Transcript TP.MCD.09.056
Yaskawa Electric America
Understanding & Applying Camming Techniques
with
MP2000iec / MotionWorks IEC
TP.MCD.09.056
i e c Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 1
Webinar Highlights
Camming Overview
•
Core Concept
Six Essential Camming features
•
Data Management
• •
Function Blocks Parameters
• • •
Engage Modes Adjust Modes Block Diagram
Application Discussions
•
Rotary Knife
• •
Linear Flying Shear Feed to Length Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 2
Camming Overview
Mechanical Origin
• Shaft rotation • • Represents the master Typically a 360 cycle • Linear motion • Position is dictated by the angular position of the shaft • Lots of limitations with mechanical cams
3 Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC
Camming Overview
Core Concept
• Electronic Camming controls the positional relationship of two axes
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360 0 Time 0 Repeat Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 0 4
Camming Overview
That’s It!
• Everything else relates back to the core concept.
• • Positional relationship of two axes.
Master can be a servo, external encoder, or time (virtual master.)
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360 0 Time 0 Repeat Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 0 5
Camming Overview
(OK we lied) There’s more
• Master / Slave lookup table is the core with these surrounding topics • We will focus on these six supporting features
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 6
Camming Overview On the Surface….
10 Function blocks • Firmware Library PLCopen-v_2_2 All functions customized by Yaskawa • Based on: • PLCopen specification • • Previous controllers cam technology Decades of synchronized motion experience The cam engine operates at the Mechatrolink update rate.
• Camming performance not dependant on application scan rate.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 7
Below the Surface….
Camming Block Diagram
Camming Overview Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 8
Function Block Breakdown
• 4 functional topics
Camming Overview Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 9
Common Theme: CamTableID
Cam Data Management
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 10
Cam Data Management
Two basic methods for loading cam data
• • Externally generated Internally generated • • These functions are only required once per power up.
If the same cam is disengaged and re engaged, the CamTableID remains valid until Y_ReleaseCamTable or power is cycled.
11 Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC
Cam Data Management Application Task Rate Mechatrolink Update Rate Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 12
Cam Data Management External Source: Cam Tool or Excel Computer Disk Controller File System Other methods for sending files will be addressed Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC Cam Memory 13
Data Structure
Cam Data Management Watch window is a great place to verify the correct data has been applied Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 14
Code Example
Cam Data Management All Cam DataTypes included in New Project Template Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 15
Cam Engagement
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 16
Cam Engagement
Cam Masters
• • Virtual External Encoder • LIO-01, LIO-02, LIO-06 – Quadrature pulses only • • Another Mechatrolink Axis Programming is identical regardless of master type. AXIS_REF function block input is a logical reference.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 17
Cam Engagement
Capabilities & Performance
• Multiple methods for engaging based on application scenarios.
• Function block input parameter lets the programmer decide how the slave should engage to the master.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 18
Cam Engagement
Engage Modes
• • ‘AtPosition’ is ideal if the master is already moving.
‘Immediate’ is best in situations when the master is stationary, and the slaves cannot wait idle for the master to move a portion of the cycle, such as during E-Stop recovery.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 19
Cam Engagement
Starting the process
0 0 360 360 0 720 360 0 1080 360 0 1440 360 0 Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 20
Cam Engagement
Engage Window Details • The window allows for detecting the Engage Position while the master is at speed.
• Determining an optimal value • Maximum master speed * Mechatrolink rate * 2 • Extremely large window will cause the slave to jump to the corresponding cam table position.
• Master slave relationship not affected by window size.
• Extremely small window may cause the slave not to engage.
• Controller might never see the master in the window.
• Default window size is 1% of the master cycle, which is appropriate for most applications.
Small (normal) window Large (oversized) window Jump Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 21
Identical function blocks, except for one input
On-The-Fly Adjustments
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 22
On-The-Fly Adjustments
Shifting
• • Master Side Adjustment Useful when a registration mark detects products on the master axis • Slave pattern is unchanged
Master Shifting is a controlled slippage of the red cam lobe on the black shaft 23 Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC
90 degree shift On-The-Fly Adjustments Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 24
On-The-Fly Adjustments
Scaling
• • • Slave Side Adjustment Simple
Multiplier
on all data points Slave pattern can be magnified or reduced.
No way to do this on a mechanical cam!
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 25
On-The-Fly Adjustments
Slave Offset
• • • Slave Side Adjustment Simple
Addition
to all data points Slave pattern can will be the same, but repositioned over a different range.
Slave Master Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 26
On-The-Fly Adjustments Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 27
On-The-Fly Adjustments
AdjustMode
• We’ve described the three types of adjustments, now lets discuss the “When” and “What.” • When should the adjustment start?
• • When must the adjustment finish?
What is the profile from A to B?
Detailed help is available by right clicking on any function block!
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 28
On-The-Fly Adjustments Finish
AdjustModes • Three types • Master Distance – The adjustment starts immediately and completes when the master has traveled the specified Master Distance. • Within Range – The adjustment starts when the master first crosses the StartPosition and completes when the master reaches the EndPosition. • Time – The adjustment starts immediately and completes within the specified Time (in seconds).
• Same Profile • Modified Sine profile sweeps the correction profile from the current to requested adjustment.
Built into the firmware Start Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 29
On-The-Fly Adjustments Smooth Motion Adjustment s Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 30
On-The-Fly Adjustments
AdjustMode – Type 1
• Y_AdjustMode#MasterDistance • The adjustment starts immediately and completes when the master has traveled the specified relative Master Distance.
• Master speed dictates the amount of time required to complete the correction
Master Position 360 270 0 90 180 180 Degrees LREAL#72.0
Y_AdjustMode#MasterDistance LREAL#180.0
n/a n/a n/a Y_CamShift.Execute
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 31
On-The-Fly Adjustments
AdjustMode – Type 2
• Y_AdjustMode#Duration •
Good method if adjustment value known before engaging the
The adjustment starts immediately and takes place over a time period.
zero for instantaneous correction.
• This is a non-synchronized correction method.
• Correction is the same regardless of machine speed.
Master Position 360 270 0 90 180 2.5 Seconds ?
LREAL#72.0
Y_AdjustMode#Duration n/a LREAL#2.5
n/a n/a Y_CamShift.Execute
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 32
On-The-Fly Adjustments
AdjustMode – Type 3 • Y_AdjustMode#WithinRange • The adjustment starts when the master is within the StartPosition and is scaled to complete when the master reaches the EndPosition.
• This mode is for applications that must move at synchronized speeds during certain portions of the cycle
Master Position 360 270 0 90 180 LREAL#72.0
Y_AdjustMode#WithinRange n/a n/a LREAL#180.0
LREAL#270.0
Waiting… Y_CamShift.Execute
180 to 270 degrees Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 33
Axis Parameters
Crucial to establishing the proper operation by coding interlocks and other logical functions.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 34
Block Diagram Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 35
Capabilities & Performance
Capabilities & Performance
• Change cam data on the fly •
Use parameter 1541, CamTableIDEngage d in cases like this to verify the currently operating profile
CamTableID can be changed and Y-CamIn can be re-executed during motion.
– Allows for use of multiple profiles with similar, yet different characteristics.
– Pick a location where the slave data is the same for a seamless switchover.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 36
Capabilities & Performance
Capabilities & Performance
• OPC Cam data transfer • Set the cam data (Y_MS_Cam_Struct) as an OPC variable, and a PC or HMI can send updated cam data to the controller.
• Execute Y_CamStructSelect or Y_WriteCamTable to load the new cam data.
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Capabilities & Performance
Capabilities & Performance
• Hundreds of small cam tables or dozens of large cam tables can be loaded into the controller flash memory.
• Exact size dependant on other application data stored in flash, such as IEC 61131 source code.
• HTTP file transfer is another method for cam file download.
• Useful for PC HMI applications
38 Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC
Application Discussions
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 39
Application Discussion
Rotary Placer – The Placer Cycle
Product Flow 0 deg Pick Decision [A] Window Pick On Pick Position
Pick Threshold
MaxShiftThreshold 90 deg mCamShiftRemaining Place Angle Adjust Region [A] 1:1 Match Point MaxShift (PickPosition PickOn) [%] 0 deg ProductPitch (MasterCycle) ProductPitch (MasterCycle) DistToLatch
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC
Product Sensor
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Application Discussion
Rotary Placer – The Product Buffer
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 41
Application Discussion
Rotary Placer – The Cam Shift
• Uses #WithinRange adjust mode
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 42
Linear Flying Shear
• • Out & Back slave Synchronized to product by registration mark
Application Discussion Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 43
Application Discussion
Linear Flying Shear
Flat part of the speed graph is the area where the master & slave are synchronized.
Out Back Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 44
Application Discussion
Assembly Machine
• • Rotary Table Assembly Stations Camming Benefits • Station synchronization at any machine speed • Use Virtual Master if Rotary table must stop during station operation ST 3 • Variable number of operable stations ST 2 ST 1 Indexer Table 6 feet
Table Station 1 Station 2 Station 3 Station 4 Station 5 Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC
ST 8
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Application Discussion MP2300Siec Activity PC Activity
OPC or Modbus PC Cam Selector CamFile download to RAM Set Next Use Cam Info To know current cam being used Next Cam Selector Logic Check for Next Use Cam Flag Y_CamFileSelect Cam Switch Logic CamSequenceStruct MC_ReadActualPosition Y_CamIn For Needle location (Stitch #) Y_ReleaseCamTable
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC
Circular usage of cam tables controlled by Array of CamSequenceStruct
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Conclusion
• Camming with the MP2000iec series requires an understanding of these pieces:
Other Resources: EM.MCD.09.043 = Manual for Simple Cam from CSV file MC.MCD.09.044 = Example Code for Simple Cam from CSV file Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 47