AXIMA Software User`s Guide

Transcription

AXIMA Software
User’s Guide
P/N 400263-00
Rev.: A1
Date: October 31, 1997
© 1997 EMERSON Motion Control. All Rights Reserved.
P/N 400260-0
AXIMA Software
User’s Guide
Information furnished by EMERSON Motion Control is believed to be accurate and
reliable. However, no responsibility is assumed by EMERSON Motion Control for its use.
EMERSON Motion Control reserves the right to change the design or operation of the
equipment described herein and any associated motion products without notice.
EMERSON Motion Control also assumes no responsibility for any errors that may
appear in this document. Information in document is subject to change without notice.
P/N 400263-00
Rev.: A1
Date: October 31, 1997
P/N 400290-00
AXIMA Software User’s Guide
Document Number: 400263-00
No part of this manual may be reproduced by any means without the written permission
of EMERSON Motion Control.
EMERSON Motion Control is a registered trademark of EMERSON Motion Control.
AXIMA is a trademark of EMERSON Motion Control.
Printed in U.S.A.
October 1997, Revision A1
Microsoft, Excel, and Windows are registered trademarks of Microsoft Corporation.
IBM is a registered trademark of International Business Machines, Inc.
Modbus is a trademark of Modicon, Inc.
Data Highway Plus are trademarks of Allen-Bradley
This document has been prepared to conform to the current released version of hardware
and software system. Because of our extensive development efforts and our desire to
further improve and enhance the product, inconsistencies may exist between the product
and documentation in some instances. Call your customer support representative if you
encounter an inconsistency.
ii
Customer Service
EMERSON Motion Control offers a wide range of services to support
our customer’s needs. Listed below are some examples:
Service Support (612) 474-8833
EMERSON Motion Control’s products are backed by a team of
professionals who will service your installation wherever it may be.
Our customer service center in Minneapolis, Minnesota is ready to
help you solve those occasional problems over the telephone. Our
customer service center is available 24 hours a day for emergency
service to help speed any problem solving. Also, all hardware
replacement parts, should they ever be needed, are available through
our customer service organization.
Need on-site help? EMERSON Motion Control provides service, in
most cases, the next day. Just call EMERSON’s customer service
center when on-site service or maintenance is required.
Training Services (612) 474-1116
EMERSON Motion Control maintains a highly trained staff of
instructors to familiarize customers with EMERSON Motion
Control’s products and their applications. A number of courses are
offered, many of which can be taught in your plant upon request.
Application Engineering
An experienced staff of factory application engineers provided
complete customer support for tough or complex applications. Our
engineers offer you a broad base of experience and knowledge of
electronic motion control applications.
Bulletin Board System
(612) 474-8835
EMERSON Motion Control maintains a BBS which provides you
access to software updates, and technical information and services.
Communications protocol: 300 to 28,800 baud, N, 8, 1
FAX
(612) 474-8711
Internet Website
www.emersonemc.com
iii
AXIMA Software User’s
Table of Contents
Introduction
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
New for Version 2.0 . . . . . . . . . . . . . . . . . . . . . . . . 2
AXIMA Software Fundamentals. . . . . . . . . . . . . . . . . 2
AXIMA Application Basics . . . . . . . . . . . . . . . . . . 2
AXIMA Software Features . . . . . . . . . . . . . . . . . . 3
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Program Quantity . . . . . . . . . . . . . . . . . . . . . . . . . 6
Program Verification . . . . . . . . . . . . . . . . . . . . . . . 7
Motion Program. . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PLC Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Auxiliary Program . . . . . . . . . . . . . . . . . . . . . . . . . 8
What is an Application?. . . . . . . . . . . . . . . . . . . . . . . . 8
AXIMA Hardware Specifications . . . . . . . . . . . . . . . . 10
Understanding Motion in a Coordinate
System
Coordinate System Hierarchy. . . . . . . . . . . . . . . . 15
How Motion is Generated . . . . . . . . . . . . . . . . . . . 15
Closed Loop Operation . . . . . . . . . . . . . . . . . . . . . 18
Understanding Programs
PLC Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Motion Programs . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Auxiliary Programs . . . . . . . . . . . . . . . . . . . . . . . . 26
Understanding Multitasking Program
Priority
Assigning Program Priorities . . . . . . . . . . . . . . . . 29
Processing High and Low Priority Programs. . . . 30
Program Priority Execution Interval Times . . . . 32
v
AXIMA Software User’s Guide
Communications Interface
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Addressing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Mode Communications. . . . . . . . . . . . .
Data Input/Output . . . . . . . . . . . . . . . . . . . . . . . .
39
39
39
42
Programming Examples
Homing an Axis Example . . . . . . . . . . . . . . . . . . . . . .
Example Program . . . . . . . . . . . . . . . . . . . . . . . . .
Product Alignment Example . . . . . . . . . . . . . . . . . . .
Example Program . . . . . . . . . . . . . . . . . . . . . . . . .
Two Axis Gluing Example . . . . . . . . . . . . . . . . . . . . .
Example Program . . . . . . . . . . . . . . . . . . . . . . . . .
MX/AXIMA Communications Example . . . . . . . . . . .
Example Program . . . . . . . . . . . . . . . . . . . . . . . . .
T60/AXIMA Communications Example . . . . . . . . . . .
Example Program . . . . . . . . . . . . . . . . . . . . . . . . .
Cam Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example Program . . . . . . . . . . . . . . . . . . . . . . . . .
Linear PLS Example . . . . . . . . . . . . . . . . . . . . . . . . . .
Example Program . . . . . . . . . . . . . . . . . . . . . . . . .
Rotary PLS Example. . . . . . . . . . . . . . . . . . . . . . . . . .
Example Program . . . . . . . . . . . . . . . . . . . . . . . . .
External Time Base Example. . . . . . . . . . . . . . . . . . .
Example Program . . . . . . . . . . . . . . . . . . . . . . . . .
Index
vi
45
46
47
48
51
53
59
60
61
61
65
71
76
77
79
81
82
82
AXIMA User’s Guide
Introduction
Overview
The AXIMA Software and controller combination is a high
performance multi-axis servo controller. The AXIMA system
provides the flexibility and functionality to perform multitasking
operations that will handle the wide range of multiaxis applications
found in plant automation and industrial machinery. The AXIMA
system provides you with the following:
Reduced application development time.
•
•
•
Microsoft Windows® standards for fast familiarity
High level programs
24 hour service support
A high performance coordinated multiaxis motion control system.
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•
•
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•
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DSP processor, with servo profile update rates as fast as 200
microseconds
Complex motion capability - arc, sine, linear, gear, cam
Multitasking
PLC digit controls
Discrete I/O
Servo controls
Pulse controls
Access to the complete EMERSON Motion Control family of motion
control components.
•
•
•
•
•
Controllers
Drives
Motors
Display panels
System Communications - Modbus® and Data Highway Plus®
1
P/N 400290-00
New for Version 2.0
•
•
•
•
•
•
•
•
•
•
•
AXIMA 2000/4000 with reconfiguration
Flash memory (AXIMA 2000/4000 only)
Stepper support
Quick encode
Com 2 autobaud override
Download and switch online
Registration Move Instruction
Auxiliary PLC
E Series drive defaults
38.4K baud RS232C setting
New flags; Positive and Negative Direction Limit, Direction
Limit Activate and Tripped
AXIMA Software Fundamentals
EMERSON Motion Control’s AXIMA Software provides you with the
ability to create, edit and maintain your controller Application.
AXIMA Application Basics
You will be building an AXIMA Application using the AXIMA
Software. The Application is downloaded into the AXIMA controller
for execution. The AXIMA Software allows you to work on multiple
Applications, but only one Application can be resident in the
controller memory at a time.
An Application contains all the information to configure and program
your AXIMA controller. This includes Motion Programs, coordinate
systems, axis, analog, connectivity options (Modbus and Data
Highway Plus), PLC Programs, Global Variables, Local Variables,
and Pre-defined Variables.
2
Introduction
The AXIMA Software provides a tool to generate your application,
download it, and monitor it’s execution. Each Application is
organized in the hierarchy shown below.
Figure 1
Application Hierarchy Example
The Application contains coordinate systems. You assign the
available axis to your coordinates. Within a coordinate system axis
moves are “coordinated moves” where the profile and each axis are
executed simultaneously. Each coordinate system is assigned a
Motion Program and a PLC Program. The Motion Program controls
all motion while the PLC Program provides high speed digital I/O
control.
AXIMA Software Features
Application Hierarchy
The Application is organized in a hierarchy and displayed on the left
of the AXIMA Application editing window. You can quickly navigate
through your Application. Double clicking collapses or expands the
hierarchy tree. The details of the selected hierarchy item are
3
displayed on the right view of the AXIMA Application editing
window.
Easy Menus
The menus in the AXIMA Software provide quick and easy access to
a variety of tools used for graphical monitoring of the controller,
program control, and diagnostics.
Graphical Monitor
The Graphical Monitor is a separate Windows program that can be
launched for the AXIMA Software. It is used to analyze the operation
of the AXIMA controller and graphically present multiple analog or
digital signals on a graph. See the Graphical Monitor Online Help for
more information.
Program Control
The Program Control dialog box is a useful tool when troubleshooting
Applications. Specifically, you can control or monitor any Motion,
Auxiliary, or PLC Programs from here. The controls available
include running, halting and monitoring program output for all
programs. You may also issue instructions to produce an immediate
affect from this dialog box.
Diagnostics
Diagnostics provides convenient display of key Pre-defined
Variables. Each key level of the hierarchy has it’s own status display.
You can monitor the execution of your Application in online mode
using the diagnostics capability. Diagnostic levels include
Application (controller), Coordinate Systems, Axes, and Programs.
Online Help
Online Help provides you with help. All AXIMA Software dialog
boxes provide a Help button. The help menu provides access to the
different help files.
4
Introduction
Communications
Communications between the AXIMA Software on your PC and the
AXIMA controller is accomplished using several options including:
•
•
•
RS232C
RS422
RS485
As an option, your AXIMA controller can be configured with Modbus
or Data Highway Plus communications hardware. These provide
interfaces between your Application, system controllers and display
panels.
Program Memory
The AXIMA controller has a total of 64K or 128K bytes of memory for
programs depending on the controller you ordered. You can view the
Total Memory Used and the Total Memory Available values from the
Controller Memory dialog box which is accessed by clicking on the
Memory button in the Applications dialog box.
Programs
There are two basic types of programs: Motion/Auxiliary and PLC.
All these programs are multitasked within the controller. You can
have up to fifteen Motion/Auxiliary Programs. Eight of these are
designated High Priority. The Motion/Auxiliary Programs are either
assigned to a coordinate or are stand-alone. Those assigned to
coordinate are Motion Programs and those that are stand-alone are
Auxiliary Programs. The Motion Program controls the axis
movement, while the Auxiliary Program is used for non-motion
functions. Auxiliary Programs instruction set is a subset of the
Motion Programs.
The PLC Program provides program logic controller capability to the
user. The user can write programs to control the external I/O bits, the
controllers pre-defined bits and user defined (Global bits).
The AXIMA controller executes these programs simultaneously by
multitasking the programs using the slicing method. The time slice
algorithm treats PLC Programs as the highest priority with High
Priority Motion/Auxiliary Program next and Low Priority last.
5
Instructions
AXIMA instructions preform high level operations. For example,
single instructions provide multiaxis coordinated moves for linear,
arc, sine, and gear motions. Program flow instruction provides if/
then, subroutine, wait on value, and dwell type instructions.
The instructions are defined using dialog boxes. For each instruction
type there is an associated dialog box. The dialog box covers all the
parameters of the instruction so you can get a clear understanding of
full instruction capability and options. Variables are user defined,
with user assignable names. These names are easily selected by drop
down boxes in each of the instruction dialogs
Cut/Copy/Paste
Cut/Copy/Paste provides a capability to take portions of one
Application and paste it into another. This allows you to copy
example programs. It also facilitates multiprogramer development.
Each programmer develops code independently. The Cut/Copy/Paste
is used to integrate the programs into one Application.
Programs
The dialog box used for creating and editing Motion, PLC or
Auxiliary Programs are very similar with the exceptions listed below:
•
•
•
•
•
Auxiliary Programs include a user defined name.
PLC Program instructions may not be commented.
PLC Programs do not have a priority adjust option.
Motion Programs default to High Priority.
Auxiliary Programs default to Low Priority.
Program Quantity
Each of the program types (Motion, PLC, and Auxiliary) have limits
on the total number of each.
6
•
Number of Motion Programs <= 8 (coordinate systems)
•
Number of PLC Programs <= 8 (coordinate systems)
Introduction
•
Number of Auxiliary Programs <= 15 minus the number of
Motion Programs
•
Number of High Priority Programs <= 8
•
Number of Low Priority Programs <= 7
Program Verification
All programs (Motion, PLC and Auxiliary) are verified as you edit
them. Warning messages are presented as inconsistencies are
created within any program. Examples include; deleting referenced
variables, labels and axes. See the Troubleshooting section for a
description of the messages produced by the AXIMA Software.
Motion Program
Each Coordinate System contains one Motion Program which
controls the motion of all axes. The Motion Program is used to control
motion parameters such as acceleration and deceleration rates,
velocities, starts and stops, input and output functions as well as
calling subroutines. The example below shows a typical Motion
Program configuration.
PLC Program
The PLC Program is a “ladder logic” type program that executes at
the SUI. The purpose of the PLC Program is to monitor controller
fault conditions, limits and safety/emergency actions. This flexibility
puts the user in total control of the application.
The PLC Program allows the Motion Program to be written without
concern of fault conditions or stop/ hold inputs. The PLC Program
provides digital processing only. PLC instructions may reference only
Global or Pre-defined Variables.
There is a maximum of eight PLC Programs, one for each Coordinate
System. Each PLC Program may have a maximum of 100
instructions. If 100 instructions is insufficient to handle the
application, an unused Coordinate System (with no axis) may be
added to make use of it's PLC Program.
7
Auxiliary Program
Auxiliary Programs are contained at the Application level. Therefore,
Auxiliary Programs can not directly control any motion. Auxiliary
Programs typically use Low Priority as opposed to High Priority
being generally reserved for Motion Programs.
Auxiliary Programs are limited to three instruction groups; Flow,
Logic and Other.
What is an Application?
An Application is the basic building block used by the AXIMA
Software. You, the user, write the Application. Applications have a
one to one relationship with the controller. Each Application contains
Coordinate Systems, Motion Programs, Auxiliary Programs and
Auxiliary PLC Programs. Each Coordinate System contains axes, a
Motion Program and a PLC Program. The Motion Program is
responsible (through the use of instructions) for controlling the
motion of the axes contained in the Coordinate System. The PLC
Program is used to monitor limit conditions and also provide high
speed digital processing. These two programs (Motion and PLC) run
simultaneously with the PLC Program running at the servo update
interval.
Application's may also contain Auxiliary Programs that contain nonmotion related instructions. This is because Auxiliary Programs are
not contained by a coordinate system and therefore the Auxiliary
Programs are not associated with the axes. This lack of association
limits the Auxiliary Programs to non-motion instructions.
The Application may also contain Auxiliary PLC Programs for
additional high-speed digital processing.
All types of programs can share process information through the use
of Global and/or Pre-defined Variables.
Coordinate Systems contain one or more axes. Each axis is assigned
to a command (digital to analog converter) output and an encoder
input. Each axis has servo loop parameters and motion limits. The
servo loop parameters include PID (Proportional, Integral,
Derivative) gains, time interval adjustments and notch filters. The
8
Introduction
Axis motion limit parameters include travel, position, velocity and
acceleration limits.
The figure below shows the relationships between Application
components.
APPLICATION
AXIMA
1st Coordinate
System
4th Coordinate
System
1st Axis
Parameter
Nth Axis
Parameter
Servo Loop
Options
Servo Loop
Options
Motion
Program
PLC
Program
Auxliary
Program 1
Auxliary
Program 7
Auxliary PLC
Program 1
Auxliary PLC
Program 7
Figure 2
Application Hierarchy Overview Diagram
9
AXIMA Hardware Specifications
See the table below for your particular AXIMA controller.
AXIMA
AXIMA
2000
AXIMA
4000
AXIMA ISA
Maximum Axis
8
2
4
8
Maximum Coordinate Systems
8
8*
8*
8
Maximum Motion Programs
8
8
8
8
Maximum Auxiliary Programs
(minus the number of
Motion Programs)
15
15
15
15
Maximum PLC Programs
8
8
8
8
Yes
Yes
Yes
Yes
Encoder Inputs
Each Axis
Each Axis
plus 2
Each Axis
Each Axis
Standard Inputs
32
16
16
32
Standard Outputs
32
12
12
32
Feature
Analog Inputs
Eight analog inputs, ±10V,
13 bit, single ended or 4
differential mode
Pre-defined Inputs
Pre-defined Outputs
Axis enable - (1) per axis, dry contact
(1) Watchdog timer, dry contact
None
7
13
None
Expanded I/O Banks (Optional)
(32 Inputs/32 Outputs)
1
2
2
4
Data Highway Plus® (Optional)
Yes
Yes
Yes
No
Modbus® (Optional)
Yes
Yes
Yes
No
Stepper Axis (Optional)
0/4/8
0/2
0/4
0/4/8
Power Requirements
96 to 264 VAC, 50/60 Hz single phase, 2 Amps max.
DSP Speed
10
27 MHz
50 MHz
50 MHz
27 MHz
Introduction
Feature
Communications
(1) 9-pin, D-sub, RS-232C
serial port.
(1) RS-232C/422/485
terminal block
19.2k max baud rate
Memory
AXIMA
AXIMA
2000
AXIMA
4000
AXIMA ISA
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
64K RAM
128K, 128
Flash
128K, 128
Flash
64K RAM
Noise Immunity
Designed to meet IEC801.2 standard
Environmental
Operating Temperature
Relative Humidity
Weight
32° to 133° F (0 to 45° ambient)
0 to 90%, non-condensing
8 lbs
5 lbs
5 lbs
>1 lbs
* Although you can enter up to eight coordinate systems for the
AXIMA 2000/4000 controllers, the AXIMA 2000 will only use the
first two coordinate systems and the AXIMA 4000 will only use
the first four coordinate systems.
11
Figure 3
12
Mechanical Dimensions of AXIMA
Introduction
Figure 4
Mechanical Dimensions of AXIMA 2000/4000
13
13.28
(337 mm)
1.25
(32 mm)
1.88
(48 mm)
3.86
4.17
(106 mm) (98 mm)
AXIMA-ISA MOTHERBOARD
STANDARD DAUGHTERBOARD
OPTIONAL I/O EXPANSION BOARD
Figure 5
14
Mechanical Dimensions of AXIMA ISA and ISA-STI-X
Understanding Motion
in a Coordinate System
There are four key concepts to understanding motion in a Coordinate
System.
1. Coordinate System Hierarchy (the relationship between a
Coordinate System, the Axes and a Motion Program).
2. How motion is generated.
3. Closed loop operation.
4. Motion program flow.
The following paragraphs and figures will help you understand these
concepts.
Coordinate System Hierarchy
The Coordinate System contains the axes and the Motion Program
(in the hierarchy). The motion of the axes in a Coordinate System is
controlled by the Motion Program. The Motion Program uses
instructions to accomplish the motion including; jog, gear, move,
sinusoidal move, etc.
How Motion is Generated
Axis motion is generated from any of four sources; the Coordinate
System Profiler, Jog Profiler, Cam Profiler and the Gear Profiler.
Any or all of these sources can generate profiles simultaneously. For
example; while Gearing, a coordinated move, can be performed on top
of the Gear Velocity. The sum of these four sources provides the
commanded position and is called the Primary set point. The fact
that these profiles are summed allows complex profiles and is a very
powerful feature of the AXIMA controller.
15
P/N 400290-00
Coordinated Move
The most commonly used source for axis motion is the Coordinate
System Move Profiler. All axes contained in the Coordinate System
are treated as one vector. The vector has a velocity, an acceleration
and a deceleration. The velocity of each axis is calculated to achieve
the programmed vector velocity. All axes programmed within a move
always start and stop at the same time.
Consider the case where a single axis is moved. The direction of the
move (vector direction) is along the motion of that (single) axis. The
velocity of the single axis is exactly the velocity specified for the
coordinate system vector (velocity, acceleration, deceleration are all
coordinate system attributes).
Figure 5
Coordinated Move
Now consider the case where two axes are involved in a coordinated
move, X axis will move five inches to the right and the Y axis moves
five inches up. The vector direction is a 45° angle between the X and
Y axes (see the Coordinated Move Figure above the Coordinated
Move diagram above). The velocity specified (say ten inches/second)
is the velocity along the vector direction (45° calculated by the
AXIMA Software). This means that the velocity of the X and Y axes
are less than ten inches/second (specifically the COS(45) times 10
inches/second or 7.07 inches/second for the X and Y axes).
Jog Profiler
The second method for generating motion is the Jog Profiler. There is
a separate Jog Profiler for each axis. All jogging motion is done on an
axis by axis basis there is no coordination between axes. The AXIMA
Software allows Jog motion for multiple axes to be programmed in
16
Understanding Motion in a Coordinate System
the same instruction, but the motion is not coordinated as it is when
the Move Instruction is used. The Jog Profiler can be used for
traditional type jogging, i.e. Accelerate, move at the programmed
speed until told to decel and stop. The Jog Profiler can also be used
to move a specified distance with accel and decel in either the
incremental or absolute mode.
Cam Profiler
The third method of generating motion is the Cam Profiler. The Cam
Profiler can be used to produce nonlinear repetitive type motions.
The follower axis position is determined by a combination of master
position and a cam table (local array). The cam table is a list of
follower positions sorted in order of increasing master axis position.
The master distance between each point within a segment is equal.
Up to eight segments can be used for each cam allowing areas of
coarse and fine cam increments. The AXIMA Software monitors the
position of the master axis and moves the follower axis to the
corresponding position according to the cam table linearly
interpolating between follower points. The AXIMA Software also has
instructions to automatically shift and scale the cam.
The Cam Profiler does not provide for automatic acceleration or
deceleration when engaging or disengaging a cam motion.
Gear Profiler
The Gear Profiler simply produces a follower axis command at the
programmed ratio of a master axis or encoder. The ratio can be
specified as a 32 bit floating point number or variable. Gear
acceleration and deceleration parameters can also be applied when
the gear function is turned on and off or when changes are made in
the gear ratio.
17
Figure 6
Axis Motion Calculations Diagram
Secondary Set Point
The final step in generating a command position is to add in the
backlash and leadscrew position error compensation correction
factors. This is added to the primary set point to generate the final
commanded position, the secondary set point (see the Servo Loop
Calculations diagram below). Another key AXIMA Software feature
is that this final commanded position is calculated at each servo
update interval providing updated trajectories of the highest possible
accuracy.
Closed Loop Operation
The closed loop operation compares the final commanded position
(secondary set point) to the encoder feedback to calculate a position
error (following error). This following error is used by the
Proportional, Integral and Derivative (PID) calculations to produce a
term (in volts) for each calculation. Feedforward velocity and
18
Understanding Motion in a Coordinate System
feedforward acceleration are open loop and use the commanded
velocity and acceleration to produce a velocity and an acceleration
term (in volts). Both feedforward terms are very useful in reducing
following error. This is because the calculation is open loop, which
means following error is not required to produce a command
response. All of the terms are summed into the summation point.
Filters may or may not be applied to the summed value. A low-pass
and/or a notch filter may be used to reduce machine vibration.
Lastly, the filter output signal may be limited by the command limit
specified in the Axis Limits dialog box or in the command limit
instruction. This result may be clamped to zero volts and the final
output signal is sent to the digital to analog converter (DAC). The
only effect on the actual voltage signal from this point on is the DAC
gain and offset values.
One of AXIMA Software’s most powerful features is the ability of the
application programmer to access information. All of the axis
commands, set points, summation points, closed loop terms and
output values etc. shown in the Servo Loop Calculations diagram
below can be accessed as Pre-defined Variables.
19
Figure 7
20
Servo Loop Calculations
Understanding
Programs
The AXIMA Software has three different types of programs; PLC,
Motion and Auxiliary. This gives you the flexibility needed to put you
in control of your application. These three programs work together to
solve the application.
Typically, a PLC program is the “master controller”, monitoring
status’s and controlling the Motion and Auxiliary Programs.
The Motion Program controls the motion and usually the logic for the
main sequence of operation.
Auxiliary Programs cannot directly control any motion, and are
typically used for such things as handling I/O communication with an
external PLC, updating the AXIMA controller’s status display, serial
operator interface and other data gathering.
NOTE:
Before you start writing programs, define the operation of
your system and write it down. Consider more than just
the motion. Consider the start/stop conditions, machine I/
O, the operator interface and the possible interface with
an external PLC. Understanding this definition will help
you define which functions to place in each program type
and what data to share between programs.
PLC Programs
The purpose of the PLC Program is to monitor controller fault
conditions, limits and safety/emergency actions. The PLC program
allows the Motion Program to be written without concern of fault
conditions or stop/hold inputs.
Each Coordinate System has one PLC Program available with a
maximum of 100 instructions. The PLC Program provides digital
processing only. PLC instructions may reference only Global or Predefined Variables. Since all Pre-defined Variables are Global, a PLC
21
P/N 400290-00
Program can control more than one Motion Program. PLC Programs
are typically selected to run on power-up.
A typical PLC Program would control the following functions:
•
•
•
•
•
•
Drive Enable Outputs.
Encoder Match (zero following error).
Feed Hold and Cycle Start.
Stop Motion.
Motion Program Run/Halt.
Axis Jog Control.
Listed below, are detailed explanations of how the following example
PLC Program controls the various system functions followed by a
PLC Program example:
22
•
Drive Enable Outputs are latched "On" when the Drive Enable
Input is momentarily turned on. Drive Enable Outputs are
turned off whenever the X or Y Over Travel Inputs are turned
“On” or “Off”, or when the Coordinate System follower limit is
exceeded.
•
When the Drive Enable Outputs are “Off”, an Encoder Match
(zero following error) is performed for both axes.
•
If the Feedhold Input is turned “On”, a feedhold is requested.
•
The Cycle Start Input is used to resume the motion from a
feedhold condition.
•
The Stop Input turns the Stop Move “On”, which decelerates the
current move to a stop. When the In Motion bit is turned “Off”,
indicating that the deceleration is complete, the Halt Motion
Program bit is turned “On” stopping the Motion Program.
•
If a Reset Input is turned “On”, and the Motion Program is not
running and the Stop Input is not “On”, a Motion Program Run
Request will be issued.
•
Jogging is controlled with the Jog Mode and Jog Direction
inputs. If the Drive Enable Output is “On”, a Jog Direction bit is
set which causes the axis will jog at the predetermined jog
velocity.
PLC Program Example:
PLC Program with 32 instruction(s), will run on power-up.
Load Contact DRIVES_ENABLE_PB
Or Contact ENABLE_X_DRIVE
And Not Contact X_OVER_TRAVEL_INPUT
And Not Contact Y_OVER_TRAVEL_INPUT
And Contact NOT_FOLLOWING_ERROR
Output ENABLE_X_DRIVE
Output ENABLE_Y_DRIVE
Load Not Contact ENABLE_X_DRIVE
Output X_ENC_MATCH
Output Y_ENC_MATCH
Load Contact FEED_HOLD_PB
Output FEED_HOLD_REQ
Load Contact CYCLE_START_PB
And Not Contact IN_FEEDHOLD
Output CYC_START_REQ
Load Contact STOP_INPUT
Output STOP_MOVE_REQ
Load Contact STOP_INPUT
And Not Contact IN_MOTION
Output HALT_MOTION_PROG_REQ
Load Not Contact STOP_INPUT
And Contact RESTART_PB
And Not Contact PROG_RUNNING
Output MOTION_PROG_RUN_REQ
Load Contact JOG_MODE_SELECT_INPUT
And Contact X_JOG_LEFT_INPUT
And Contact ENABLE_X_DRIVE
Output X_JOG_FWD
Load Contact JOG_MODE_SELECT_INPUT
And Contact X_JOG_RIGHT_INPUT
And Contact ENABLE_X_DRIVE
Output X_JOG_REV
23
Motion Programs
Each Coordinate System contains one Motion Program which
controls the motion and usually the logic for the main sequence of
operation of all axes within that Coordinate System.
In a typical application, the Motion Program would control multiple
modes of operation such as Homing, Jogging and the Automatic
Cycle. The best way to handle the different modes of operation is to
program a subroutine for each mode. The beginning of the program
will usually require a variable initialization section then a main loop
with If/Then instructions used to call a specific subroutine.
Motion Program Flow
It is important to understand the flow of a Motion Program. Most
instructions are obvious such as If/Then, GoTo, Call Subroutine,
Wait, Dwell, etc. When the program encounters a Cam, Gear or Jog
instruction it processes the instruction and starts the appropriate
motion while the program continues on to process the next
instruction without waiting for that motion to be completed.
In the case of a Move Instruction, the motion profile is calculated and
the move is started. Program execution will continue until another
Move Instruction (or other program control instructions such as
Wait, Dwell, etc.) is encountered.
Since only one Move Instruction can be performed at a time, the
program preprocess (buffers) the second move and suspends program
execution until the first move is completed. The second Move
Instruction is then executed and the program continues.
Motion Program Example:
Motion Program with 30 instruction(s) will run on power up
Comment = Initialize variables, only exicutes the first time the
Comment = program is run on power up or after a program halt.
PART_COUNT = 0
LOAD_OFFSET = 1.0025
Set And Clear Bits
Clear Bit HOME_COMPLETE
LABEL = MAINLOOP
24
If (HOME_INPUT ) Then Do
Call Subroutine HOMESUBROUTINE
End If/Then
If (JOG_INPUT ) Then Do
Call Subroutine JOGSUBROUTINE
End If/Then
If (AUTO_MODE_INPUT AND HOME_COMPLETE ) Then Do
Call Subroutine AUTOMODESUBROUTINE
End If/Then
GoTo MAINLOOP
LABEL = HOMESUBROUTINE
Comment = add home logic and motion here Return From Subroutine
LABEL = JOGSUBROUTINE
Comment = Add jog definintion here.
Comment = Jog logic and motion can be done here or
Comment = in a PLC program, it usually easier in PLC program.
Return From Subroutine
LABEL = AUTOMODESUBROUTINE
Comment = Add auto mode logic and motion here
If (AUTO_MODE_INPUT AND NOT ( CYCLE_STOP_INPUT ) ) Then Do
GoTo AUTOMODESUBROUTINE
End If/Then
25
Figure 8
Motion Program Flow
Special types of moves such as Move Wait and Trigger Move operate
differently. This operation is explained in the Move Instruction
section.
Auxiliary Programs
Auxiliary Programs are contained at the application level. Therefore,
Auxiliary Programs can not directly control the motion of an axis.
Auxiliary programs typically use the Low Priority as High Priority is
generally reserved for Motion Programs. Auxiliary Programs are
limited to three instruction groups: Flow, Logic and Other.
26
Auxiliary Program Example:
The example Auxiliary Program shown below controls when an
analog input value (converted to user "velocity" units) is added to the
constant velocity of an axis's motion being controlled from a Motion
Program.
LABEL = TOP
If (SET_WEB_SPEED) Then Do
NEW_SPEED = 1
GoTo TOP
End If/Then
NEW_SPEED = 1 + (0.1*ADC_CHANNEL1)
NEW_DWELL = 1 + ADC_CHANNEL2)
GoTo TOP
The following variables are used in this program:
Name
Scope
Type
Description
NEW_DWELL
Global
Integer
ADC_CHANNEL1
Pre-Defined
Floating Point 32
Analog Input Number 1
ADC_CHANNEL2
Pre-Defined
Floating point 32
Analog Input Number 2
NEW_SPEED
Pre-Defined
Floating Point 32
Coordinate System #1
Feedrate Override
SET_WEB_SPEED
Pre-Defined
Bit
Input Number 1
Referring to the example program, when the SET_WEB_SPEED
input is on, the speed of the axis will remain unchanged
(NEW_SPEED = 1), when this input is off, the value of
ADC_CHANNEL1 (analog channel 1) will be added to the Feedrate
Override which will change the velocity of the axis.
27
Understanding
Multitasking
Program Priority
Motion and PLC Programs are automatically assigned when a
Coordinate System is defined.
AXIMA Software has a total of 23 different user programs available
in an Application. These 23 programs are made up of a combination
of Motion, PLC and Auxiliary Programs. The maximum number of
each program (Motion, PLC and Auxiliary) that you can have in an
AXIMA Software application is shown below:
MOTION PROGRAMS = 8
PLC PROGRAMS = 8
AUXILIARY PROGRAMS = 15
For example, if your Application had eight Coordinate Systems
defined, you would automatically have eight Motion and PLC
Programs giving you a total of sixteen user programs used.
Therefore, you could assign up to seven Auxiliary Programs giving
you a total of 23 user program in your Application.
Each program is ‘prioritized’ for processor execution position and
‘timesliced’ for duration amount. This is necessary since there is only
one Digital Signal Processor (DSP) contained within AXIMA
controller. The goal is to maximize the DSP’s processing performance
while providing smooth motion, efficient fault handling and fast I/O
processing.
Assigning Program Priorities
There are a total number of eight High Priority programs available
and generally speaking, these are Motion Programs (AXIMA
Software’s default selection). Motion Programs are automatically
assigned as High Priority when establishing the Coordinate System.
29
P/N 400290-00
Likewise, the total number of Low Priority programs is set at seven
which is initially assigned to the Auxiliary Programs as the default
condition.
Along with High and Low Priority programs, PLC Programs have the
Highest Priority available. This priority level is strictly reserved for
PLC Programs and is not changeable.
For the 23 possible programs, the total number of priority
assignments is as follows:
HIGH PRIORITY PROGRAMS total = 8 (PLC only)
HIGH PRIORITY PROGRAMS total = 8 (Motion or Auxiliary)
LOW PRIORITY PROGRAMS total = 7 (Motion or Auxiliary)
The default relationship between the High Priority (Motion)
programs and Low Priority (Auxiliary) programs can be overwritten
as necessary. To do so, select Advanced (indicated by a check mark in
front) under Options in the toolbar section of the Application View
dialog box. The next time the user enters any Motion or Auxiliary
Program, the bottom right hand corner of the program indicates a
radio button box for either High or Low Priority selection.
Flexibility within the AXIMA Software allows the user to define
Motion and Auxiliary Programs in any High or Low Priority fashion
as long as all parameters listed previously are met. AXIMA Software
is also designed to prevent the user from going beyond the stated
limitations. For instance, if the user has already defined a maximum
of eight High Priority programs, only Low Priority programs will
automatically be added.
AXIMA Software allows complete flexibility while easily providing
access to define the application as defined by the machine or process
requirements.
Processing High and Low Priority
Programs
The rates of execution for a Highest Priority program is set at the
Servo Loop Update Interval (SUI). The SUI is user selectable and is
dependent on the total number of axes configured at the time of
selection. Each PLC Program is limited to no more than 100 lines of
30
Understanding Multitasking Program Priority
code. Since we have a total number of eight PLC Programs available,
up to 800 lines of PLC code are possible.
High Priority and Low Priority programs are defaulted in the Motion
and Auxiliary Programs but limitations exist. The duration of
processor execution on both High and Low Priority programs is set
for a total of one millisecond each by the DSP.
On average, the one millisecond execution block may process
approximately 3 to 5 program instructions but this is very dependent
upon instruction type. As of yet, no consideration has been given to
updating the servo loops. After one millisecond of program execution,
the DSP ‘holds’ the current program point in the process and moves
on to the next program in the ‘execution cycle’. This process allows a
single processor to multitask multiple programs.
The difference between priority distinctions are that all High Priority
programs and only one Low Priority program are executed within one
execution cycle. During the next execution cycle, all High Priority
programs are again executed for one millisecond each and the next
Low Priority in the queue is executed. The process continues and
repeats until halted.
To further illustrate this concept, the following example would be a
typical depiction of program priority execution for three High, and
two Low Priority programs.
Table 5
Program Priority Example
High
Low
MP1
MP2
MP3
AP1
t0
t1
t2
t3
t4
t5
t6
t8
t9
t10
AP2
t7
t11…
* where t x = one millisecond of fixed time to execute program
instructions
31
Figure 9
Program Priority Execution
Program Priority Execution Interval Times
The overall results of the DSP execution process should be
considered, especially for larger applications. To calculate the
interval of leaving one particular program and returning to that
same program again, after processing other programs in the
execution cycle, the user would want to know how long it may take.
This could affect motion or any logic function if the time between
operations is too long. The following equations would be the resultant
after selection of High and Low Priority programs for the application:
If no LOW PRIORITY and HIGH PRIORITY programs exist, then...
PROGRAM TIME interval = (# of programs) * 1 msec
If any LOW PRIORITY programs exists, then...
PROGRAM TIME interval, High Priority = (1 + # of HIGH
PRIORITY programs) * 1 msec
PROGRAM TIME interval, Low Priority = [(1 + # of HIGH
PRIORITY programs) * # of LOW PRIORITY programs] *
1 msec
For the example outlined above, the time it would take to return to
any one High Priority (Motion) program is four millisecond. It also
32
follows then that the Low Priority (Auxiliary) program time interval
is eight millisecond.
!
CAUTION
If we were to maximize AXIMA Software’s capabilities in one
Application and use all programs, the interval time to return to any
particular High or Low Priority Program is nine millisecond and 63
millisecond respectively.
This only takes into account the time interval returns to programs.
The number and type of instructions within those programs will also
have a bearing on Application performance. One can quickly realize
that if an operation within a particular program is somewhat time
dependent, understanding High and Low Priority interval times
becomes crucial.
If a program is halted or in a Wait state such as a Wait For Bit
Instruction, no time is spent on the halted program and the next
program in the execution string is executed.
Effects of PLC Program (High Priority) on
Processor Execution Time
Since PLC Programs are defined as having the High Priority, one
PLC Program will be scanned within one SUI. Since the AXIMA
Software can achieve SUIs of 50 scanned within 50 Other factors still
need to be considered to complete the controller requirements.
The number of user selected PLC Programs are normally established
during the design and configuration stages (with user limitations of
eight total. This execution cycle follows the pattern detailed below:
Therefore, if any PLC programs exists, then...
PLC PROGRAMS total = PLC programs + 2
Because of PLC background operations, the AXIMA Software assigns
two additional PLC programmed scan blocks to complete the needed
process tasks. These two PLC time blocks evaluate the entire
Application for all possible timers*, latches* and counters* in one
program and scan the AXIMA "hardware" inputs & outputs (I/O) in
the other. Therefore, the total number of PLC Programs can never be
33
more than ten. (*Note: Indicated as TLC with a total limit of eight
each for timers, latches and counters.)
Like High and Low Priority programs, PLC Programs also have an
execution cycle but it is exclusive to the High Priority Programs and
all instructions are executed.
Figure 10
PLC Program Execution Order
The time it then takes to evaluate all of the PLC Programs, called the
PLC execution cycle time, is:
PLC EXECUTION CYCLE TIME = (PLC programs + 2) * SUI
The PLC execution cycle is the time guaranteed to process all PLC
instructions and PLC assigned I/O and this will vary from
Application to Application.
From our previous example, if we assume that only one PLC Program
was needed to satisfy the Application and the SUI is set at the fastest
rate of 200 second/axis with four axes), our PLC scan cycle would be
0.6 millisecond. But if we needed eight PLC Programs and the SUI
rate was set at the longest time of 700 PLC cycle would then be 7.0
millisecond - more than ten times longer!
Completing The Timeslicing Process ‘Picture’
With SUI
The SUI is user selectable within the AXIMA Software and all axes
will be updated within the SUI (up to 700 by the Watchdog timer). To
change the default selection, (400 qual to 8 axes at 50 of Hierarchy
Level at the Application View. Present the Application dialog box by
‘double clicking’ the Application Name on the right side’s Text View.
34
Under the Options button, select a different value in s step it may be
wise to verify the axes setting number for the application. This will
allow the appropriate update range for the SUI. To do so, select the
Controller line under Options in the toolbar section of the Application
View. This presents an Axes radio button area, among other items, to
configuration the application to actual AXIMA hardware.
The quicker the SUI rate setting, the more frequent the axes servo
loops will be updated. But the frequency of faster updates takes
processing duration away from Motion or Auxiliary Program
instructions. Remember, Motion and Auxiliary Program execution
time is fixed at one millisecond.
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Recommendations are therefore made to the user to select an SUI at
the slowest allowable setting (while still receiving superb positioning
and/or PLC updates as demanded by the application) to provide
ample program instruction execution time. The goal is to balance
DSP performance by providing as much processing time for all
Motion, Auxiliary and PLC Programs and updating the servo loops
adequately.
T(msec)
ime
MP2
MP1
SUI 1
1
MP3
2
Figure 11 Timeslicing Process Diagram.
A complete time line depicting our example, called ‘timeslicing’, is
shown above. In this example, the SUI is set at 222 servo loops for an
Application with three High Priority Motion Programs and two PLC
Programs.
The light gray area represents the actual duration of time to
complete all servo loop updates. This verifies and commands the
positioner to be on target at that moment in time. The duration of
35
updating the servo loops will be less than the frequency of which
these updates are needed, as indicated by extra dark gray and white
time duration within one SUI time frame. The dark gray duration is
the physical time required to scan one PLC program. This too is
required to occur within one SUI.
Together the combination of light and dark gray processing duration
subtracted from the SUI represents the time remaining to
accomplish Motion or Auxiliary program instructions. Added all
together within a one millisecondof fixed time block, this becomes a
significant factor of processor time. In this example, there is
relatively little time remaining for adequately processing either
Motion or Auxiliary Program instructions.
Effect of Lengthening the SUI
In the diagram in section 6, the SUI was set to approximately 222
effect of this setting is the low amount of processing time during 1
servo loop update interval given to execute instructions in either the
Motion or Auxiliary programs.
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To ensure more instructions are processed while not sacrificing
motion or PLC performance, the diagram below illustrates the same
scenario but with a slower SUI setting. Let us assume a new SUI
setting of 700 rform as indicated in the ‘timeslice’ diagram below.
T(msec)
ime
MP2
MP1
SUI 1
Figure 12
36
1
MP3
2
Timeslicing Servo Update Interval Diagram
Timeslicing Process Consideration Conclusions
You have complete control in the selection of updating the SUI within
the AXIMA Software. The range is from 200 to 700 per system or 100
the quicker the servo loop will be updated. But the slower Motion and
Auxiliary Programs will execute.
A balance will need to be maintained to provide excellent system
performance in all Application aspects. As a general design rule for
larger Applications, as much of the system solution that can be
achieved with PLC instructions should be attempted while selecting
the slowest SUI frequency rate as possible (assuming motion is not
adversely effected). This will guarantee the most processing of all
Motion and Auxiliary Program instructions as possible.
37
Communications
Interface
Overview
This section describes the details that are required to interface an
external interface to the AXIMA controller COM1 or COM2. This
interface is accomplished with ASCII serial communications.
The communications may be accomplished using either the RS-232C
or RS232C/485 COM port. The RS485 specification supports up to 32
AXIMA controllers on a single multi-drop communications network.
Addressing
Each AXIMA controller has a unique address that is used to
distinguish one controller from the next.
Terminal Mode Communications
In a multi-drop configuration you can communicate with any or all of
the AXIMA controller's in your system using special control
characters and echo modes.
Echo Modes
All non-zero addresses default to Echo Mode 6 at power-up. Any
AXIMA controller with an address of zero will default to Echo Mode
1. Use the table below to set the desired Echo Mode. To change the
Echo Mode type; echo# <CR>. Where # is the Echo Mode from the
table below.
39
P/N 400290-00
Table 6
Echo Modes
Echo Mode
Command
Prompt
Error
Messages
Character
Echo
0
On
On
Off
1
On
On
On
2
On
Off
Off
3
On
Off
On
4
Off
On
Off
5
Off
On
On
6
Off
Off
Off
7
Off
Off
On
Establishing Communications
Use the table below to establish communications with individual or
all addresses.
Table 7
Establishing Communications
Syntax
40
Result
<CR> <CR>
Send two carriage returns to activate
serial ports and baud rate information.
CNTL A <CR>
Opens communications to all controllers.
CNTL B <CR>
Closes communications to all controllers.
CNTL A <address> <CR>
Opens communications to an individual
controller.
CNTL B <address> <CR>
Closes communications to an individual
controller.
To simultaneously communicate with all addresses in a multi-drop
system, all AXIMA controllers must be in Echo Mode 6.
!
CAUTION
Use caution when sending commands to more than one AXIMA
controller simultaneously. Because all addresses are using Echo Mode
6, the AXIMA controllers do not echo a response. To verify that a
command, or group of commands, was received by all addresses in
your system, each address must be queried individually using Echo
Mode 1. Also, sending a large number of commands simultaneously,
such as an entire Application, could cause communication problems.
For example
In this example we will have two AXIMA controllers in a multi-drop
configuration. Their addresses are 1 and 2. Upon power-up they will
be in Echo Mode 6 (i.e. only responses to queries will be echoed back).
Lets assume you want to communicate with AXIMA controller #1. To
establish communications with AXIMA controller #1 type the
following:
Type
Result
<CR> <CR>
Sends two carriage returns to activate serial
ports and baud rate detection.
CNTL B <CR>
Closes communications to all AXIMA
controllers in the system. (Not necessary but
helpful to establish a starting point).
CNTL A 1 <CR>
Opens communications with AXIMA
controller #1 only.
Echo1 <CR>
Changes the Echo Mode of AXIMA controller
#1 to echo mode 1.
Now that you have established communications, a set of commands
are available for sending data to the AXIMA controller as well as
retrieving data from the controller.
41
For example
If you wanted to query AXIMA controller #1 for the value of a Global
Variable you previously defined in a program. For this example we
will use the variable P1 and parameter P12291.
Prompt/Display
Result
SYS>?P1 <CR>
Queries AXIMA controller #1 for the value of
P1 (Because we are in echo mode 1, the system
prompt SYS> is displayed).
SYS>643
The value of P1 is displayed.
SYS>prog1
Move to program 1 level.
PO1>?P12291 <CR>
Queries AXIMA controller #1 for the value of
P12291.
14
The value of P12291 is displayed.
P01>
PO1>Echo6 <CR>
Changes the Echo Mode of AXIMA controller
#1 to Echo Mode 6. The prompt is not displayed
in Echo Mode 6.
-14
?P12291 was sent but only the value of variable
is displayed.
Echo1 <CR> was typed.
PO1>
The prompt is displayed again.
Data Input/Output
This following describes the retrieval of Global and Pre-defined
Variables. Local Variables, input and output are not described here.
Global and Pre-defined Variables are listed in the printout generated
by the AXIMA Software. The printout includes the name and type for
each variable. The basic names used by the AXIMA controller can
also be included in the printout by checking the Advanced Mode
option in the General tab in the Preferences dialog box (accessed from
the Options menu).
A fourth column is added to the list of variables and includes either
a bit number or a P number. Bit numbers are used for digital
information and P numbers are used for analog information.
42
Digital
To send digital information to the AXIMA controller the command is
BIT followed by the bit number, the equals sign and either one(1) or
zero (0).
For example
SET 512 <CR>
This will set bit 512.
CLR 513 <CR>
This will clear bit 513.
To retrieve digital information from the AXIMA controller the
command is question mark then BIT followed by the bit number.
For example
?BIT 512 <CR>
This will retrieve the status of bit 512.
If bit 512 is off, a zero is returned, if it is on, a minus one (-1) is
returned.
Analog
To send analog information to the AXIMA controller the command is
"P" followed by the parameter number equals the new value.
For example
P8192 = 1 <CR>
This will set P 8192 to the value of one (1).
To retrieve digital information from the AXIMA controller the
command is question mark then "P" followed by the parameter
number.
For example
?P8192 <CR>
This will retrieve the status of parameter 8192.
Both integer and floating point analog data is sent and retrieved in
the same way. Obviously, floating point analog data must include the
decimal point.
43
Programming
Examples
Homing an Axis Example
We want to position the carriage to the physical location of the
external HOME_SWITCH sensor and then to the encoder maker.
Gear Reducer
External
Home Sensor
Motor With
Resolver
Carriage
Offset
Distance
Mechanical
Zero Point
Figure 13 Homing Example
The Move Type used in this example is an Interruptible Move (see
Move Instruction in the Instructions section). When the program
executes an Interruptible Move, the axis will start the move unless
the “Interruptible on bit” is true in which case the “If interrupted”
move is executed.
45
P/N 400290-00
Example Program
Motion program with 19 Instruction(s) will run on power-up
Set Velocity To 0.25 inches/Sec
Set Acceleration Ramp To 100.0 inches/Sec/Sec
Set Deceleration Ramp To 100.0 inches/Sec/Sec
LABEL = HOMING_AXIS_1
Comment = Program will suspend further execution until HOME_INITIATE
(input 16) is set.
Wait Until HOME_INITIATE is Set
Comment = The HOME_DONE (output 48) is cleared.
Set And Clear Bits
Clear Bit HOME_DONE
Comment = If the HOME_SWITCH (input 24) is set, the axis moves CCW 2
inches. If during this move the HOME_SWITCH is cleared or it's cleared to
start with, the axis will move CCW 0.25 inches
Move,
Wait until complete
Interruptible on bit HOME_SWITCH set,
Axis -1 Incrementally CCW 2.0 inches
If interrupted, incrementally CCW 0.25 inches
Comment = Moves CW until the HOME_SWITCH (input 24) is set then moves
CCW 0.25 inches.
Move,
Wait until complete
Interruptible on bit HOME_SWITCH set,
Axis -1 Incrementally CW 12.0 inches
If interrupted, incrementally CCW 0.25 inches
Comment = After HOME_SWITCH (input 24) is set the motor moves to the encoder marker (home position).
Home,
Axis-1 1.0 inches CCW (Rising, Encoder 1 Marker)
Comment = Program will suspend further execution until HOME_COMP(Axis
1 capture complete) is set.
Wait Until HOME_COMP is Set
Comment = HOME_DONE (output 48) is set.
Set And Clear Bits
Set Bit HOME_DONE
GoTo HOMING_AXIS_1
46
Product Alignment Example
The AXIMA controller is used to align a product that is randomly feed
onto a conveyer. Sensors connected to the AXIMA controller’s high
speed inputs are used to detect the presence of each end the product
as they move onto the conveyer.
We used the Gear Instruction in a Motion Program to slave Axes 1
and 2 to Axis 3. The Encoder Capture Instruction is used to capture
the position of each motors encoder as the product triggers each of the
sensors. The encoder position values are stored as encoder counts in
the “Hardware Capture” Pre-Defined Variable, and the “Capture
Complete” bit is set.
The motion program uses the “Phase Error” to align the product
before it is transferred to the final conveyer. The phase error is
calculated using the following formula:
PE = HC1 - PP HC2
Where
PE = Phase Error
HC1 = Hardware Capture Axis #1
PP = Profiler Position
HC2 = Hardware Capture Axis #2
The result is converted from encoder counts to user units and loaded
into the Move Instruction which is used to advance or retard that belt
to align the part. Notice the AXIMA controller is executing a Move
Instruction on top of a Gear Instruction.
47
Figure 14
Product Alignment Example
Example Program
Motion program with 26 Instruction(s) will run on power-up
Comment = The Encoder Preload instruction sets all positions to zero.
Encoder Preload,
48
Axis #1 to 0.0 inches,
Comment = Defines the relationship between the master conveyor and slaves.
Gear Definition,
Axis #2 Encoder=3, Pulses=4096.0, Ratio=1.0:1.0,
Preload=0.0,
Axis #1 Encoder=3, Pulses=4096.0, Ratio=1.0:1.0,
Preload=0.0
Comment = Turns the gearing on.
Gear Control,
Axis #1 On offset=0 counts,
Axis #2 On offset=0 counts
Comment = Defines the parameters to be used when jogging.
Jog Definition,
Axis #3 Velocity=2.0, Accel=100.0, Decel=100.0
LABEL = START
Comment = The program is waiting for READY to be set before axis 3 jogs.
Wait Until READY is Set
Comment = Starts the jog as defined in Jog Definition for incoming conveyor.
Jog Control,
Axis #3 CW and Reset
LABEL = LOOP
Comment = Set an encoder capture as defined.
Encoder Capture,
Axis #1 (Rising, Input 24),
Axis #2 (Rising, Input 25)
Comment = The program will wait until axis 1 encoder capture is set
Wait Until A1_CAP_COMP is Set
Comment = The program will wait until axis 2 encoder capture is set.
Wait Until A2_CAP_COMP is Set
Comment = PHASER is phase Error calculated by AXIMA.
PHASER = A1HARDCAP - PROFILER_POSITION - A2HARDCAP
Comment = Phaser is in encoder counts and needs to be in user units.
PHASERU = PHASER / 4096
Comment = Axis 1 will move the distance of PHASERU on top of the gearing.
Move,
Wait until complete,
Axis #1 Incrementally CW PHASERU inches
If (READY) Then Do
GoTo LOOP
49
End If/Then
Jog Control,
Axis #3 Stop and Reset
GoTo START
50
Two Axis Gluing Example
We use two axes (X and Y) to apply glue to the perimeter of a nine
inch paperboard product with two inch radii rounded corners.
Initially, an external shuttle (not shown in the diagram below) moves
the paperboard into position triggering a sensor. If sensor input
conditions are met (verified by the PLC program), the Motion
Program moves the glue tip applicator to a start position above the
paperboard.
Upon reaching the start position, glue is dispensed during the X-Y
travel outlining a nine inch square with two inch radii rounded
corners. The process will continue again and again as long as
paperboard is shuttled and no error conditions occur.
Figure 15 Two Axis Gluing Application
51
Input condition checking is accomplished by the PLC Program for
certain machine state requests. For example, stop conditions from
either paperboard jam, operator inputs of either normal Stop or
Emergency Stop (E-Stop), or excessive following error buildup. Each
results in different recovery schemes and could be very useful in
many other applications as well.
Since the AXIMA Software and controller provides both circular
interpolation and compounded indexing capabilities, continuous
path velocities are possible. This yields a glue bead that is uniform
throughout X-Y motion and requires less On/Off control of the glue
dispenser solenoid. The end results are faster throughputs, higher
qualities, larger yields and reduced machine component wear.
Variables Used:
Inputs (defined and assigned by User)
START_HOME
Bit
Pre-defined
BIT 0
PAPERBOARD_PRESENT
Bit
Pre-defined
BIT 1
RUN
Bit
Pre-defined
BIT 2
RESUME_PROCESS
Bit
Pre-defined
BIT 3
X_HOME_SENSOR
Bit
Pre-defined
BIT 24
Y_HOME_SENSOR
Bit
Pre-defined
BIT 25
STOP_PROCESS
Bit
Pre-defined
BIT 30
E_STOP
Bit
Pre-defined
BIT 31
Outputs (defined and assigned by User)
52
X_AXIS_ENABLE
Bit
Pre-defined
BIT 32
Y_AXIS_ENABLE
Bit
Pre-defined
BIT 33
JAM_ALARM
Bit
Pre-defined
BIT 37
MACHINE_STOPPED
Bit
Pre-defined
BIT 38
GLUING
Bit
Pre-defined
BIT 39
Global References (defined by User)
DISPENSE_GLUE_OK
Bit
Global
BIT 128
PAPERBOARD_GLUED
Bit
Global
BIT 129
ENABLE_DRIVES
Bit
Global
BIT 130
OK_TO_RUN
Bit
Global
BIT 131
PAPERBOARD_JAM
Bit
Global
BIT 132
Internal References (assigned by User)
IN_MOTION
Bit
Pre-defined
BIT 516
IN_FEEDHOLD
Bit
Pre-defined
BIT 519
FEEDHOLD_REQUEST
Bit
Pre-defined
BIT 520
CYCLE_START_REQUEST
Bit
Pre-defined
BIT 521
NOT_FOLLOWING_ERROR
Bit
Pre-defined
BIT 529
X_MARKER_CAPTURE_COMPLE
Bit
Pre-defined
BIT 777
Y_MARKER_CAPTURE_COMPLE
Bit
Pre-defined
BIT 809
HALT_MOTION_PROGRAM
Bit
Pre-defined
BIT 033
RUN_MOTION_PROGRAM
Bit
Pre-defined
BIT 1032
Example Program
Motion Program with 50 instruction(s) will run on power-up
Comment = The next 3 instructions set the profile for the Homing Routine's acceleration, deceleration and speed.
Comment = The Encoder Match instruction zeros out any accumulated following error, regardless of current position. This in effect will prevent unwanted
motor motion.
Encoder Match,
X-axis,
Y-axis
Comment = The next 3 instructions initiate a Global bit for the PLC program
to enable the drives (Output's #32 & #33). Setting, dwelling and clearing of a
Global bit in this Motion Program is the basis for the PLC Program’s latching
circuit (see PLC program).
Set And Clear Bits
53
Set Bit ENABLE_DRIVES
Dwell For 0.1 Seconds
Set And Clear Bits
Clear Bit ENABLE_DRIVES
Comment = The many following instruction constitute a Homing Routine.
LABEL = HOME_ROUTINE
Comment = The following Wait Until instruction holds the program until
Start Home input (Input #0) is set.
Wait Until START_HOME is Set
Comment = The following Home instruction move each axis in a direction toward external sensors (X-axis > Input #24 and Y-axis > Input #25).
Home,
X-axis 20.0 inches left (Rising, Input 24)
Wait Until X_MARKER_CAPTURE_COMPLETE is Set
Wait Until IN_MOTION is Clear
Home,
Y-axis 20.0 inches down (Rising, Input 25)
Wait Until Y_MARKER_CAPTURE_COMPLETE is Set
Comment = The following Homes instructions rotate the axes to the motor's
marker (make sure to complete at least one revolution). This reduces exact sensor location error.
Home,
X-axis 1.1 inches right (Rising, Encoder 1 Marker)
Wait Until X_MARKER_CAPTURE_COMPLETE is Set
Home,
Y-axis 1.1 inches up (Rising, Encoder 2 Marker)
Wait Until Y_MARKER_CAPTURE_COMPLETE is Set
Comment = The following Encoder Preload instruction establishes the machine's repeated absolute 'Zero Point' (assuming the motors were not removed
from last Powered State and the Home Sensors weren’t grossly moved).
Encoder Preload,
X-axis to 0.0 inches,
Y-axis to 0.0 inches
Comment = HOME ROUTINE END
Comment = The following 3 instructions establishes new acceleration, deceleration and speed for normal machine operation.
54
Comment = The following Batch Routine sets up the process.
LABEL = BEGIN_BATCH
Comment = The following Wait instruction holds the program until Input #2 is
set. This is the operator's RUN button which is monitored by the PLC program.
Wait Until OK_TO_RUN is Set
Comment = The following If/Then instruction initiates a ‘Clear Paperboard’
alarm if it occurred later in the program. This is enunciated by the PLC program.
If (PAPERBOARD_JAM) Then Do
Set And Clear Bits
Clear Bit PAPERBOARD_JAM
End If/Then
Comment = The following Wait instruction holds the program until new paperboard has been sensed (Input #1).
Wait Until PAPERBOARD_PRESENT is Set
Comment = The following Move & Wait instruction is a move to pattern start
point with no glue being dispensed along the way.
Move & Wait,
X-axis To Absolute Position 3.0 inches,
Y-axis To Absolute Position 4.0 inches
Comment = The following Glue Pattern Routine establishes a 9" rounded corner square on the paperboard.
LABEL = CORNERED_SQUARE_LOOP
Comment = ALL MOVES WITHIN THE PATTERN ARE COMPOUNDED TO
PROVIDE A CONTINUOUS PATH VELOCITY PROFILE. This increases system efficiency and distributes a uniform glue bead whether on a straight side or
on the arc.
Comment = The following Set Bit instruction will send the PLC program a Global Bit stating O.K. to dispense glue. (The PLC Program will determine if all
other conditions have been met as well.)
Set And Clear Bits
Set Bit DISPENSE_GLUE_OK
Comment = The following Move instruction is a linear move to the right along
the bottom horizontal side.
Compound Move,
X-axis Incrementally right 5.0 inches
Comment = The following Sinusoidal Move instruction is a 90 degree arc to
turn CCW to meet the right vertical side.
Compound Sinusoidal Move,
X-axis Destination=10.0 inches, Sweep=90.0, Phase=0.0, Amplitude=2.0,
Y-axis Destination=6.0 inches, Sweep=90.0, Phase=270.0, Amplitude=2.0
Comment = The following Move instruction is a linear move outward along the
right vertical side.
55
Compound Move,
Y-axis Incrementally up 5.0 inches
turn CCW to meet the far horizontal side.
Comment = The following Move instruction is a linear move along the far horizontal side.
Compound Move,
X-axis Incrementally left 5.0 inches
turn CCW to meet the left vertical side.
Comment = The following Move instruction is a linear move inward along the
left vertical side.
Compound Move,
Y-axis Incrementally down 5.0 inches
turn CCW to meet the near horizontal side. Note that the Wait Until In Motion
is Cleared check box was used. This will allow the glue dispenser to continue
dispensing until the exact moment motion is stopped (view the very next instruction). Had this option not been selected, the dispenser would have stopped just
after this Sinusoidal Move instruction was commanded.
Sinusoidal Move and Wait,
Comment = The following Set Bit instruction will send the PLC Program a Global Bit stopping the dispensing of glue.
Set And Clear Bits
Clear Bit DISPENSE_GLUE_OK
Comment = The following Dwell allows for glue to stop dripping from the dispenser tip.
Comment = The following routine portion will evaluate paperboard removal
(with glue). If paperboard is not removed, or 'jam' detected, then a return to 'Zero Point' is sent.
Comment = The following Set Bit instruction sends a Global bit to the PLC to
initiate paperboard (with glue) removal.
Set And Clear Bits
Set Bit PAPERBOARD_GLUED
56
Comment = The following Dwell allows for removal of the paperboard using
the PLC program's, Output #40, control of an external solenoid.
Comment = The following If/Then instruction will prevent continuance if paperboard is not cleared.
If (PAPERBOARD_PRESENT) Then Do
Comment = The following Set Bit instruction alarms the operator that a potential paperboard 'jam' has occurred. This Global Bit is seen by the PLC program
for processing.
Set And Clear Bits
Set Bit PAPERBOARD_JAM
Comment = The following Move instruction is a return to the 'Zero Point'. This
allows manual paperboard removal without obstruction from mechanical machine elements.
Move,
X-axis To Absolute Position 0.0 inches,
Y-axis To Absolute Position 0.0 inches
Comment = The following Clear Bit instruction sends a Global bit to the PLC
program which drops out the RUN contact.
Set And Clear Bits
Clear Bit OK_TO_RUN
Comment = The following Go To instruction sends the program back to the
Batch Routine to start again.
GoTo BEGIN_BATCH
End If/Then
Comment = The following Wait instruction holds the program until new paperboard has been sensed (Input #1).
Wait Until PAPERBOARD_PRESENT is Set
Comment = The following unconditional Go To instruction directs the program
to the continual production process.
GoTo CORNERED_SQUARE_LOOP
PLC Program with 27 instruction(s) will run on power-up
Load Contact ENABLE_DRIVES
Or Contact X_AXIS_ENABLE
Or Contact Y_AXIS_ENABLE
Load Contact NOT_FOLLOWING_ERROR
And Load
Output X_AXIS_ENABLE
Output Y_AXIS_ENABLE
Load Contact RUN
Output OK_TO_RUN
Load Not Contact IN_FEEDHOLD
57
And Contact IN_MOTION
And Contact DISPENSE_GLUE_OK
Output GLUING
Load Contact PAPERBOARD_JAM
Output JAM_ALARM
Load Contact STOP_PROCESS
Output FEEDHOLD_REQUEST
Load Contact RUN
And Contact IN_FEEDHOLD
Output CYCLE_START_REQUEST
Load Contact E_STOP
Or Not Contact NOT_FOLLOWING_ERROR
Output HALT_MOTION_PROGRAM
Load Contact JAM_ALARM
Or Contact FEEDHOLD_REQUEST
Or Contact IN_FEEDHOLD
Output MACHINE_STOPPED
58
MX/AXIMA Communications Example
This example demonstrates how to read the value of an MX drive
parameter (Pr83, motor position) and write to an MX parameter
(Pr01, Digital Speed Preset). The protocol is documented in the serial
communications section of the MX manual. Two MX parameters
(Pr22 and Pr23) and three bits (b21, b51, and b52) need to be properly
entered before communications can be established. Information on
these parameters and bits can be found in the MX manual.
The MX drive’s serial communications plug D and AXIMA
controller’s COM 2 serial port should be wired as shown in the
following diagram:
Figure 16 AXIMA To MX Drive Serial Communications Diagram
The AXIMA controller's COM 2 port must be configured for RS422
communications. To configure the AXIMA controller's COM 2 serial
port for RS422 communications, perform the following procedure:
1. Set jumper JP3 to 422 (between pins 2 and 3).
2. Remove JP1 of the daughterboard by cutting it with a wire
cutter.
The following AXIMA Motion Program is used to establish serial
communications between an AXIMA controller and an MX drive.
The variable "Motor Position" (P0), is defined as a global integer.
59
Example Program
Motion Program with 25 instruction(s)
LABEL = MAIN_LOOP
Call Subroutine COMMUNICATIONS
Comment = Reset encoder to the value read from Pr 83.
Encoder #1, Reset To MOTOR_POSITION
GoTo MAIN_LOOP
LABEL = COMMUNICATIONS
Comment = Dimension 2 string variables of 10 characters each.
Generic = DIM $V(2,10)
Comment = Open com port 2 for 19200 baud, no parity, 8 data bits, 1 stop bit
Generic = OPEN "COM2:19200,N,8,1" AS #2
Comment = Write -1000 rpm into Pr01 of the MX.
Generic = PRINT #2, CHR$(4)+"0011"+CHR$(2)+"011000"+CHR$(3)+CHR$(13)
Comment = Dwell for short time to separate the print statements for MX drive
processing.
Comment = Query the MX drive for Pr 83.
Generic = PRINT #2, CHR$(4)+"001183"+CHR$(5)
Comment = Put response in string variable $V0.
Generic = INPUT #2, $V0
Comment = Strip away all characters from the response except for the data
asked for.
Generic = $V1=MID$($V0,5,4)
Comment = P0 is the variable called motor position. VAL converts a character
string to a number.
Generic = P0=VAL($V1)
Comment = Close com port 2.
Generic = CLOSE #2
60
T60/AXIMA Communications Example
The T-60 BUILD program in this example shows how to program the
T60/T61 in order to communicate with an AXIMA controller. An
example of the T-60/61 pseudocode is included to show:
1. How to establish communications and verify the AXIMA
controller’s address.
2. How to monitor machine status.
3. How to verify, with every reply received, that communications
are up and running.
4. How to build subroutines that open communications, send
messages, and get replies.
Example Program
GOTO SCREEN begin
*>SCREEN begin
COMMENT "Open communications and verify that communications work by
querying"
COMMENT "the AXIMA's address (0). P4098 is a parameter in which the 5
least"
COMMENT "significant bits are the address. Anding with 255 masks the"
COMMENT "nonaddress bits. The additional three bits are verified to be in an"
COMMENT "off position. If multiple AXIMAs with different addresses are to
be"
COMMENT "communicated with, then the decimal equivalents of the ASCII"
COMMENT "control characters CNTL A and CNTL B must be used to open and
close"
COMMENT "communications with the individual AXIMAs."
PUT TEXT AT (7,2): "Checking Communications ..."
GOSUB opencom
msg$ = "?P4098AND255"
GOSUB sendmsg
GOSUB getreply
IF noreply% = 1 THEN resp$="NO REPLY"
IF (noreply%=0 AND VAL(reply$)=0) THEN resp$="READY"
61
IF (noreply%=0 AND VAL(reply$)<>0) THEN resp$="WRONG ADDRESS"
PUT TEXT AT (7,4): "Status:"
PUT TEXT AT (16,4): resp$
DELAY 2000
IF resp$="READY" THEN GOTO checkflt
SOFTKEY (2) "RETRY" GOTO SCREEN begin
SOFTKEY WAIT
COMMENT "This screen runs in a continuous loop to query the AXIMA for machine"
COMMENT "faults. Loss of communications is checked along with the fault"
COMMENT "status. Bit 137 is an example of a user defined global bit in the"
COMMENT "AXIMA PLC program that is monitored to determine if a fault
has"
COMMENT "occurred."
*>SCREEN checkflt
PUT LARGE TEXT AT (4,1): "MACHINE STATUS"
msg$ = "?bit137"
GOSUB sendmsg
GOSUB getreply
IF noreply%=1 THEN GOTO lostcomm
IF reply$ = "0" THEN GOTO sysflt
PUT TEXT AT (7,4): "All Systems are operating."
DELAY 2000
GOTO checkflt
LABEL sysflt
PUT TEXT AT (7,4): "FAULT HAS OCCURRED !!!!!!"
DELAY 2000
GOTO checkflt
*>SCREEN lostcomm
PUT TEXT AT (6,2): "LOST COMMUNICATIONS WITH AXIMA"
PUT TEXT AT (4,4): "Press RETRY to attempt to establish"
PUT TEXT AT (4,5): "communications."
SOFTKEY (2) "RETRY" GOTO SCREEN begin
SOFTKEY WAIT
COMMENT "*************** Subroutines **********************"
COMMENT "Open communication ports. Com 1 and Com 2 are RS232."
COMMENT "Procedure is to send at least one carriage return, then put AXIMA"
COMMENT "into echo 6 mode."
STOP
LABEL opencom
COM: INIT COM 1 ECHO 0 BAUD 192 HANDSHAKE 0 TIMEOUT 0 STRIP 0
62
COM: INIT COM 2 ECHO 0 BAUD 192 HANDSHAKE 0 TIMEOUT 0 STRIP 0
msg$ = CHR$(13)
GOSUB sendmsg
DELAY 100
msg$ = CHR$(13)
GOSUB sendmsg
DELAY 100
msg$ = "echo6"
GOSUB sendmsg
DELAY 100
RETURN
COMMENT "Build message string by taking message and adding a carriage return"
COMMENT "to it. Send message out Com 1 with Print statement."
STOP
LABEL sendmsg
COM: INIT COM 1 ECHO 0 BAUD 192 HANDSHAKE 0 TIMEOUT 100 STRIP
0
msg$ = msg$ + CHR$(13)
PRINT #1, msg$;
RETURN
COMMENT "Read reply in from AXIMA with Line input statement."
COMMENT "Check to see that there actually was a reply."
STOP
LABEL getreply
LINE INPUT #1, reply$
IF LEN(reply$) = 0 THEN noreply%=1 ELSE noreply%=0
RETURN
END OF PSEUDOCODE
63
T-60 and T61 RS232C/RS485 Wiring Diagrams
Figure 17
T-60 to AXIMA RS232C Serial Communications
Figure 18
T-60 to AXIMA RS485 Serial Communications
NOTE:
Figure 19
64
If you use an RS485 configuration, you must add the
basic instruction "RS422 ON, #1" to your T-60 or T-61
build program in the "OPENCOM" subroutine, after the
"COM: INIT COM 1.…" pseudocode.
T-61 to AXIMA RS232C Serial Communications
Figure 20 T-61 to AXIMA RS485 Serial Communications
Cam Example
This example demonstrates the steps required to run cam profiles
with the AXIMA controller. The application used in the example is a
flying cut-off mechanism. The master axis is an encoder which is
monitoring the speed of a continuously moving web of material to be
cut (imagine cutting a continuous web of paper into eight foot long
sheets). The follower axis is the flying cut-off head which is controlled
by the AXIMA controller. The cycle sequence is as follows:
1. The flying cut-off head accelerates from a stop to matched speed
with the web.
2. The cutting knife is activated to cut the web while at matched
speed.
3. The cut-off head decelerates to a stop and reverses direction to
return to the start position.
4. The cut-off head waits until it is time to start the next cut.
65
5. The part length is determined by the rollover point of the
master cycle.
Figure 21
Flying Cut-off Example
To create the cam profile we created a spreadsheet with Microsoft
Excel®. This spreadsheet creates the cam profile using master
position and follower velocity information. The output of the
spreadsheet is a table of corresponding master and follower axis
positions.
In the motion program, the master axis is a second motor which can
be jogged back and forth (fast or slow) using inputs 16 to 19, to allow
the user to see how the cam profile will perform.
The Motion Program can be summarized as follows:
•
66
The two LX drives are enabled.
•
Both axes’ positions are set to 0.0
•
The cam profile is defined (this consists of putting the cam
profile positions into the array variables used by the cam
functions)
•
The cam profile is setup and started. This is well commented in
the program.
•
The main loop of the program is used for jogging of the master
axis using inputs 16 - 19.
Calculating a Cam Profile
Shown below is the Excel spreadsheet we used to calculate the cam
profile for the AXIMA Software’s Motion Program.
Cam Profile Generation Spreadsheet
Worksheet Setup
Master Axis Units
in
Follower Axis Units
in
Follower Scale (Units/Motor Rev.)
1
in/rev
Max Speed of Master Axis
20
in/sec
Mapping Interval (>= 2 ms)
4
ms
Initial Follower Position =
0
in
Calculated Motor Sizing Parameters
Max. Speed of Follower Motor
####
rpm
Max. Accel. of Follower Motor
200
rev/s^2
Steps
Sug. Steps
Enter These Values
Segment #
Master Position (in)
Follower Velocity (in/in)
0
0
0
1
2
1
20
25
2
8
1
1
1
3
10
0
20
25
4
12
-1
20
25
5
18
-1
1
1
67
Cam Profile Generation Spreadsheet
6
20
0
20
25
7
30
0
1
1
Figure 22
Cam Profile Graph
The Pre-defined Variables and the AXIMA Software’s programs used
in this Application examples are listed on the following pages:
68
Variables Used:
Enable_Master
Bit
Pre-defined
BIT 32
Enable_Follower
Bit
Pre-defined
BIT 33
Input_16
Bit
Pre-defined
BIT 16
Jogging
Bit
Pre-defined
BIT 792
Jog_Forward
Bit
Pre-defined
BIT 796
Input_17
Bit
Pre-defined
BIT 17
Jog_Reverse
Bit
Pre-defined
BIT 797
Input_18
Bit
Pre-defined
BIT 18
Input_19
Bit
Pre-defined
BIT 19
Pre-defined Variables for Flying Cut-off Machine
Distance Into Move
(Float)
8192
Vector Velocity
(Float)
8193
Vector Acceleration
(Float)
8194
Vector Length
(Float)
8196
Target Velocity
(Float)
8197
Distance To Go
(Float)
8200
Feedrate Override
(Float)
8201
Manual Vector
(Float)
8202
Total Distance
(Float)
8203
Distance Squared
(Float)
8204
Velocity Squared
(Float)
8205
Fraction Into Move
(Float)
8206
Fraction Into Path
(Float)
8207
(Integer)
8208
Accelerating
(Bit)
512
Decelerating
(Bit)
513
Stopping
(Bit)
514
In Motion
(Bit)
516
Move Buffered
(Bit)
517
Feedholding
(Bit)
518
In Feedhold
(Bit)
519
Move Counter
69
70
Feedhold Request
(Bit)
520
Cycle Start Request
(Bit)
521
Kill Move Request
(Bit)
522
Stop Move Request
(Bit)
523
Final Velocity Zero
Pending
(Bit)
524
Final Velocity Zero
Active
(Bit)
525
Feedrate Override
Lock Pending
(Bit)
526
Feedrate Override
Lock Active
(Bit)
527
Not In Position
(Bit)
528
Not Following Error
(Bit)
529
Within Travel Limit A
(Bit)
530
Not Within Travel
Limit B
(Bit)
531
Not Command Limit
(Bit)
532
Not In Command Band
(Bit)
533
Decrement Count
(Bit)
536
Increment Count
(Bit)
537
Interrupt On Move
(Bit)
538
Trigger Pending
(Bit)
539
Start Move Inhibit
(Bit)
540
Encoder Match
Request
(Bit)
541
Pre-defined Variables for Motion Program
Program Running
(BIT)
1024
Program Dwelling
(BIT)
1025
Program Inhibited
(BIT)
1026
Move Pending
(BIT)
1027
Program Timeout
(BIT)
1028
Program Modified
(BIT)
1029
Run Request
(BIT)
1032
Halt Request
(BIT)
1033
Example Program
Motion Program with 190 instruction(s) will run on power-up
Local Variables
CAM_SEGMENT_0(21) Integer LA0
Instructions
Set And Clear Bits
Set Bit ENABLE_MASTER
Set Bit ENABLE_FOLLOWER
Comment = Enable both drives.
Encoder Preload ,
Master Axis to 0.0 inches,
Follower Axis to 0.0 inches
Comment = Zero the position of each axis.
Call Subroutine DEFINE_CAM_PROFILE
Update Status Display
Left Digit = C
Right Digit = P
Call Subroutine START_CAM_PROFILE
LABEL = MAIN_LOOP
Comment = This main loop allows jogging of the master
Comment = axis using inputs 16-19.
Comment = Input 16: Jog Reverse Fast
71
Comment = Input 17: Jog Reverse Slow
Comment = Input 18: Jog Forward Slow
Comment = Input 19: Jog Forward Fast
If (INPUT_19 ) Then Do
Jog Definition
Master Axis Velocity=30.0, Accel=500.0, Decel=500.0
Set And Clear Bits
Set Bit JOG_FORWARD
Cam Flying Cut-off 4/12/1996 03:00:01 PM
Wait Until INPUT_19 is Clear
Set And Clear Bits
Clear Bit JOG_FORWARD
End If/Then
Jog Definition ,
Set And Clear Bits
Set Bit JOG_REVERSE
Set And Clear Bits
Clear Bit JOG_REVERSE
End If/Then
Jog Definition ,
Set And Clear Bits
Set Bit JOG_FORWARD
Set And Clear Bits
Clear Bit JOG_FORWARD
End If/Then
Jog Definition ,
Set And Clear Bits
Set Bit JOG_REVERSE
Set And Clear Bits
Clear Bit JOG_REVERSE
End If/Then
GoTo MAIN_LOOP
LABEL = START_CAM_PROFILE
72
Comment = This subroutine sets up and initiates the cam profile.
Generic = CAM DIM B6
Comment = First cam profile B (axis 2) is dimensioned to have 6 segments.
Generic = CAM SRC B0
Comment = The CAM SRC B0 command assigns the master axis encoder as 0
(Axis 1) for cam profile B.
Generic = CAM SEG B(0,8192,LA0)
Comment = Acceleration Segment
Comment = The CAM SEG commands set up each of the Cam segments (in cam
profile B).
Comment = Segment 0 is used for the first 8192 master axis encoder counts.
Comment = LA0 is the array variable of evenly spaced follower positions.
Comment = LA0 is the same as the CAM_SEGMENT_0 variable assigned below.
Comment = To see what variables are assigned to which labels (like LA0), turn
on advanced mode and look in the Variables screen (see "Variables" button in
this dialog box).
Comment = Run forward at speed segment
Comment = Decelerate and Accelerate Backwards Segment
Comment = Run backwards at speed segment
Comment = Decelerate to a stop segment
Comment = Wait in position segment
Comment = Changing the length of this segment will change the part length.
Generic = CAM SCALE B 0.0001
Comment = The CAM SCALE command is used to convert the
Comment = follower positions stored in the integer profile arrays back into
units that make sense.
Generic = CAM FLZ B0
Comment = This CAM FLZ command sets profile B's offset to 0.
Generic = CAM ON B
Comment = The CAM ON command start the cam profile (profile B here).
LABEL = DEFINE_CAM_PROFILE
Comment = Cam Segment 0 Follower Position Points
Comment = (Accel Ramp) (integer values)
CAM_SEGMENT_0 ( 0 ) = 0
73
CAM_SEGMENT_0 ( 7 ) = 1225
CAM_SEGMENT_0 ( 8 ) = 1600
CAM_SEGMENT_0 ( 9 ) = 2025
CAM_SEGMENT_0 ( 10 ) = 2500
CAM_SEGMENT_0 ( 11 ) = 3025
CAM_SEGMENT_0 ( 12 ) = 3600
CAM_SEGMENT_0 ( 13 ) = 4225
CAM_SEGMENT_0 ( 14 ) = 4900
CAM_SEGMENT_0 ( 15 ) = 5625
CAM_SEGMENT_0 ( 16 ) = 6400
CAM_SEGMENT_0 ( 17 ) = 7225
CAM_SEGMENT_0 ( 18 ) = 8100
CAM_SEGMENT_0 ( 19 ) = 9025
CAM_SEGMENT_0 ( 20 ) = 10000
Comment = Cam Segment 1 Follower Position Points (Run at Speed)
CAM_SEGMENT_1 ( 0 ) = 10000
CAM_SEGMENT_1 ( 1 ) = 70000
Comment = Cam Segment 2 Follower Profile Points (Decel and Accel Backwards)
CAM_SEGMENT_2 ( 0 ) = 70000
CAM_SEGMENT_2 ( 1 ) = 70975
CAM_SEGMENT_2 ( 2 ) = 71900
CAM_SEGMENT_2 ( 3 ) = 72775
CAM_SEGMENT_2 ( 4 ) = 73600
CAM_SEGMENT_2 ( 5 ) = 74375
CAM_SEGMENT_2 ( 6 ) = 75100
CAM_SEGMENT_2 ( 7 ) = 75775
CAM_SEGMENT_2 ( 8 ) = 76400
CAM_SEGMENT_2 ( 9 ) = 76975
CAM_SEGMENT_2 ( 10 ) = 77500
CAM_SEGMENT_2 ( 11 ) = 77975
CAM_SEGMENT_2 ( 12 ) = 78400
CAM_SEGMENT_2 ( 13 ) = 78775
CAM_SEGMENT_2 ( 14 ) = 79100
CAM_SEGMENT_2 ( 15 ) = 79375
CAM_SEGMENT_2 ( 16 ) = 79600
74
CAM_SEGMENT_2 ( 17 ) = 79775
CAM_SEGMENT_2 ( 18 ) = 79900
CAM_SEGMENT_2 ( 19 ) = 79975
CAM_SEGMENT_2 ( 20 ) = 80000
CAM_SEGMENT_2 ( 21 ) = 79975
CAM_SEGMENT_2 ( 22 ) = 79900
CAM_SEGMENT_2 ( 23 ) = 79775
CAM_SEGMENT_2 ( 24 ) = 79600
CAM_SEGMENT_2 ( 25 ) = 79375
CAM_SEGMENT_2 ( 26 ) = 79100
CAM_SEGMENT_2 ( 27 ) = 78775
CAM_SEGMENT_2 ( 28 ) = 78400
CAM_SEGMENT_2 ( 29 ) = 77975
CAM_SEGMENT_2 ( 30 ) = 77500
CAM_SEGMENT_2 ( 31 ) = 76975
CAM_SEGMENT_2 ( 32 ) = 76400
CAM_SEGMENT_2 ( 33 ) = 75775
CAM_SEGMENT_2 ( 34 ) = 75100
CAM_SEGMENT_2 ( 35 ) = 74375
CAM_SEGMENT_2 ( 36 ) = 73600
CAM_SEGMENT_2 ( 37 ) = 72775
CAM_SEGMENT_2 ( 38 ) = 71900
CAM_SEGMENT_2 ( 39 ) = 70975
CAM_SEGMENT_2 ( 40 ) = 70000
Comment = Cam Segment 3 Follower Profile Points (Run at Speed Backwards)
CAM_SEGMENT_3 ( 0 ) = 70000
CAM_SEGMENT_3 ( 1 ) = 10000
Comment = Cam Segment 4 Follower Profile Points (Decel Backwards)
CAM_SEGMENT_4 ( 0 ) = 10000
CAM_SEGMENT_4 ( 1 ) = 9025
CAM_SEGMENT_4 ( 2 ) = 8100
CAM_SEGMENT_4 ( 3 ) = 7225
CAM_SEGMENT_4 ( 4 ) = 6400
CAM_SEGMENT_4 ( 5 ) = 5625
CAM_SEGMENT_4 ( 6 ) = 4900
CAM_SEGMENT_4 ( 7 ) = 4225
CAM_SEGMENT_4 ( 8 ) = 3600
CAM_SEGMENT_4 ( 9 ) = 3025
CAM_SEGMENT_4 ( 10 ) = 2500
CAM_SEGMENT_4 ( 11 ) = 2025
CAM_SEGMENT_4 ( 12 ) = 1600
CAM_SEGMENT_4 ( 13 ) = 1225
75
CAM_SEGMENT_4 ( 14 ) = 900
CAM_SEGMENT_4 ( 15 ) = 625
CAM_SEGMENT_4 ( 16 ) = 400
CAM_SEGMENT_4 ( 17 ) = 225
CAM_SEGMENT_4 ( 18 ) = 100
Comment = Cam Segment 5 Follower Profile Points (Wait in home position)
Linear PLS Example
This example demonstrates the use of PLS (Programmable Limit
Switches) in a linear slide application with 4096 encoder counts per
linear inch of travel. The linear slide in this example requires two
outputs (#39 and # 40), output 39 will be on between 4 inches and 12
inches, output 40 will be on from 3 inch to 4 inch, 6 inch to 9 inch and
11 inch to 12 inch. This example assumes you are using an AXIMA
controller.
Solution
Use a PLS broken into one inch segments.
Calculate Multiplier
The multiplier is 1/(counts per array segment). PLS multiplier is 1/
4096 = 0.0002441.
Array
This PLS requires twelve 1 inch segments so a 12 element array (0
through 11) will be required
76
Array Values
To calculate array values make a table of the output pattern for each
segment.
Segment
Array
Element #
Output 39
on/off
Output 40
on/off
Array integer
value
0-1 inch
0
Off
Off
0
1-2
1
Off
Off
0
2-3
2
Off
Off
0
3-4
3
Off
On
256
4-5
4
On
Off
128
5-6
5
On
Off
128
6-7
6
On
On
384
7-8
7
On
On
384
8-9
8
On
On
384
9-10
9
On
On
384
10-11
10
On
Off
128
11-12
11
On
On
384
Mask
Since we only want the PLS to control outputs 39 and 40 the mask
should be set to 384. 2**(39-32) + 2 ** (40-32)
Example Program
Motion Program with 40 instructions) will run on power-up
Comment = This is an example of the PLS instruction to control outputs 39 and
40.
Comment = Output 39 will be on between 4 and 12 inches.
Comment = Output 40 will be on between 3 and 4 inches, 6 to 9 inches and 11
to 12 inches.
Comment = 1st step, set up PLS array, it is not necessary to set elements with a
value of zero.
Comment = array value to turn on output 40 only PLS OUTPUT (3= 256)
Comment = array value to turn on output 39 only
PLS_OUTPUT (4) = 128
77
Comment = array value to turn on outputs 39 and 40
Comment = array value to turn on output 39 only
PLS_OUTPUT ( 10 ) = 128
Comment = array value to turn on outputs 39 and 40
PLS_OUTPUT ( 11 ) = 384
Comment = reset the encoder position to 0
Encoder Preload,
X to 0.0 INCHES
Comment = Next set use the PLS definition instruction
PLS 1 On Using ENC# 1, A Scale Ratio Of 0.000244
An Array Index Offset Of 0, A Mask Of 384
Data Array PLS_OUTPUT
Comment = The PLS is now active
Comment = The PLS information needs to be set up only once and should not
be in a program loop.
Comment = Use the PLS Control Instruction to turn on and off the PLS.
Set Velocity To 5.0 INCHES/Sec
Set Acceleration Ramp To 100.0 INCHES/Sec/Sec
Set Deceleration Ramp To 200.0 INCHES/Sec/Sec
Comment = Make a move loop
LABEL = LOOP
Wait Until INPUT_16 is Set
Move,
X To Absolute Position 15.0 INCHES
Move,
X To Absolute Position 0.0 INCHES
GoTo LOOP
78
Rotary PLS Example
This example demonstrates the use of PLS in a rotary application for
the AXIMA 2000/4000 with a 10:1 gear reduction and 8192 encoder
counts per motor revolution which equals 40960 counts per 360°. In
this application output 11 will turn on for 10° and go off for 10°, on
from 10 to 20, off from 20 to 30 etc. output 12 is to turn on at 90° to
180° and remain off for the rest of the cycle.
Solution
Use a PLS programmed in 10° segments with the following
specifications:
Calculate multiplier
The multiplier is 1/(counts per array segment). PLS multiplier is 1/
(8192*10*10/360) = .2949120, to make use of AXIMA’s 64 bit math
capability we can enter a variable name in the PLS multiplier field.
For example, PLS_RATIO. Then insert a Formula instruction
immediately before the PLS Definition Instruction. PLS_RAITO = 1/
(4096*10*10*/360).
Rotary
Enter a PLS Rotary Value of 81920.
Arrays
This PLS requires 36, 10° segments so a 36 element array (0 through
35) will be required.
Array values
To calculate array values make a table of the output pattern for each
segment.
Segment
Array
Element #
Output 11
on/off
Output 12
on/off
Array Integer
Value
0-10
0
Off
Off
0
10-20
1
On
Off
16536
20-30
2
Off
Off
0
79
80
Segment
Array
Element #
Output 11
on/off
Output 12
on/off
Array Integer
Value
30-40
3
On
Off
16536
40-50
4
Off
Off
0
50-60
5
On
Off
49152
60-70
6
Off
Off
0
70-80
7
On
Off
49152
80-90
8
Off
Off
0
90-100
9
On
On
49152
100-110
10
Off
On
327768
110-120
11
On
On
49152
120-130
12
Off
On
327768
130-140
13
On
On
49152
140-150
14
Off
On
327768
150-160
15
On
On
49152
160-170
16
Off
On
327768
170-180
17
On
On
49152
180-190
18
Off
Off
0
190-200
19
On
Off
16536
200-210
20
Off
Off
0
210-220
21
On
Off
16536
220-230
22
Off
Off
0
230-240
23
On
Off
16536
240-250
24
Off
Off
0
250-260
25
On
Off
16536
260-270
26
Off
Off
0
270-280
27
On
Off
16536
280-290
28
Off
Off
0
290-300
29
On
Off
16536
300-310
30
Off
Off
0
310-320
31
On
Off
16536
320-330
32
Off
Off
0
330-340
33
On
Off
16536
340-350
34
Off
Off
0
Segment
Array
Element #
Output 11
on/off
Output 12
on/off
Array Integer
Value
350-360
35
On
Off
16536
Mask
Since we only want the PLS control to outputs 11 and 12, the mask
should be set to 16536. 2**(11-32) - 2** (12-32). Notice the minus sign
since output 12 is used.
Example Program
Motion Program with 32 instruction(s) will run on power up
Variable Name
Type
Name
PLS_OUTPUT
Integer
LA0
Instructions
Comment = This is an example program to demonstrate the rortay PLS function.
Comment = Outputs 11 and 12 will be controlled by the PLS. Output 11
Comment = will toggel on and off every 10 degrees, Output 12 will be on
Comment = between 90 and 180 degress. The motor (8192 counts per revolution
Comment = is connected to a 10:1 gear box. The PLS tracks the output
Comment = of the gear box.
Comment = 1st step is to set the PLS array, it is not necessary to set elements with
Comment = a zero value.
N=1
Comment = A loop can be used to fill some of the array elements
LABEL = INCREMENTLOOP LABEL = INCREMENTLOOP LABEL = INCREMENTLOOP
PLS_OUTPUT ( N ) = 16384
N=N+2
If (N < 36 ) Then Do
GoTo INCREMENTLOOP
End If/Then
PLS_OUTPUT ( 9 ) = 49152
PLS_OUTPUT ( 10 ) = 32768
PLS_OUTPUT ( 11 ) = 49152
PLS_OUTPUT ( 12 ) = 32768
PLS_OUTPUT ( 13 ) = 49152
PLS_OUTPUT ( 14 ) = 32768
PLS_OUTPUT ( 15 ) = 49152
PLS_OUTPUT ( 16 ) = 32768
81
PLS_OUTPUT ( 17 ) = 49152
Comment = define PLS ratio, 8192 cnts per rev, 10 :1 gear box, 10 deg / inc
Comment = 360 deg. per rev. PLS_RATIO = 1 / ( 8192 * 10 * 10 / 360 ) PLS 1 On,
using ENC# 1, a Rotary Length of 81920, a Ratio of PLS_RATIO,
an Array Index Offset of 0, a Mask of 49152, and using Data Array: PLS_OUTPUT
Comment = The PLS only needs to be setup once,
Comment = donot put it in a program loop. The PLS control instruction
Comment = can be used to turn the PLS on and off as required.
External Time Base Example
This example demonstrates the use of the External Time Base
Instruction in a two axis system. Axis #1 is the master and axis #2 is
the follower. In the Coordinate System Parameters the external time
base is set up with encoder #1 as the source, the master units is “rev”,
the counts per master unit is set to 4096 and the signal
interpretation is set to comp +.
This example jogs axis #1 to simulate a master while input 17 selects
two different jog speeds for axis 1. When input 16 is set axis #2 moves
to 20 inches at velocity of one inch per revolution of the master. Time
base is switched back to real time and axis #2 returns to zero at 20
inches per second.
Example Program
Motion Program With X Instruction(s) will run on power up
Set And Clear Bits
Set Bit OUT33
Set Bit OUT32
Encoder Preload ,
Axis #1 to 0.0 revs,
Axis #2 to 0.0 inches
Comment = for demonstration purposes the left lx is used as a master
Comment = input 17 is used to select between different jog speeds for the master.
Jog Definition ,
Axis #1 Velocity=JOGVEL, Accel=100.0, Decel=100.0
Jog Control ,
Axis #1 CW
LABEL = LOOP
82
If (INPUT17 ) Then Do
JOGVEL = 2
GoTo JOGSPEED
End If/Then
JOGVEL = 5
LABEL = JOGSPEED
Jog Definition ,
Axis #1 Velocity=JOGVEL, Accel=100.0, Decel=100.0
Comment = switch to external time base
Begin External Time, Velocity of 1.0 Inches/revs, Acceleration of 2.0 Inches/revs/
revs,
Deceleration of 2.0 Inches/revs/revs
Comment = dwell for demonstration purpose only
Wait Until INPUT16 is Set
Comment = move to 20 inches in synchronized time base.
Move,,
Axis #2 To Absolute Position 20.0 inches
Comment = switch back to internal time base.
Begin Real Time, Velocity of 20.0 Inches/Sec, Acceleration of
100.0 Inches/Sec/Sec, Deceleration of 100.0 Inches/Sec/Sec
Comment = dwell for demonstration purpose only
Comment = move back to zero at 20 inches/sec
Move,,
Axis #2 To Absolute Position 0.0 inches
GoTo LOOP
83
AXIMA Software User’s
Index
A
F
application
basics, 2
description, 8
overview
diagram, 9
auxiliary program
example, 27
overview, 8
auxiliary programs
overview, 26
AXIMA controller
description, 10
feature list, 10
features, 1, 3
application hierarchy , 3
communications , 5
cut/copy/paste, 6
diagnostics, 4
graphical monitor , 4
instructions , 6
menus, 4
online help, 4
program control, 4
program memory , 5
programs , 5
fundamentals , 2
C
G
cam profiler, 17
closed loop operation, 18
gear profiler, 17
graphical monitor , 4
E
I
examples, 45
cam, 65
external time base, 82
homing an axis, 45
linear PLS, 76
MX/AXIMA communications, 59
product alignment, 47
rotary PLS, 79
T60/AXIMA communications, 61
two axis gluing, 51
instructions
overview, 6
J
jog profiler, 16
85
M
motion concept
jog profiler, 16
motion concepts , 15
cam profiler, 17
coordinate system hierarchy , 15
coordinated move, 16
gear profiler , 17
generating motion , 15
secondary set point , 18
motion program
flow , 24
overview , 7, 24
multitasking programs , 29
O
online help , 4
operator interface
addressing, 39
data I/O, 42
analog , 43
digital, 43
overview , 39
terminal mode , 39
echo, 39
establishing , 40
example , 41
P
PLC program
example , 23
overview , 7, 21
program priority , 29
assigning , 29
execution interval times, 32
processing, 30
86
timeslicing, 34
programming examples, 45
programs
quantity, 6
type, 6, 21
auxiliary, 8
motion, 7
PLC, 7
verification, 7
T
timeslicing, 34
diagram, 35
U
understanding motion, 15
understanding programs, 21

AXIMA Software User`s Guide

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