Transcript MP2000iec Presentation - Camming Webinar.ppt

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Yaskawa Electric America
Understanding & Applying Camming
Techniques
with
MP2000iec / MotionWorks IEC
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC
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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
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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
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Camming Overview
 Core Concept
• Electronic Camming controls the
positional relationship of two axes
360
3.00
360
Master Position
Slave Position
3.00
0
Time
0
0
Repeat
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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.)
360
3.00
360
Master Position
Slave Position
3.00
0
Time
0
0
Repeat
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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
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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.
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Camming Overview
Below the Surface….
 Camming Block Diagram
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Camming Overview
 Function Block Breakdown
• 4 functional topics
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Common Theme: CamTableID
Cam Data Management
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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.
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Cam Data Management
Application Task Rate
Mechatrolink Update Rate
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Cam Data Management
External Source: Cam Tool or Excel
Computer Disk
Controller File System
Other methods
for sending
files will be
addressed
Cam Memory
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Cam Data Management
 Data Structure
Watch window is a great place
to verify the correct data has
been applied
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Cam Data Management
 Code Example
All Cam
DataTypes
included in New
Project Template
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Cam Engagement
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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.
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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.
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Cam Engagement
 Engage Modes
• AtPosition is better if the master is already moving.
• Immediate is 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.
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Cam Engagement
 Starting the process
1440
1080
720
360
0
0
360
360
360
360
0
0
0
0
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Identical function
blocks, except for
one input
On-The-Fly Adjustments
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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
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180 degree duration
On-The-Fly Adjustments
90 degree shift
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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!
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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
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On-The-Fly Adjustments
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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!
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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
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On-The-Fly Adjustments
Smooth
Motion
Adjustment
s
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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
LREAL#72.0
180
Y_AdjustMode#MasterDistance
LREAL#180.0
90
n/a
0
180 Degrees
n/a
n/a
Y_CamShift.Execute
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On-The-Fly Adjustments
 AdjustMode – Type 2
Good method if
adjustment value known
before engaging the
slave. Set Duration to
zero for instantaneous
correction.
• Y_AdjustMode#Duration
• The adjustment starts immediately and takes place over a
time period.
• This is a non-synchronized correction method.
• Correction is the same regardless of machine speed.
Master Position
360
270
LREAL#72.0
180
Y_AdjustMode#Duration
?
90
n/a
LREAL#2.5
0
2.5 Seconds
n/a
n/a
Y_CamShift.Execute
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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
LREAL#72.0
180
Y_AdjustMode#WithinRange
n/a
90
n/a
0
LREAL#180.0
Waiting…
180 to 270 degrees
LREAL#270.0
Y_CamShift.Execute
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Axis Parameters
 Crucial to establishing the proper
operation by coding interlocks and
other logical functions.
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Block Diagram
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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.
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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
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Application Discussions
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Application Discussion
 Rotary Placer – The Placer Cycle
Product Flow
0 deg
[A]
Pick Decision
Pick Position
Window
Pick On
Pick Threshold
MaxShiftThreshold
90 deg
mCamShiftRemaining
[A]
1:1 Match Point
Adjust Region
Place Angle
MaxShift
Product Sensor
(PickPosition PickOn) [%]
0 deg
ProductPitch
(MasterCycle)
ProductPitch
(MasterCycle)
DistToLatch
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Application Discussion
 Rotary Placer – The Product Buffer
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Application Discussion
 Rotary Placer – The Cam Shift
• Uses #WithinRange adjust mode
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Application Discussion
 Linear Flying Shear
• Out & Back slave
• Synchronized to product by
registration mark
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Application Discussion
 Linear Flying Shear
Flat part of the speed
graph is the area where
the master & slave are
synchronized.
Out
Back
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Application Discussion
ST 1
 Assembly Machine
ST 8
• Rotary Table
• Assembly Stations
ST 2
Indexer Table
ST 3
 Camming Benefits
6 feet
• Station synchronization at any
machine speed
• Use Virtual Master if Rotary table
must stop during station operation
• Variable number of operable stations
Table
Station 1
Station 2
Station 3
Station 4
Station 5
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Application Discussion
PC Activity
MP2300Siec Activity
OPC or
Modbus
PC Cam
Selector
CamFile
download
to RAM
Set
Next Use
Cam Info
Check for
Next Use
Cam Flag
Y_CamFileSelect
Cam Switch
Logic
To know
current cam
being used
Next Cam
Selector
Logic
Y_CamIn
Y_ReleaseCamTable
For
Needle
location
(Stitch #)
CamSequenceStruct
MC_ReadActualPosition
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
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