheet Adaptive Depth Control Programming Flowchart EPROM Programmer Outline Drawing Program Parameter EPROM Insertion Rev 1 l 0424045 KUN w F D O O i j G gt 150 eh O i Oon 9 16 9 18 T l 1 O t agen B GO O wh N RD OI O tOo O 0 3 0 N he 200009 O O 1 1 amp a Cw D 2 90 TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Paragraph e Title Page Table No Title Page 4 1 Parameter Limit Formulas 4 4 9 1 Bit Values for Positive Correction 9 25 9 2 Options 9 31 Appendix A PARAMETER RECORD SHEETS Parameter Record Sheet TRO4 TRO6 TRO7 Software A Parameter Record Sheet TRO5 Software A Parameter Record Sheet TRIX Through TR2X Software A Parameter Record Sheet TR2X 3 0 and Above A Appendix B HARDWARE AND SOFTWARE TYPE CODE KEYS TRANS 01 Hardware Type Code Key B 1 TRANS 0i Executive Software Type Code Key B 3 TRANS 01 Executive Software Detail B 4 Appendix C TRANS SYSTEM CABLE REOUIREMENTS System Cable Requirements C 2 Trans 01 Cables C 7 Appendix D INTERCONNECTS AND BLOCK DIAGRAMS DRAWING NAME DRAWING NUMBER TVM TDM MAC TRANS 01 209 0036 1603 10A D 3 DSC3 MAC TRANS 01 209 0030 1715 02A D 4
11. er Interrupt Handling 6 19 CHAPTER 7 MOUNTING AND INSTALLATION 7 1 General 7 1 7 2 Arrangement and Installation of Electrical Equipment 7 1 7 21 Distributed Control 7 1 e 7 2 2 Mounting Considerations 7 2 7 2 3 Heat Dissipation 7 2 7 2 4 Requirement for External Voltage Source 7 2 7 2 5 Rules for Installation 7 4 IA 30058 Rev D 2 90 TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Paragraph Title Page 7 3 Mounting the Servomotor 7 4 7 4 Establishing a Position Reference 7 4 7 4 1 General 7 4 7 4 2 Reference Homing Procedure 7 5 7 4 3 Slide Mechanics Requirements 7 7 7 4 4 Placement of the Reference Position 7 7 7 4 5 Position the Home Limit Switch 7 7 7 4 6 Actuating the Home Limit Switch 7 7 7 5 Limit Switch Positioning on a Numerically Controlled Axis 7 8 7 5 1 Primary Overtravel Limit Switches 7 8 7 5 2 Home Limit Switch 7 10 7 5 3 Safety Emergency Limit Switch 7 10 7 6 TRANS 01 Input Output Circuits 7 11 TA Checkout Motor Direction Polarity on Start up 7 15 7 8 Spindle Drive Control 7 15 7 8 1 Spindle Drive System Reguirements When Using Spindle Positioning 7 16 7 8 2 Spindle Drive Installation and Start up 7 16 CHAPTER 8 DIAGNOSTICS 8 1 General 8 1 8 2 Types of Diagnostic Messages 8 1 8 2 1 Normal Status Diagnostics 8 1 8 2 2 Temporary Fault 8 1 8 2 3 Soft Fault 8 2 8 2 4 Hard Fault 8 2 8 2 5 External Fault Reset 8 2 8 2 6 Extended Diagnostic Messages 8 3 8 3 Diagnostic Messages 8
12. faults or disturbances are detected the control switches to the Diagnostic Mode shuts the system down and issues a simple English language diagnostic message on the control panel display This aids in the quick determination and correction of faults A special advantage is that the control records causes of intermittent problems which may already have disappeared again and also diagnoses and identifies faults which trigger sequential events such as loss of main power This aids in guick correction of faults by plant personnel rather than specialized electronic technicians With the addition of the Line Control Adaptor and TRXX version 6 X and above the customer has the option of choosing his own extended diagnostics The user can select up to 9 additional messages in addition to the standard TRANS diagnostics This enables the user to pinpoint problems and suggest remedies that are unigue to the machine itself For example 1 Ackn Inp 7 wait on lt Normal Status Diagnostic 2 Check wire 32 for output 3 Check wire 40 for signal The diagnostic status of the control can be interrogated at any time even when no error is present by selecting Diagnostic Display Mode Thus normal status indications such as NO START can be observed and causes of interruptions which do not appear as errors such as the control waiting for an auxiliary function acknowledgment can be determined In on line operation the fault can be detected by the
13. he basic program for standard motions is preprogrammed The user simply prepares a program of up to 128 motion control blocks each consisting of up to 9 operating commands such as type and length of axis movement feedrate homing BCD outputs dwelis and auxiliary operations Jump programming including a jump based on external inputs and repetition of one or a number of commands is easily selected for programming cyclic operations Tool position corrections can be programmed to allow operator compensation for tool wear When using numeric controls programming a control requires the memorizing of many NC codes and symbols that are recognizable by the control but not particularly meaningful to the operator This problem is eliminated in the TRANS 01 by using simple English language dialog programming The TRANS 01 talks with the programmer requesting him to select a function then prompting him through the entry of the information required to perform that function using simple English prompts in the operator panel display IA 30058 1 7 Rev D 2 90 1 5 OPERATOR KEYBOARD DISPLAY PANEL The TRANS 01 is simple and easy to program The operator keyboard display panel contains all controls and indicators necessary to program and operate the control The program keys are identified with ISO symbols which indicate their function The keyboard display panel is used 1 To enter parameters such as maximum feedrate rapid traverse rate etc
14. in 8388 600 mm programmable programmable 0 1 to 3276 7 in min 1 0 to 32767 mm min 19 600 in min 196000 mm min forward reverse up to 128 up to 99 up to 20 programmable from 0 01 to 99 99 sec individually programmable on off up to 8 include encoder pulses motor rev maximum feedrate jog speed inch metric units auto home direction reversal zero reference position rapid traverse rate jogging speed motor direction reversal etc up to 16 deep detection of over 75 possible malfunctions including encoder fault invalid system parameter motor overtemperature limit switch activated servo voltage error normal stop enable signal missing auxiliary function acknowledgment missing memory overflow etc 1 10 Rev D 2 90 Interface Requirements Input signals Output signals Parallel cycle interface Parallel operator interface Servo interface Auxiliary functions acknowledgments RS422 serial interface IA 30058 24 Vdc Imin 0 01 A isolated from internal control circuitry 24 Vdc Imax 50 mA Cycle Interface and BCD outputs 150 mA auxiliary outputs per output short circuit protected isolated from internal control circuitry used to exchange control interlock and status information with a Line Control used for control signals to from a local Operator Station provides control of a servo drive with incremental position feedback and inputs for home and overtravel limit switche
15. l can be found in Indramat Publication IA 74706 1 1 2 2 Programming with EPROMS An EPROM is prepared by first manually entering the user program into the TRANS 01 control then burning this program into the EPROM using the optional EPROM programmer on the LCA The EPROM can then be inserted into a socket on the back of the TRANS 01 to provide a permanent program can be used with the EPROM programmer to enter the program into the CMOS RAM memory of another TRANS 01 control or can be stored for program backup An EPROM can be erased off line with an ultraviolet light then can be reprogrammed and reused IA 30058 1 3 Rev D 2 90 1 1 3 Keyboard Display Panel The standard control is eguipped with a keyboard for programming start up and service and with an alphanumeric display for display of current program data axis position data system status diagnostics and program information Using simple English commands the TRANS 01 user program is entered via the keyboard directly into the CMOS RAM memory of the control Program changes and editing of program data are accomplished in the same manner directly at the control panel 1 1 4 Diagnostic Monitoring The TRANS 01 control continuously monitors all important functions of the system for correct operation This includes all inputs outputs operating voltages axis components servomotor tachometer incremental encoder limit switches parameters and the user program When operating
16. master control via the data bus 1 1 5 Adaptability of the Control The TRANS 01 is integrated to the machine and the drive by entering various parameters when the system is initialized e g maximum feedrate accel decel rate incremental encoder cycles per revolution etc IA 30058 1 4 Rev D 2 90 This feature allows drive conditions and positioning resolution characteristics for a number of different machines to be adapted to a single type of control with the control then producing correct position gain Thus standard programming procedures are maintained regardless of machine structure With this system ballscrew pitch and gear ratios can be chosen based solely on thrust needs and desired rapid traverse rates Thus feed drives and position encoders can be standardized This concept permits standard components to easily be adapted to differing machine requirements reduces requirements for spares and allows quick and easy replacement of controls by plant electricians if service is necessary SPINDLE DRIVE CONTROL With TRANS 01 controls containing TRxx 004 0 or later Executive Software in addition to the standard axis a spindle drive may be controlled via the TRANS Spindle speeds can be entered in any block in a user program directly in spindle drive train output speed e g tool RPM Velocity commands are performed using a standard 0 10V analog command signal As with the axis drive monitoring of the spindle motor and it s con
17. nction of the Line Control is to convey commands to and receive information from each TRANS 01 in the system It can do this using discrete wires to each TRANS the parallel Cycle Interface or it can use Indramat s optional Line Control Adaptor LCA and communicate using one RS 232 serial channel throughout the system The Cycle Interface provides control lines for one TRANS 01 while the Line Control Adaptor LCA can communicate with up to 30 TRANS controls receiving status and position data transmitting commands and transferring programs and parameters The Line Control can control the TRANS via the LCA or the LCA can be used to monitor position and status information for display with the actual control handled over the Cycle Interface This is determined by setting up TRANS parameters The TRANS 01 can be operated both on line controlled by the Line Control and off line controlled from an Operator Station mounted on the transfer unit and or by the keyboard display panel of the TRANS 01 itself A typical system consists of an Indramat TRANS 01 Control a model MAC AC Servo motor with integral incremental encoder for position feedback and a Servo Controller amplifier such as a DSC Compact Controller Complete interconnect cable sets are also available from Indramat Components are chosen to best fit the required application and are matched through plug in personality modules to provide optimum performance without further field adj
18. odules AC Output Modules ar ee dees es se O 0 0 0 0 0 N 5 200 00 0 0 80 D anon Rev D 2 90 Paragraph Figure No I j One MH HH ja I DN O 3 0 wear i O Qn A G gt T J 9 8 9 10 9 11 9 12 9 13 9 15 9 22 9 23 9 24 9 25 9 26 9 27 9 28 9 29 9 30 IA 30058 TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Title List of Figures Title TRANS 01 System Block Diagram TRANS 01 Control Panel TRANS 01 Keyboard with Labels for ISO Key Symbols Display Mode Keys Typical Emergency Stop Circuit Example of Auxiliary Function Timing TRANS 01 Outline Drawing Homing Motion Profile Transfer Unit Design Criteria Limit Switch Positioning Typical TRANS 01 Input Output Circuits Spindle Control Programming Worksheet Speed Profile when Jump on Event signal is received with a Direction Reversal Programmed Speed Profile without direction reversal Programming example and program sequence Jump on Event signal before the program Start is rec d Jump on Event signal received and released before the Start is received Jump on Event signal received during an Enable Forward signal Jump on Event signal before a Homing signal is rec d Programming Worksheet External Tool Correction Option Parallel interface module mounting outline Executive EPROM locations in TRANS 01 Programming Worksheet Rotary motion control software KDS Personality Module Adaptive Feed Progr
19. portant information concerning operation exceptions or other detailed information not covered previously CAUTION Used when conditions exist which could cause damage to the equipment WARNING Used when conditions exist which could result in personal injury Please note that due to the variations in applications operating conditions and work environment the special notations in this manual cannot identify all potential problems or hazards Caution and discretion must always be used in operating machinery and with the use of electrical power Equipment should only be installed and operated by trained personnel Installation and training services are available from Rexroth Indramat TA ASAFA Dar DY 9 aNn Paragraph 1 1 1 1 1 1 1 2 1 1 2 1 1 1 2 2 1 1 3 1 1 4 1 1 5 1 1 6 1 2 1 3 1 4 1 5 1 6 1 7 1 8 2 1 2 2 2 3 2 4 2 9 2 6 2 8 2 9 2 10 2 11 3 1 3 2 3 3 3 4 3 4 1 JA 30058 TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Title CHAPTER 1 GENERAL DESCRIPTION Introduction General Programming Line Control Adaptor Programming with EPROMS Keyboard Display Panel Diagnostic Monitoring Adaptability of the Control Option Operation Modes Display Modes English language Programming Operator Keyboard Display Panel User Access Levels System Elements Technical Data CHAPTER 2 TRANS 01 CONTROL PANEL DESCRIPTION General 32 Character Alphanumeric Display Display Mode Selec
20. r 5 Toolsetter Interface Because special knowledge is needed for the toolsetter level the TRANS 01 keyboard display is accessible only by unlocking the panel cover The toolsetter can then examine the program and parameters operate the manual controls and enter tool correction values as described in Chapter 3 He cannot change the program or parameters without using an additional keyswitch to separately enable each of those modes IA 30058 1 8 Rev D 2 90 4 Operator Interface Because it is necessary for an Operator to have access to Manual Mode controls in the course of normal operation the TRANS 01 includes a parallel interface for a unit Operator Station This station and its contro buttons and switches is provided by the machine builder Normal programmed movements including forward reverse homing and move to toolchange position can be commanded from this station assuming the necessary enables are provided by the TRANS 01 Operator functions are described in Chapter 3 5 Cycle Interface For operation of the TRANS 01 by the customer s Line Control it is equipped with a parallel cycle interface over which operating commands can be transmitted In Automatic Mode all controls of the TRANS 01 occurs either via this interface or the optional Line Control Adaptor The Cycle Interface is described in Chapter 6 1 7 SYSTEM ELEMENTS The TRANS 01 Control System includes The control computer with diagnostic system and monitor
21. rogram be interrupted by an external signal or event and from that point continue in a different manner Beginning with TRxx 005 0 TRANS Executive Software will include this option IA 30058 1 5 Rev D 2 90 1 1 6 Options A number of options are available with the TRANS 01 including EPROMS for permanent storage of programs and parameters an EPROM programmer and interface for 115 Vac signals By installing the appropriate optional software adaptive depth control feed adaption rotary motion control or feed ramp capabilities are provided In addition the TRANS can be set to provide external tool correction linear scale feedback and an analog output for spindle control Options including interfacing and programming are discussed in Chapter 9 1 2 OPERATING MODES The TRANS 01 is a complete NC control and can be operated off line or can be tied to a Line Control system over a data bus This permits the TRANS to be employed for completely self contained tasks When complete processing lines are put into initial operation this off line capability allows initial operation and testing of each distributed processing TRANS 01 unit even before the Line Control installation has been completed The following modes of operation are provided by the TRANS 01 for execution of its control functions Automatic Operation Remote operation via the Cycle Interface signals supplied from the customer s Line Control device Functions Include
22. s used for direct control and acknowledgment of program dependent switching functions used for high speed communication with Indramat s Line Control Adaptor LCA Functions include program or parameter downloading or uploading status and diagnostics reporting and line operation 1 11 Rev D 2 90
23. tion Keys Programming and Parameter Mode Keys Programmable Function Keys Jog Keys Keyswitches Miscellaneous Function Keys Numeric Keypad Power Indicators Operation Mode Keys CHAPTER 3 OPERATING THE TRANS 01 CONTROL General Operator Functions Toolsetter Display Functions Block Display Mode t l l A O O O l e OWMWPMAIAADA LH j gt i O F ji jami k jani F PF 2 F K l 1 1 a ur De a O 0 O OO I p t ee ee p gt Do TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Paragraph Title Page 3 4 2 Actual Position Display Mode 3 6 3 4 3 Destination Position Display Mode 3 6 3 4 4 Deviation Display Mode 3 6 3 4 5 Feedrate BCD Output and Tool Display Mode 3 7 3 4 6 Diagnostics Mode 3 7 3 4 7 Tool Correction Display Mode 3 7 3 5 Display Program Blocks 3 8 3 5 1 Block Display Mode 3 8 3 5 2 Feedrate Spindle and Tool Display Mode 3 9 3 6 Display Parameter Values 3 9 3 7 Jogging Controls 3 10 3 8 Selecting Feedrate Override 3 11 3 9 Selecting Feedrate Override 3 11 3 10 Entering Tool Corrections 3 11 3 11 Clearing Faults 3 13 CHAPTER 4 READING ENTERING SYSTEM PARAMETERS 4 1 General 4 1 4 2 Parameter Numbers 4 1 4 2 1 The Effect of Software Revision Levels on Parameter Numbers 4 1 4 2 2 Scrolling the Parameter Display 4 1 4 2 3 Checking for Software Revision Level 4 2 4 3 Parameter Limit Formulas 4 4 4 4 TRANS 01 Parameter List 4 5 4 5 Display Par
24. tioning Dwell Feed To Positive Stop Miscellaneous Functions Program Editing Procedures Programming Flowcharts Programming Examples Example Program 1 Example Program 2 CHAPTER 6 FUNCTIONAL DESCRIPTIONS General Enables Enable Enable Forward Operator Interface Automatic Manual Forward Return Reverse Rev is D 1 F M m U 00 00 0 l moo PD R D 2 90 TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Paragraph Title Page 6 3 4 Toolchange 6 5 6 4 Cycle Interface 6 5 6 4 1 Enable amp Enable Forward 6 5 6 4 2 Start 6 6 6 4 3 Homing 6 6 6 4 4 Restart 6 7 6 4 5 Ready 6 7 6 4 6 Run 6 8 6 4 7 Home 6 8 6 4 8 Power Interrupt 6 8 6 4 9 Fault 6 9 6 4 10 Thrust Missing Available with TR24 6 9 6 4 11 Excessive Thrust Available with TR24 6 9 6 5 Brake Output 6 10 6 6 Conditional Jump Inputs 6 10 6 6 1 Jump On Event 6 11 6 7 Primary Overtravel Limit Switches 6 11 6 8 Home Limit Switch 6 12 6 9 Emergency Stop Circuit 6 12 6 9 1 Emergency Stop 6 14 6 9 2 Safety Limit Switch 6 14 6 9 3 Main Contactor Control 6 14 6 10 Auxiliary Functions 6 15 6 10 i Auxiliary Function Outputs 6 15 6 10 2 Auxiliary Acknowledgments 6 15 6 10 3 Line Control Interface Guidelines 6 16 6 11 BCD Coded Outputs 6 17 6 11 1 Spindle Ready 6 17 6 11 2 Spindle Analog Speed Command 6 18 6 11 3 Spindle Enable 6 18 6 11 4 N actual N commanded N Ncmd 6 18 6 11 5 Spindle Enable Manual Mode 6 19 6 12 Pow
25. troller is automatically performed by the TRANS and appropriate diagnostic or fault messages are displayed The TRANS intelligently monitors the spindle s speed allowing it to accelerate during a rapid traverse motion but insuring it remains within tolerance of programmed speed during other program functions Provisions are made to allow returning the slide in the event of a spindle overload or malfunction and to allow operation of the slide without the spindle operational useful in set up or tool change conditions Beginning with TRxx 005 0 TRANS Executive Software also includes the ability to command spindle positions orient the spindle by closing a position loop around the spindle motor and an incremental encoder Any position between 0 0 degrees and 359 9 degrees at the spindle drive train output e g tool may be programmed Programming resolution is 0 1 degrees A spindle position can be programmed in any block within the user program As the spindle encoder is mounted directly on the spindle drive train positions are programmed directly in spindle drive train output units e g tool position Spindle orientation can be performed when a transmission is present between the motor and output NOTE Spindle positioning may not be used in conjunction with the Adaptive Depth Control Option Executive Software TRXx5 xxx x nor with the Adaptive Feed Option TRx4 xxx x JUMP ON EVENT Certain applications require that the current running p
26. ustments Figure 1 1 is a block diagram illustrating typical system configurations IA 30058 1 1 Rev D 2 90 CUSTOMER LINE CONTROL CYCLE INTERFACE SERVO AMPLIFIER SERVO MOTOR ST1 TARANS 1 ST2 ST3 ST4 TACHOMETER FEEDBACK POSITION FEEDBACK SERVO AC POWER TO TRANS AUXILIARY OUTPUTS BCD OUTPUTS OPERATOR ACKNOWLEDGEMENTS PANEL MISC CONTROL SIGNALS OPERATOR INTERFACE TRANS 1 SINGLE AXIS INTERCONNECT SPINOLE POSITION FEEDBACK SPINOLE SPINDLE AMPLIFIER MOTOR STS CUSTOMER SERVO AMPLIFIER LINE CONTROL CYCLE INTERFACE STL TRANS 1 ST3 ST4 TACHOMETER FEEDBACK POSITION FEEDBACK SERVO AC POWER TO TRANS AUXILIARY OUTPUTS BCD OUTPUTS ACKNOWLEDGEMENTS MISC CONTROL SIGNALS OPERATOR PANEL OPERATOA INTERFACE SPINDLE BLOCK DIAGRAM WITH SPINDLE POSITIONING Figure 1 1 TRANS 01 System Block Diagram IA 30058 1 2 Rev D 2 90 Both positioning accuracy and system speed are optimized by utilizing closed loop digital positioning The axis can be positioned either incrementally or absolutely The TRANS 01 control includes a memory which can store up to 128 program blocks Each block contains up to 7 instructions which control some aspect of axis positioning They are Homing or Position Command Feedrate or Dwell Time Auxiliary Functions BCD Output Tool Correction Block Repeats and Program Jumps In addition
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