Rod 431 Rotary Pulse Encoder

This encoder has two output channels (U a1 and U a2) which are phase shifted by 90. The encoder has 1024 increments per revolution. Channel U a0 is a reference pulse which occurs once per revolution. When power is initially applied to the servomotor the drive will not know the exact position of the rotor. Rotor position can only be calculated within one revolution once the zero reference mark has been crossed the first time. Because synchronous servomotors must know rotor position within one revolution this encoder can only be used with 1PH7, 1PL6, and 1PH4 asynchronous servomotors.

By comparing channel U a1 and U a2 the drive can determine which direction the motor is running.

51

ERN 1387/1381 Encoders

The ERN 1387 encoder has four tracks and a reference pulse. A1 channel produces one sine signal per revolution and B1 channel produces one cosine signal. These signals are used to determine exact rotor position from initial power up within one revolution. After each revolution the calculated position is adjusted to the position indicated by the reference pulse position, if necessary. This encoder is suitable for use with all Siemens synchronous and asynchronous motors. The 1381 encoder is a two-channel device which does not produce A1 and B1 signals. The 1381should be used only with asynchronous servomotors. Tracks A and B on both encoders produce a sinewave output of 2048 microperiods per revolution. Evaluation electronics within the MASTERDRIVE MC can increase the resolution to 16.8 x 106 periods per revolution (ppr).

52

EQN 1325 AbsoluteValue Encoder

The EQN 1325 absolute value encoder is made up of two sections. The outer ring is identical to the ERN 1387 and is used to provide speed and direction information. Two output channels, A and B, produce 2048 periods per revolution. Channel B is offset from channel A by 180 degrees. The drive can determine which direction the motor is running by comparing channel A with channel B. A second feature of the EQN 1325 is the coded inner rings. These provide a unique code for 8192 positions. This unique code is sent to the drive via an EnDat interface. The drive uses this unique code number to determine rotor positon.

In addition, the encoder uses a mechanical gear sequence to count up to 4096 revolutions and store them. As long as the distance the application moves is less than 4096 revolutions there is no need to home the application as the absolute position is always known by the encoder count. As soon as it counts 4096 revolutions the encoder starts counting again from zero. These encoders are designed for use with synchronous and asynchronous servomotors.

53

Two-Pole Resolver

A resolver is similar to an encoder, but instead of using a photoelectric sensor a rotating transformer is employed. The primary is located on the rotor of the resolver. Two secondary windings, arranged at right angles to each other, make up the stator. The amplitude of the sinewave induced into each stator winding depends on the angular position of the rotor winding. Since the amplitude variations available at the stator windings are 90 apart, one signal is called a sine signal and the other is called a cosine signal. The sine signal and the cosine signal are both applied to the MASTERDRIVE MC. By comparing the two signals, the MASTERDRIVE MC can determine the angular position of the rotor and its direction of rotation. Each revolution of the rotor is divided into 4096 increments. Once the initial position of an axis is determined by finding a home position, exact position of an axis will be tracked by the MASTERDRIVE MC over multiple revolutions of the resolver. Two-pole resolvers are designed for use with synchronous and asynchronous servomotors.

54

Pulse Width Modulation

Before discussing the MASTERDRIVE MC it is necessary to know something about Pulse Width Modulation (PWM). Pulse width modulation is one type of technology used by AC drives, such as the MASTERDRIVE MC. PWM drives convert a fixed voltage, fixed frequency into a variable voltage, variable frequency output to control the speed of an AC motor. Pulse width modulation provides a more nearly sinusoidal current output to control frequency and voltage supplied to an AC motor than other technologies. PWM drives are more efficient and typically provide higher levels of performance than other drives. A basic PWM drive consists of a converter, control logic, and an inverter.

55

Converter

The converter section consists of a either a fixed diode bridge rectifier or a thyristor bridge rectifier which converts the threephase power supply to a DC voltage. The C1 capacitor(s) smooths the converted DC voltage by limiting current peaks and reducing harmonics. The rectified DC value is approximately 1.35 times the line-to-line value of the supply voltage. For example, the rectified DC value is approximately 650 VDC for a 480 VAC supply.

Control Logic and Converter

Output voltage and frequency to the motor are controlled by the control logic and inverter section. The inverter section consists of six switching devices. Various devices can be used such as thyristors, bipolar transistors, MOSFETS and IGBTs. The following schematic shows an inverter that utilizes IGBTs. The control logic uses a microprocessor to switch the IGBTs on and off providing a variable voltage and frequency to the motor.

56

IGBTs

IGBTs (insulated gate bipolar transistors) provide the high switching speed necessary for PWM inverter operation. IGBTs are capable of switching on and off several thousand times a second. An IGBT can turn on in less than 400 nanoseconds and off in approximately 500 nanoseconds. An IGBT consists of a gate, collector and an emitter. When the control circuit applies a positive voltage (typically +15 VDC) to the gate the IGBT will turn on. This is similar to closing a switch. Current will flow between the collector and emitter. An IGBT is turned off by removing the positive voltage from the gate. During the off state the IGBT gate voltage is normally held at a small negative voltage (-15 VDC) to prevent the device from turning on.

Developing PWM Waveforms

There are several PWM techniques. It is beyond the scope of this book to describe them all in detail. The following text and illustrations describe one method. An IGBT can be switched on, connecting the motor to the positive value of DC voltage (650 VDC from the converter). Current flows in the motor. The IGBT is switched on for a short period of time, allowing only a small amount of current to build up in the motor, and then switched off. The IGBT is switched on and left on for progressively longer periods of time, allowing current to build up to higher levels until current in the motor reaches a peak. The IGBT is then switched on for progressively shorter periods of time, decreasing current build up in the motor.

57

The negative half of the sine wave is generated by switching an IGBT connected to the negative value of the converted DC voltage.

The voltage and frequency are controlled electronically by circuitry within the AC drive. The fixed DC voltage (650 VDC) is modulated, or clipped, with this method to provide a variable voltage and frequency. At low output frequencies a low output voltage is required. The switching devices are turned on for shorter periods of time. Voltage and current build up in the motor is low. At high output frequencies a high voltage is required. The switching devices are turned on for longer periods of time. Voltage and current build up in the motor increases.

58

Regeneration and Braking

In the speed-torque chart there are four quadrants according to direction of rotation and direction of torque. Quadrant I is forward motoring or driving (CW). Quadrant III is reverse motoring or driving (CCW). Reverse motoring is achieved by reversing the direction of the rotating magnetic field. The dynamics of certain loads, such as those associated with many motion control applications, require four-quadrant operation. Torque will always act to cause the rotor to run towards synchronous speed. If the synchronous speed is suddenly reduced, negative torque is developed in the motor. This could occur, for example when a stop command is initiated and the drive tries to slow down to bring the motor to a stop. The motor acts like a generator by converting mechanical power from the shaft into electrical power which is returned to the AC Drive. This is known as regeneration, and helps slow the motor. A similar process occurs when coasting downhill in a car. The cars engine will act as a brake. Braking occurs in quadrants II and IV.

One method of dealing with negative torque and the current it produces is controlled deceleration. Voltage and frequency is reduced gradually until the motor is at stop. This would be similar to slowly removing your foot from the accelerator of a car. Many applications, however, require the motor to stop quicker, and the drive must be capable of handling the excess energy produced by motor when this is done.

59

Braking Resistors

Electrical energy returned to the drive from the motor during regeneration can cause the DC link voltage to become excessively high. Braking resistors are one method used to control regeneration during a rapid deceleration. A braking resistor is placed across the DC link, through an IGBT. Energy returned by the motor is seen on the DC link. When the DC link reaches a predetermined limit the control logic switches on the IGBT, completing the path from the negative to the positive DC link through the IGBT and resistor. Excess energy is dissipated by the resistor, reducing bus voltage. When DC link voltage is reduced to a safe level the IGBT is switched off, removing the resistor from the DC link. This process allows the motor to act as a brake, slowing the connected load quickly.

60

Rectifier Regenerative Front End

Another method of dealing with excessive regeneration is with a rectifier regenerative front end. Diodes in the converter section are replaced with SCRs and a second regen bridge is added. An SCR functions similarily to a dode rectifier, except that it has a gate lead, which is used to turn the SCR on. This allows the control logic to control when the converter bridge and regen bridge are turned on.

A simplified block diagram provides a clearer view of the regen process. When the servomotor needs motoring energy to accelerate or maintain speed against the inertia of a load, the converter bridge is turned on. When the motor is in the regenerative mode, it acts like a generator, supplying electrical energy back to the DC link. When the DC link voltage reaches a predetermined level the motoring SCRs are switched off and the regen (generating) SCRs are switched on. This allows the excess energy to be returned to the AC line in the form of AC current.

61

ACTIVE FRONT END

An ACTIVE FRONT END (AFE) is another option available to control regenerative voltage. With this option the diodes in the converter bridge are replaced with IGBT modules and a Clean Power Filter. The IGBT, controlled by control logic, operates in both motoring and regenerating modes. In addition, AFE provides low stressing of the line supply. Harmonics are extremely low and the power returned is in the form of sinusoidal current.

Review 5 1. The Rod 431 rotary pulse encoder can only be used with ____________ servomotors. The EQN 1325 absolute-value encoder can count up to ____________ revolutions. Braking occurs in quadrants ____________ and ____________ . ____________ ____________ ____________ is one type of regenerative braking that uses IGBTs in the converter section.

2.

3.

4.

62

Siemens MASTERDRIVE MC Family

Siemens offers a broad range of AC drives, including the MICROMASTER, MIDIMASTER, and MASTERDRIVE families. The MASTERDRIVE family is further divided into vector control (VC) and motion control (MC). This section will focus on the MASTERDRIVE MC. These drives are specially designed for servo drive application. Drives are available from 0.55 kW to 200 kW (0.75 HP to 270 HP). Selection and ordering information, as well as engineering information and dimension drawings, can be found in Part 1 of the General Motion Control Catalog, available from your local Siemens sales representative.

The MASTERDRIVE MC family consists of Compact PLUS, Compact, and Chassis units.

MC Drive Compact PLUS Compact Chassis

kW 0.55 - 18.5 2.2 - 37 45 - 200

HP 0.75 - 25 3 - 50 60 - 270

63

MASTERDRIVE MC Compact PLUS

Power Connections

The following drawing is a layout illustration of a 4 kW Compact PLUS drive. X9, X100, X101, and X103 are control terminals for user wiring. The main power supply (380 - 480 VAC) is connected to X1. A feature of the drive is the X3 DC bus link which allows for quick connection of one unit to another in multi-drive configurations. Terminals are provided on X6 for braking resistors and a precharge module. Programming is done with the PMU keypad. The servomotor is connected to X2. Three slots (slot A, B, and C) are provided for option boards.

Programming and Operating Sources

Acces is gained to the MASTERDRIVE MC for programming operating parameters and motion profiles from the following sources: Operator Control Panel (OP1S) Parameterization Unit (PMU) Various Serial Interfaces PC Based Software (Simovis)

64

PMU and OP1S

Parameters, such as ramp times, minimum and maximum frequencies, and modes of operation are easily set. The changeover key (P) toggles the display between a parameter number and the value of the parameter. The up and down pushbuttons scroll through parameters and are used to select a parameter value, once the P key sets the parameter. The OP1S has a numbered key pad for direct entry. In the event of a failure the inverter switches off and a fault code appears in the display. In addition the drive can be started, stopped, and reversed. The OP1S stores up to eight parameter sets.

Control Terminals

The following schematic illustrates the control wiring of one control board available for the Compact PLUS. The control unit (CU) is the brains of the drive. The control unit controls all drive functions such as start, stop, acceleration, deceleration, motor voltage and frequency, monitoring, and other functions.

65

24 Volt Power Supply

When the DC link is charged control voltage is supplied by an internal source. In addition, a 24 volt power supply can be connected to the drive. This enables parameterization and monitoring of the unit even when the DC link voltage has been discharged. The 24 VDC can be cascaded on AC - AC units via terminals 33 and 34 of X100. X100 also provides a connection to cascade a serial USS interface (RS485). Switch S1 is used to turn the USS interface on and off. There are four bidirectional digital inputs and outputs. These can be programmed for various functions. Outputs, for example, can be programmed to signal a run or stop condition. Inputs can be programmed as start/stop commands. There are two additional digital inputs, which can be used for high speed inputs with a sampling time of 1 s. There is one analog input and one analog output. An OP1S, PC, or other device can be connected to X103 serial port. An internal link to the USS RS485 interface makes it possible to communicate with other devices which are connected to the serial USS interface. SAFE OFF is a function that prevents unintended movement or restarting of a drive after shutdown. This function is available as an option in Compact PLUS drives.

X101 Control Terminal

X103 Terminal

SAFE OFF

66

Rectifier Unit

The rectifier unit can be used with one or more inverters. Rectifier units are available in 41, 120, and 230 amps. Main power is connected to X1. Rectified DC voltage (510 - 650 VDC) is supplied to connected inverters through X3. There are some advantages to using one Compact PLUS rectifier unit to supply multiple inverters: One drive in braking mode can regenerate energy via the DC link (X3) to supply energy to drives in motoring mode. Built-in braking chopper requiring only a resistor for excess regeneration. Less input line components. For example, main line to rectifier as opposed to individual breakers and line rectifiers to each unit

Option Boards

Up to three option boards can be installed in the Compact PLUS unit. The encoder board for the servomotor (closed-loop motion control) must be plugged into slot C. An additional encoder board for the controlled machine can be plugged into one of the other slots.
Option Boards Encoder Boards SBP SBR NP NP SBM Communication Boards CBP CBC SIMOLINK Board SLB Expansion Boards EB1 EB2 Preferred Slot Possible Slot Not Possible Slot B A C

NP

67

Encoder Boards

The encoder board selected would depend on the encoder or resolver used with the servomotor or controlled machine. A maximum of two encoder boards can be used with the Compact PLUS. SBP The SBP is used to connect pulse encoders to the drive. The SBP can also be used to monitor an external encoder, such as might be connected to the driven machine. All normally available 2, 4, and 6-pole resolvers can be connected to this option board. This encoder board is also used to connect a resolver. In addition, this board provides pulse-encoder simulation. This simply means that the SBR2 generates 1024 pulses per resolver pole-pair. The SBM is used for sine/cosine encoders as well as absolute value encoders.

SBR1

SBR2

SBM

Communication Boards

There are a number of communication boards available for use with the MASTERDRIVE MC. The CBP board is used to connect the drive over the open field bus, PROFIBUS-DP. This protocol gives the MASTERDRIVE MC connection to all of Siemens automation products for a totally integrated solution. A maximum of two communication boards can be used. The SLB board is used for peer-to-peer communication with other drives via SIMOLINK. SIMOLINK is a high speed (11 mbaud) fiber optic ring bus that allows various data to be passed from one drive to the next. When used with MASTERDRIVE MC, SIMOLINK provides the media for synchronizing all MC drives on the ring. An application example of synchronized MASTERDRIVE MC drives used to control offset printing can be found in the Applications section of this book.

SIMOLINK Board

68

Expansion Boards

Expansion boards are used to expand the number of digital and analog inputs and outputs. The EB1 board has three digital inputs and four bidirectional digital I/O. Bidirectional I/O can be configured as a digital input or output. One of the analog inputs is used as a voltage or current reference input. Two of the analog inputs can also be configured as digital inputs. The EB2 board has two digital inputs, one analog input, and one analog output. In addition, the EB2 has four relay contacts. Three of the contacts are normally open (NO) and one of the contacts can be configured as normally open (NO) or normally closed (NC).
I/O Digital Inputs Bidirectional Digital I/O Analog Inputs Analog Outputs Relay Outputs Input for 24 V Power Supply EB1 3 4 3 2 0 1 EB2 2 0 1 1 4 1

AC - AC (Converter)

The terms AC - AC and DC - AC refers to methods of configuring drives. AC - AC in the MASTERDRIVE MC family refers to a single drive, connected to an AC source, controlling an AC servomotor with an encoder or resolver.

69

AC - AC Example

The following example shows the concept of an AC - AC configuration. Three-phase power is applied to the drive through the main circuit breaker. A line contactor (Q1) connects/ disconnects the system to/from the power supply. The line contactor is controlled by an on/off switch connected to a 230 VAC power supply. The 24 volt power supply, connected to X9, is required for maintaining communication and diagnostics when the supply voltage (380 - 480 VAC) is removed. An output contactor can be used to connect/disconnect the servomotor from the drive at U2, V2, and W2. Digital inputs/outputs are configured on X101. An OP1S operator panel can be connected to X103. As an option, a capacitor module or brake resistor can be added to absorb short-time energy peaks. A line filter can be included to further reduce RFI if local codes require.

70

DC - AC (Inverter)

The MASTERDRIVE MC can also be configured so that one unit acts as a common DC bus (rectifier) for two or more AC inverters. In the following illustration, for example, one DC unit (rectifier) supplies DC power to two DC - AC units (inverters) through connector X3. The combined total output of the inverters must not be greater than the DC power supplied by the rectifier unit. This is referred to as a common bus arrangement. Multi-axis control is one situation where a common bus arrangement would be used. This configuration allows for multiple axes to be connected to the same DC bus for sharing energy.

71

Common Bus Example Using Compact PLUS

The following drawing illustrates a multi-axis, common bus setup. A single AC - AC can be used to further supply the DC bus and 24 VDC control power of up to two additional DC - AC (inverter) units. This is due to an oversized input rectifier bridge and internal power supply in the AC - AC unit. Multi-axis systems can be implemented in a compact and efficient manner. If one axis is braked, the braking energy is fed back into the DC link and made available to the other connected motors. Excess energy can further be reduced by means of an external braking resistor. In this example the SAFE OFF and capacitor module options have been added.

72

MASTERDRIVE MC Compact and Chassis

The MASTERDRIVE MC compact and chassis drives have the same features as the Compact PLUS. Drives are available as AC - AC and DC - AC. These drives can be configured for multiaxis control. Compact and chassis drives can be programmed and operated from the Operator Control Panel (OP1S), Parameterization Unit (PMU), and various serial interfaces. Compact Drive The compact drive is available in four frame or enclosure sizes. The following drawing is a layout illustration of enclosure sizes A, B, and C. A larger enclosure is available for size D. The main power supply (380 - 480 VAC) is connected to X1. The DC link is available at X3. The servomotor is connected to X2.

73

Chassis Drive

The chassis drive uses an open architecture for cabinet mounting. The following drawing illustrates enclosure sizes E and F. A similar larger enclosure is available for size G.

Electronics Box

The compact and chassis units have an electronics box for control and option boards. There are up to six slots available for mounting option boards in the electronics box. The slots are designated with the letters A to G. Slot B does not exist in the compact and chassis units. An LBA (Local Bus Adapter) is required if mounting positions 2 or 3 are needed. In addition, adapter boards (ADB) are necessary for Slots D and E, and F and G when utilizing the half-size option boards.

74

CUMC Control Board

The compact and chassis motion control drive uses the same main control board (CUMC). The CUMC board is located in the electronics box. Control wiring is the same for both drives.

X101

X101 is similar to the Compact PLUS. There are four bidirectional digital inputs and outputs. These can be programmed for various functions. Outputs, for example, can be programmed to signal a run or stop condition. Inputs can be programmed as start/stop commands. There are two additional digital inputs, one analog input, and one analog output. X103 is two USS RS485 serial interfaces, which make it possible to communicate with other connected serial devices. An OP1S or PC can be connected to X300 for programming.

X103

X300

75

Option Boards

Up to six boards can be installed in the electronics box of the compact and chassis units. The encoder board for closed-loop control must be plugged into slot C. An additional encoder board for the machine encoder can be plugged into one of the other slots. A maximum of two expansion boards, two communication boards, and two encoder boards can be used.

Mounting Position 1 CUMC CUR A Encoder Boards SBP SBR NP NP NP NP NP SBM Communication Boards* CBP SIMOLINK Board SLB Expansion Boards** EB1 EB2 Preferred Slot Possible Slot Not Possible * Use Slot G with T100/T300 **Use Slot A or C with T100/T300 NP NP NP C F 3 Slots G D E 2

Option Boards

Maximum No. of Components in Electronics Box

76

Review 6 1. The maximum kW available in a Compact unit is ____________ kW. The main power supply of a Compact PLUS is connected to ____________ . A 24 volt power supply can be cascaded on Compact PLUS AC - AC units from one drive to the next utilizing connector X ____________ . The preferred slot for the SBP encoder board is ____________ . The ____________ board is used to communicate with PROFIBUS-DP. A single drive, that includes a rectifier and inverter in one unit, is referred to as a ____________ . An ____________ is required if mounting positions 2 or 3 are needed in the electronics box of a Compact or Chassis unit.

2.

3.

4.

5.

6.

7.

77

Technology Options

Technology software is an option available with the MASTERDRIVE MC. Technology software can be divided into three main categories: General Technology Functions General technology functions include linear axis, rotary axis, and roll feeding. Positioning Positioning includes point-to-point positioning or automatic positioning which combines muliple point-to-point moves. Synchronous Operation Synchronous operation involves the synchronizing of two or more axes via electronics. Synchronous operation includes electronic gears, cams, clutches, and so on.

78

Basic Function Software

Some technology functions are readily available and can be implemented at any time. These include cam control and brake control. A cam controller switches digital outputs on and off. With this function external switching elements, such as pneumatic valves, may be operated at defined points. Two cam controllers are available with the basic technology software. Each controller has two positioning cams, making a total of four cams whose switch-on and switch-off positions can be set independently of each other. Digital outputs from the MASTERDRIVE MC signal the on/off position to the controlled equipment.

Cam Controller

Brake Control

Applying and releasing a brake can be effected by means of external commands. However, with the brake control function built into the MASTERDRIVE MC braking can be fully automated without intervention by an external machine control unit. There are three ways to operate a brake: Relay Output on the EB1 Expansion Board Digital Output from the MASTERDRIVE MC to an External Relay The Relay for Operating the Main Contactor in the Chassis and Compact Unit, when the Main Contactor is not used

79

Technology Software F01

The following position and synchronizing functions are software options that can be purchased with the MASTERDRIVE MC, or ordered and enabled at a later date. They are part of the technology option software (F01) package. The linear axis function is designed to traverse an object along a specified range with fixed stops. A traversing car is an example of a linear axis.

Linear Axis Function

Rotary Axis Function

A turntable is an example of a rotary axis. The rotary axis function is designed to move an object the shortest distance around a 360 path. Depending on where an object is, and where it must be moved to, the servomotor will turn the table either clockwise or counter clockwise.

Roll Feed

This function works with a permanently rotating rotary axis and incorporates a cut-to-length function. A roll feeding into a cutting machine is one example.

80

Positioning

The MASTERDRIVE MC drive has a positioning control system capable of executing a variety of positioning tasks such as: Setup - Manually jogging an axis into position with acceleration and speed determined by preset parameters Homing - Moving the axis to a predefined zero position with acceleration and speed determined by preset parameters Point-to-Point Positioning using Manula Data Input (MDI) Moving the axis to either an absolute or relative position at a given speed and acceleration Roll Feed - Automatic cut-to-length feature useful for presses, punching machines, and cross-cutters Automatic Mode - Automatic execution of complete positioning programs

Although the MASTERDRIVE MC may be operated in multiple modes in a given application, understanding a basic application that involves automatic mode and homing would be beneficial at this point. Since velocity versus time profiles are commonly used to describe positioning applications, a simple example is provided along with the explanation. A velocity versus time profile provides a graphical representation of the velocity of an axis at any point in time. Velocity includes speed and direction. Speed in one direction is considered to be positive velocity and speed in the opposite direction is considered to be negative velocity. Positive velocity is graphed above the time axis and negative velocity is graphed below the time axis.

81

In the following example the MASTERDRIVE MC controls the vertical movement of a drill. The drill will penetrate a composite material that has been moved into position. The drilling sequence is: Point A to B - From the home position, the drive is started and accelerated to full speed. As the drill approached the workpiece it decelerates to 190 millimeters per second (mm/s). Point B to C - The drill penetrates the hard top layer. Point C to D - The drill is accelerated to 1000 mm/s to drill through the soft middle layer. Point D to E - The drill is decelerated to drill through the hard bottom layer, then slows to zero at point E. Point E to F - The drill is accelerated to -1500 mm/s (negative velocity) while it is raised out of the workpiece and returned to the home position at point F.

82

Electronic Cam

The following illustration is representative of two sample electronic cam profiles available in the MASTERDRIVE MC. Electronic cam profiles are used to replace mechanical cams, and follow a specific cam pattern. The examples illustrate a linear axis coordinated with a rotary axis. Both axes are positioned at a known reference position to run the cam profile. In this example the rotary axis is designated the master and the linear axis is the slave. The slave axis (linear slider) will track the master (black line on rotating cam). With the MASTERDRIVE MC, unlike a mechanical cam, the profile can be changed easily, almost on the fly For example, sample profile 2 can replace . sample profile 1.

Each angular position on the cam is assigned a position on the slider, creating a cam table like the following example. Mathematical interpolation is used to control the move between the points on the table. In sample profile 1, for example, when the marker on the cam is 340 from the known cam reference position, the slider marker is 20 mm from the known slider reference position.
Master 360/0 10 20 30 40 50 60 70 80 ----340 350 Slave 0 mm 20 mm 40 mm 50 mm 60 mm 70 mm 80 mm 90 mm 105 mm ----20 mm 10 mm

83

Electronic Gear Box

The electronic gear box function can be used to replace a mechanical gear box on a machine. In the following illustration two axes are used to control the speed of two carousels. One carousel is the master and one is the slave. In this example empty paint cans are loaded onto the master carousel where a filling process is carried out. The cans are then transferred to the slave carousel where lids are applied. In many applications such as this there must be a difference in speed between the two processes. It may take longer, for example, to fill the can than to apply the lid. With the electronic gear box function an electronic speed ratio exits between the two carousels. Increasing the speed of the slave carousel, for example, will decrease the ratio. The ratio can be set anywhere from 32,767:32,767, allowing for precise gear ratio adjustments. It should also be noted that the speed of the entire process can be changed while maintaining a desired ratio. For example, once the process is running it may be desirable to increase the process speed which will increase the production.

84

Electronic Clutch Engage/Disengage

The electronic clutch function allows an axis to be engaged or disengaged without losing position synchronization. This is particularly important when several parts of a complex machine are dependent on each other. In the following illustration, for example, one axis controls an ejector. If a defective product is detected the ejector is engaged for one cycle while the ejector removes the defective product. A second axis disengages (stops) the carousel for one cycle. At the end of the cycle the ejector is disengaged and the carousel engaged. If a missing object is detected on the infeed the electronic clutch disengages the slave axis for one cycle to allow the next object in line to be loaded into the slave axis. The clutch is then engaged and the process is switched back to synchronous mode operation.

85

Print Mark Registration

Print mark registration is used to compensate for creep, stretch, and thermal expansion of a printing operation. Registration marks are sensed within 1 s, allowing for appropriate compensation at each print roll and at the cutter. The slaves position is evaluated relative to the registration mark. The motion control drives correct for any deviation. Without this correction creep, accumulates with every revolution. This creep would cause printing and cutting to be unsynchronized.

86

Cables

Power and encoder/resolver cables can be ordered by the meter or are available prefabricated with appropriate plugs and connectors.

Power and encoder (feedback) cables have a maximum allowable length. Typically feedback cable length can be greater than power cable length (approximately 492 ft or 150 m). The following tables show the maximum power cable lengths.

Compact PLUS

Output

Unscreened

Screened

0.55 kW Converters 328 ft (100 m) 229 ft (70 m) 0.75 kW Inverters 1.1 kW - 18.5 kW 426 ft (130 m) 328 ft (100 m)

Compact and Chassis

Output up to 4 kW 5.5 kW 7.5 kW 11 kW 15 kW 18.5 kW 22 kW - 200 kW

Unscreened 164 ft (50 m) 229 ft (70 m)

Screened 114 ft (35 m) 164 ft (50 m)

328 ft (100 m) 219 ft (67 m) 360 ft (110 m) 246 ft (75 m) 410 ft (125 m) 278 ft (85 m) 442 ft (135 m) 295 ft (90 m) 492 ft (150 m) 328 ft (100 m)

87

Applications

There are any number of applications where motion control can be utilized. The features and functions of the MASTERDRIVE MC product line provides appropriate solutions for these application requirements. Choosing the right components can be confusing and takes careful thought and planning. As you have seen throughout this book there are a number of servomotors, encoders, drives, and technology options to chose from. The following application examples, along with the selection flow chart in the next section, will help you in the planning process. There are, of course, many applications other than the ones illustrated in this section appropriate for the MASTERDRIVE MC.

88

Offset Printing

Offset printing traditionally uses a mechanical line shaft to synchronize the different color print stations. The mechanical devices involved require high maintenace, and the system is limited in speed. The mechanical line shaft system can be replaced with individual servomotors which are precisely synchronized through the MASTERDRIVE MC and SIMOLINK. Communication to higher level controls, such as a SIMATIC S7 PLC, for evaluation of system status and drive setpoint signals, is accomplished with PROFIBUS-DP.

Application Requirement MASTERDRIVE MC Feature MASTERDRIVE MC Solution/Benefit

Web Handling with Synchronization Synchronization: Virtual Master, Real Master, Gear Box (Electronic Line Shaft) Increased Accuracy and Production Print Speed. Flexibility to Add and Remove Print Stations with Minimum Downtime.

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Bottle Filling

Some bottle filling applications, such as cosmetics, require the distance between the filling pipe and the liquid level in the bottle to be kept constant. In addition, the filling pump must maintain a constant flow. These two axes can be precisely synchronized with the MASTERDRIVE MC. In this application, the pump drive acts as the master and the filling gantry acts as the slave. As the pump provides a constant flow of product, the filling gantry movement is synchronized, through a cam profile that corresponds to the bottle contour. This maintains a constant filling pipe to liquid distance.

Application Requirement MASTERDRIVE MC Feature MASTERDRIVE MC Solution/Benefit

2-Axis Synchronized Control Synchronization with Cam Profiling Quick Cam Profile Change to Accommodate Bottle Contour Change. Increased Production for Multi-Product Line Runs.

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Horizontal Bagging

This application involves a continuous roll of foil for horizontal bagging. The sealing station handles the foil transport. Electronic line shaft and print mark registration ensure the foil is synchronized with the products being packaged. Electronic line shafting also ensures the product feeder belt and the foil are in continuous position synchronization. Print mark registration will accelerate or decelerate the foil to make up for possible stretch. This ensures that printed labels on the foil will be correctly positioned on the package. The transverse sealing station must travel with the line in order to achieve continuous packaging. This is accomplished with the MASTERDRIVE MCs electronic line shaft and electronic cam functions. The sealing station is accelerted with the electronic line shaft function to the speed of the product (x-axis). The electronic cam function closes the sealing jaws (y-axis) while the sealer moves across and simultaneously seals the package.

Application Requirement MASTERDRIVE MC Feature MASTERDRIVE MC Solution/Benefit

Continous Positioning and Synchronization. Continuous Packaging Print Mark Registration Synchronization: Electronic Line Shaft Control Including Cam Profile Continous Adjustment to Compensate for Foil Stretch. Multi-Axis Coordination for Sealing and Bagging Sections.

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Composite Drilling

Positioning the x- and y-axis to locate the drilling tool can be accomplished with the manual data input (MDI) mode. Once the drilling tool has reached the desired location, the automatic function takes over and controls the movement of the z-axis. The following instruction set is an example of a drilling profile.

Moving from A to B the drilling gantry rapidly traverses to just in front of the board and starts to reduce the feed velocity. At point B the drill reaches the reduced feed velocity to drill through a plastic laminate. Moving from B to C the drill slows to drill through the laminate. Moving from C to D the drill increases to normal velocity to drill through core. Moving from D to E the drill reduces velocity to drill through bottom laminate. Moving from E to F the drill returns with increased velocity.

Application Requirement 3-Axis Positioning (Composite Drilling). MASTERDRIVE MC Feature MASTERDRIVE MC Solution/Benefit MDI Point-to-Point Positioning. Automatic Mode Positioning. High Accuracy Drill Bit Placement and Optimized Drilling Speed to Improve Quality of Cut and Tool Life.

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Cut to Length Rotary Knife/Sheater

In Cut to Length applications, the purpose is to cut material to a precise length. For a fixed cut length, and a knife circumference of the same length, it is simply a matter of maintaining a constant speed between the web and the knife. However, for products that require various cut lengths, the knifes circumference would have to vary to match these new cut lengths. Since this would not be practical, the knife speed is often profiled. By varying the knife speed various cut lengths can be obtained. Furthermore, the rotary knife is accelerated so that as the cutting edge comes into contact with the material it is traveling at the same velocity. This is done to avoid ripping the material. To accomplish this task a Cam profile is often employed. Using the technology features of the MASTERDRIVES MC, a number of cam profiles can be created to perform the needed contoured movement that is synchronized with the material to perform the cut.

Application Requirement MASTERDRIVE MC Feature MASTERDRIVE MC Solution/Benefit

Variable Speed and Product Cut Lengths. Synchronization with Cam Profiling Short Current Rise Time allows for High Dynamic Response. Multiple Cam Profiles Allow for Quick Changeover to Various Product Lengths.

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Pick and Place

Pick and Place applications involve the precise movement of product from one location to another. Using the Point-to-Point positioning features (MDI mode) of the MASTERDRIVES MC, this precise movement can be realized. Typically the gripper claw is homed to the starting location during initialization of the system. From that point, as product is sensed, the gripper closes on it and the Point-to-Point move is made. Once the final destination point is reached the gripper releases the product and the return move to home position is carried out. SIMOLINK is the perfect choice to coordinate these actions. It allows for easily sending all of the appropriate status and control signals from one axis drive to the next.

Application Requirement MASTERDRIVE MC Feature MASTERDRIVE MC Solution/Benefit

Pick and Place Positioning MDI Point-to-Point Positioning High Accuracy Organization and Location of Product Packaging

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Selection

The following flow diagram, along with Part 1 and Part 2 of the General Motion Control Catalog, will help you select the right equipment for your motion control system.

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SIMODRIVE

In addition to the MASTERDRIVE MC, Siemens offers additional general motion control products. Two examples from the SIMODRIVE family of servodrives are described in the following paragraphs. POSMO A The SIMODRIVE POSMO A is an integrated motion control system. POSMO consists of a motion control drive, servomotor, gearbox, and incremental position transducer in one unit. POSMO can be integrated into any PROFIBUS-DP environment. Its only requirement is 24 VDC and PROFIBUS for programming and control. The unit can even act as a stand alone unit by programming it over PROFIBUS and utilizing two digital inputs to perform various position moves.

POSMO Data

Degree of Protection Voltage Power Gear Drive

IP54 24 VDC 20% 62 W 4.5:1 to 162:1

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SIMODRIVE 611 Universal

The SIMODRIVE 611 Universal is a closed-loop control plug-in unit. The 611 Universal is made up of an infeed module and a power module. The infeed module contains a complete electronics power supply and is used to convert the incoming AC line (400 to 480 VAC) to DC. The power module houses the 611 Universal and provides the output to the servomotor. The 611 Universal will support 1 or 2 axis. Like the POSMO, the SIMODRIVE 611 Universal can be integrated into any PROFIBUS -DP environment. This drive is rated from 3 - 250 amps. It is designed for positioning tasks and can operate both sinewave servomotors and linear motors.

Review 7 1. Which of the following is not part of the basic function software? a. Cam controller b. Brake control c. Electronic Clutch 2. The gear ratio of the electronic gear box function can be set anywhere from ____________ . Registration marks are sensed within ____________ s with the print mark registration function. The maximum screened cable length of a 5.5 kW Compact unit is ____________ ft. When selecting a motion control system the speed and ____________ load cycles must be known.

3.

4.

5.

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Review Answers

Review 1 Review 2

1) MASTERDRIVE; 2) linear, rotational; 3) h. 1) force; 2) 5 N; 3) torque; 4) 6; 5) inertia; 6) 1:1; 7) Work; 8) torque, power; 9) SimoSize. 1) synchronous, asynchronous; 2) 120; 3) synchronous; 4) slip; 5) b; 6) 105; 7) 64. 1) S1; 2) 10; 3) continuous, intermittent; 4) 81; 5) asynchronous. 1) asynchronous; 2) 4096; 3) II, IV; 4) ACTIVE FRONT END 1) 37; 2) X1; 3) 100; 4) C; 5) CBP; 6) converter; 7) LBA. 1) C; 2) 32,767:32,767; 3) 1; 4) 164; 5) torque

Review 3

Review 4 Review 5 Review 6 Review 7

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Final Exam

The final exam is intended to be a learning tool. The book may be used during the exam. A tear-out answer sheet is provided. After completing the test, mail the answer sheet in for grading. A grade of 70% or better is passing. Upon successful completion of the test a certificate will be issued. Questions 1. ____________ is a twisting or turning force that causes an object to rotate. a. b. 2. Torque Friction c. d. Inertia Acceleration

Ideally it is desirable to have a ____________ ratio between the load and the motor. a. b. 1:2 1:1 c. d. 2:1 2:2

3.

The torque required to accelerate a system with a total inertia of 0.010 kgm2 from rest to 2500 RPM in 0.1 seconds is ____________ Nm. a. b. 7.85 13.08 c. d. 26.17 32.56

4.

____________ is a Siemens PC program designed to accelerate the process of calculating speed, torque, and inertia of a motion control system. a. b. SIMOLINK PROFIBUS-DP c. d. SimoSize POSMO

5.

The maximum temperature rise of a motor with Class F insulation, not including the margin for a hot spot, is ____________ K. a. b. 80 125 c. d. 130 105

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6.

A motor with an enclosure that protects against dust and water jets would be classified as IP ____________ . a. b. 23 55 c. d. 68 65

7.

____________ is a duty cycle which operates for an intermittent period without starting between cycles. a. b. S1 S3 c. d. S2 S4

8.

Winding version ____________ is rated for 6000 RPM. a. b. A G c. d. F K

9.

The range of rated torque of a 1PH7 motor is ____________ Nm. a. b. 22 - 1145 0.8 - 16.5 c. d. 370 - 1720 34 - 78

10.

The ____________ encoder has 8192 coded positions and uses a mechanical gear sequence to count up to 4096 revolutions. a. b. c. d. Rod 431 ERN 1381 ERN 1387 EQN 1325

11.

____________ is a method of braking which uses IGBTs in the converter section and provides sinusoidal regen current back to the incoming power supply. a. b. c. d. ACTIVE FRONT END Rectifier Regenerative Front End Pulsed Resistor Braking Pulse Width Modulation

12.

The maximum kW rating of a Compact PLUS dirve is ____________ kW. a. b. 15 22 c. d. 18.5 37

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13.

The Compact PLUS has ____________ programmable bi-directional inputs and outputs. a. b. two three c. d. four six

14.

Up to ____________ option boards can be installed in the Compact PLUS. a. b. two three c. d. four six

15.

____________ is an encoder board used for sine/ cosine encoders as well as absolute value encoders. a. d. SPB SBR2 c. d. SBR1 SBM

16.

____________ refers to a system in which one rectifier supplys DC power to multiple AC inverters. a. b. Multi-Axis SIMOLINK c. d. PROFIBUS-DP Common Bus

17.

____________ is the preferred slot for an encoder board in the Compact PLUS, Compact, and Chassis drives. a. b. A B c. d. C D

18.

The Cam controller is part of the ____________ . a. b. c. d. basic function software rotary axis function linear axis function Roll feed function

19.

The maximum length of a screened cable used on a 0.55 kW converter is ____________ meters. a. b. 35 50 c. d. 65 70

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20.

____________ is a type of motion control drive that has an integrated motion control drive, servomotor, gear box, and incremental position transducer is one unit. a. b. c. d. SIMODRIVE 611 Universal POSMO Compact PLUS PROFIBUS-DP

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Notes

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