Flexible Manufacturing System
Courseware Sample
85092-F0
A
FLEXIBLE MANUFACTURING SYSTEM
COURSEWARE SAMPLE
by
the Staff
of
Lab-Volt Ltd.
Copyright © 2008 Lab-Volt Ltd.
All rights reserved. No part of this publication may be reproduced,
in any form or by any means, without the prior written permission
of Lab-Volt Ltd.
Printed in Canada
January 2009
Table of Contents
Courseware Outline
Servo Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Sample Job Sheet Extracted from Servo Control
Job Sheet 2
Testing the Digital Servo Drive . . . . . . . . . . . . . . . . . . . . . . . 3
Instructor Guide Sample Job Sheet Extracted from Servo Control
Job Sheet 2
Testing the Digital Servo Drive . . . . . . . . . . . . . . . . . . . . . . 21
III
IV
Courseware Outline
SERVO CONTROL
Job Sheet 1
Tuning the Digital Servo Drive
Job Sheet 2
Testing the Digital Servo Drive
Job Sheet 3
Using the Digital Servo Drive with the FMS
Appendices
A
B
C
D
Equipment Utilization Chart
Documentation Provided on the Lab-Volt Flexible
Manufacturing System (Advanced Applications)
Resource Kit CD-ROM
Safety Procedures
Troubleshooting
V
VI
Sample Job Sheet
Extracted from
Servo Control
2
TESTING THE DIGITAL SERVO DRIVE
OBJECTIVE
Test the Digital Servo Drive and the Linear Guide with the Flexible Manufacturing
System.
PROCEDURE
G
1. Perform the basic safety procedures listed in Appendix C of this manual.
G
2. Use Table 2-1 and Figure 2-2 to identify the new component used in this
Job Sheet.
NAME
MODEL
Conveyor Optical Encoder
5928
DESCRIPTION/FUNCTION
Sensor used to determine the position and the
direction of rotation of the servo motor.
Table 2-1. New components used for Job Sheet 2.
System setup
G
3. Connect the equipment as shown in the wiring diagram presented in
Figure 2-1.
SERVO CONTROL
3
TESTING THE DIGITAL SERVO DRIVE
Figure 2-1. Testing the Digital Servo Drive wiring diagram.
G
4
4. Do not forget to connect the Conveyor Optical Encoder to the Digital Servo
Drive (Figure 2-2)
SERVO CONTROL
TESTING THE DIGITAL SERVO DRIVE
Figure 2-2. Conveyor Optical Encoder.
G
5. Once completed, the setup should look as shown in Figure 2-3.
Figure 2-3. Testing the Digital Servo Drive setup.
G
6. Once the setup is complete, start the system. Make sure the Digital Servo
Drive is powered, if the drive is correctly connected to a 24-V dc source, the
drive indicator LED lights green.
SERVO CONTROL
5
TESTING THE DIGITAL SERVO DRIVE
G
7. Start the Elmo Composer software.
G
8. Once the software is started, click on the Open an Existing Application
button. This opens the Open Existing Application window (Figure 2-4).
Figure 2-4. Open Existing Application window.
G
9. Select the Flexible_Manufacturing_System.dat configuration file saved at
the end of Job Sheet 1. Click on the Download button to download the
configuration to the Digital Servo Drive flash memory.
G 10. Once the configuration is downloaded to the Digital Servo Drive flash
memory, the Smart_Terminal window opens automatically (Figure 2-5).
6
SERVO CONTROL
TESTING THE DIGITAL SERVO DRIVE
Figure 2-5. Smart_Terminal window.
G 11. The Smart Terminal is used to manually modify the configuration of the
Digital Servo Drive and send commands to the motor. The Smart Terminal
window is divided into two sections. In the left section, text commands can
be sent to the drive and messages from the drive are displayed below the
Enter Command text area. In the right section, tabbed dialog boxes allow
you to send different commands to the drive. When a command is sent to
the drive, its text equivalent is displayed in the left section of the Smart
Terminal.
Experimenting with the Smart Terminal
G 12. In the Enter Command text area, enter "UM=1" and click on the Send button
to send the command to the Digital Servo Drive (Figure 2-6). Table 2-1
resumes the different unit modes available through the UM command.
Notice that when the Digital Servo Drive unit mode is changed using the
command line, the Profile tab appearance changes to match the selected
mode.
SERVO CONTROL
7
TESTING THE DIGITAL SERVO DRIVE
Figure 2-6. Changing the unit mode.
UNIT MODE (UM)
DESCRIPTION
1
Torque control mode
2
Speed control mode
3
Micro-stepper mode
4
Dual feedback position control
5
Single loop position control
Table 2-1. Unit modes.
G 13. The UM=1 command is used to set the drive to the torque control mode. In
this mode, a current is used as an input parameter instead of a position or
a velocity.
G 14. In the Profile tab, enter "0.2" in the Torque Command text area of the Test
Motion section.
G 15. Press the Go button and observe the motion of the Part Feeder on the
Linear Guide. Press the Stop button before the Part Feeder reaches the end
of the Linear Guide.
G 16. Observe the text command in the message section at the left of the Smart
Terminal. Three different commands should be displayed in this section:
UM, MO, and TC. The MO command is used to turn the motor ON, while the
TC command sends the specified current to the motor.
8
SERVO CONTROL
TESTING THE DIGITAL SERVO DRIVE
G 17. Enter "MO=0" in the Enter Command text area and press the Send button
to stop the motor (the motor must be stopped to change the unit mode).
G 18. Set the Digital Servo Drive to the speed control mode (refer to Table 2-1).
G 19. Use the Test Motion section of the Profile tab to make the motor rotate at a
speed of 200 rpm (Figure 2-7). Test both directions. Make sure to stop the
motor before the Part Feeder reaches the end of the Linear Guide.
Figure 2-7. Smart_Terminal window.
G 20. Note in Table 2-2 below the new text commands that are displayed in the
message section when changing the speed, starting, and stopping the drive
using the Test Motion section of the Profile tab. Briefly describe the use of
each command.
COMMAND
DESCRIPTION
Table 2-2.
G 21. The motor can also be started and stopped using the Elmo Composer's
toolbar. To start the motor, press the Run icon
press the Stop icon
and to stop the motor
.
SERVO CONTROL
9
TESTING THE DIGITAL SERVO DRIVE
Tabs for advanced users
Protections tab
G 22. The Protections tab is used to set the range of the drive protections such as
overcurrent, overvoltage, brake problem, velocity and position tracking error.
Browse through the different options of the Protections tab, refer to the
software manual for details (Figure 2-8).
Figure 2-8. Protections tab.
Limits tab
G 23. The Limits tab is used to set the range of the limits of the drive such as
maximum current, minimum and maximum velocity, maximum and minimum
position, and feedback counting range. Browse through the different options
of the Limits tab, refer to the software manual for details (Figure 2-9).
Figure 2-9. Limits tab.
10
SERVO CONTROL
TESTING THE DIGITAL SERVO DRIVE
Input Logic and Output Logic tabs
G 24. The Input Logic and Output Logic tabs are used to define the action that
must be taken if a mechanical limit switch is activated by an incoming signal
or an output signal. Browse through the different options of the Input Logic
and Output Logic tabs, refer to the software manual for details (Figure 2-10).
Figure 2-10. Input Logic tab.
Elmo Studio
Elmo Studio is used to create and edit user programs for the Digital Servo Drive. A
user program can contain anything from a list of commands to complex algorithms
built using the operators and functions available.
A program is required to test the drive configuration. This program can be found on
Lab-Volt Flexible Manufacturing System (Advanced Applications) Resource Kit
CD-ROM. Follow the steps below to familiarize yourself with Elmo Studio and with
some of the Digital Servo Drive commands.
G 25. From the Elmo Composer software Tools menu, select Elmo Studio or click
on the Elmo Studio icon
software.
in the tool bar to open the Elmo Studio
G 26. From the File menu, select Open to open the Open Program File window.
G 27. In the Open Program File window, select the JS2.ehl program file. This file
is located on the Lab-Volt Flexible Manufacturing System (Advanced
Applications) Resource Kit CD-ROM (Figure 2-11). Click the Open button
to open the program file.
SERVO CONTROL
11
TESTING THE DIGITAL SERVO DRIVE
Figure 2-11. Opening a program file.
Note: The "JS2 with comments.ehl" file contains comments that
can help you to understand the structure of the program.
However, due to the Digital Servo Drive memory limitations, this
file is too large to be downloaded to the drive memory. Thus,
make sure to use the "JS2.ehl" file when trying to download the
program file to the drive.
G 28. Browse through the JS2.ehl program and use the SimplIQ - Command
Reference Manual (MAN-SIMCR.pdf) to identify the various commands
used in the program and fill in the blanks in Table 2-3 below.
COMMAND
COMMAND NAME
DESCRIPTION
Used to set the maximum
acceleration in
counts/second2.
AC
BG
Used to set the maximum
deceleration in
counts/second2.
FR[N]
Follower Ratio
Read the value of the Nth
digital input bit.
IB[N]
LC
Used to set the follower
ratio.
Jogging Velocity
Used to set the motor
speed. The speed of the
motor is set in
counts/second.
Current Limit Flag
Reports the status of the
current limiting process.
Used to enable the
motor (1) or disable the
motor (0).
12
SERVO CONTROL
TESTING THE DIGITAL SERVO DRIVE
COMMAND
COMMAND NAME
DESCRIPTION
MS
Reports the status of the
motion.
OB[N]
Used to set and reset the
Nth digital output bit.
PA
Absolute Position
Defines the next absolute
position of the motor.
PR
Relative Position
Used to position the motor
relatively to its current
position.
PX
Main Position
Used to set the value of the
position counter.
Used to specify the use of
an external reference.
RM
SP
Speed for PTP Mode
Used to set the maximum
speed for the point-to-point
motion mode.
ST
TR[1]
Sets the target radius in
counts. The target radius is
the maximum error allowed
for the positioning of the
motor.
Used to select the drive
control algorithm. Either
torque control, speed
control, micro-stepper, dual
feedback position, or single
loop position.
Table 2-3. Commands used in the JS2.ehl program.
G 29. Compiling and downloading the program is done using the Elmo Studio's
Build function. From the Build menu, select Build or click on the build
icon
to build the program and download it to the Digital Servo
Drive (Figure 2-12). If the program is successfully compiled and downloaded
to the drive, no error messages should appear in the message area at the
bottom of the Elmo Studio window.
SERVO CONTROL
13
TESTING THE DIGITAL SERVO DRIVE
Figure 2-12. Building the program.
G 30. Once the program is downloaded to the Digital Servo Drive, close Elmo
Studio and get back to the Elmo Composer software window.
Testing the subroutines
Note: If the servo system does not run smoothly when you use it,
perform the auto tuning procedure given in Job Sheet 1 again
with a different setting for the Response and System Noise
parameters.
Velocity subroutine
G 31. Now that the program is downloaded to the drive, you can execute its
subroutines using the XQ command. To test the velocity routine, enter
14
SERVO CONTROL
TESTING THE DIGITAL SERVO DRIVE
"XQ##velocity" in the Enter Command text area of the Smart Terminal and
press the Send button (Figure 2-13).
Figure 2-13. Executing a drive program subroutine.
G 32. Once the velocity subroutine is executed, you can test the Digital Servo
Drive in the velocity mode using the Indicator Light/Push-Button Station.
Pressing the green push button starts the movement of the Part Feeder in
the positive direction, pressing the yellow push button starts the movement
of the Part Feeder in the negative direction, and pressing the red push
button stops any motion.
CAUTION!
Make sure to stop the motion of the Part Feeder before it
reaches the end of the Linear Guide.
G 33. From the Test Motion section of the Profile tab of the Smart Terminal, set
the speed to 50 rpm and press the Apply button to apply the changes.
G 34. Test the velocity subroutine again. Is the Part Feeder moving faster or
slower than before?
G 35. In the Enter Command text area, type "KL" and press the Send button. This
stops the execution of the program on the Digital Servo Drive.
Inc subroutine
G 36. Move the Part Feeder by hand in the middle of the Linear Guide.
SERVO CONTROL
15
TESTING THE DIGITAL SERVO DRIVE
G 37. Enter "XQ##inc" in the Enter Command text area of the Smart Terminal and
press the Send button.
G 38. Use the Indicator Light/Push-Button Station to test the Inc subroutine. The
Part Feeder moves 10000 counts to the right if the green push button is
pressed, it moves -10000 counts to the left if the yellow push button is
pressed, and it returns in the middle of the Linear Guide if the red push
button is pressed. If the green or yellow push button is held down, the Part
Feeder moves by steps of 10000 counts until the push button is released.
G 39. In the Enter Command text area, type "KL" and press the Send button. This
stops the execution of the program on the Digital Servo Drive.
Follow subroutine
G 40. Move the Part Feeder by hand in the middle of the Linear Guide.
G 41. Enter "XQ##follow" in the Enter Command text area of the Smart Terminal
and press the Send button.
G 42. Start the AC Drive and set it for manual control, refer to the Familiarization
with the AC Drive procedure given in Job Sheet 1 of the Introduction to
Manufacturing manual (p/n 38770-20).
G 43. Use the AC Drive to start the Flat Belt Conveyor (clockwise rotation).
G 44. Use the AC Drive potentiometer to set the Flat Belt Conveyor speed to half
its maximum value.
G 45. On the Indicator Light/Push-Button Station, press the green push button.
The Part Feeder should move in the same direction and at the same speed
as the Flat Belt Conveyor. Make sure to press the red push button to stop
the Part Feeder before it reaches the end of the Linear Guide. Pressing the
red push button returns the Part Feeder to the middle of the Linear Guide.
G 46. Use the AC Drive to reverse the rotation direction of the Flat Belt Conveyor.
G 47. On the Indicator Light/Push-Button Station, press the green push button and
observe the Part Feeder movement.
16
SERVO CONTROL
TESTING THE DIGITAL SERVO DRIVE
G 48. In which direction does the Part Feeder move?
G 49. Ask the instructor to check and approve your work.
Name:
Date:
Instructor's approval:
SERVO CONTROL
17
Instructor Guide Sample
Job Sheet Extracted from
Servo Control
Servo Control
JOB SHEET 2
TESTING THE DIGITAL SERVO DRIVE
ANSWERS TO PROCEDURE STEP QUESTIONS
G 20.
COMMAND
DESCRIPTION
JV
Used to set the motor speed. The speed
of the motor is set in counts/second.
BG
Used to start the next programmed
motion.
ST
Stops any motion.
G 28.
COMMAND
COMMAND NAME
DESCRIPTION
AC
Acceleration
Used to set the maximum
acceleration in
counts/second2.
BG
Begin Motion
Used to start the next
programmed motion.
DC
Deceleration
Used to set the maximum
deceleration in
counts/second2.
FR[N]
Follower Ratio
Used to set the follower
ratio.
IB[N]
Input Bits Array
Read the value of the Nth
digital input bit.
JV
Jogging Velocity
Used to set the motor
speed. The speed of the
motor is set in
counts/second.
LC
Current Limit Flag
Reports the status of the
current limiting process.
MO
Motor Enable/Disable
MS
Motion Status
Reports the status of the
motion.
OB[N]
Output Bits Array
Used to set and reset the
Nth digital output bit.
PA
Absolute Position
Defines the next absolute
position of the motor.
Used to enable the motor
(MO=0) or disable the motor
(MO=1).
SERVO CONTROL
21
Servo Control
COMMAND
COMMAND NAME
PR
Relative Position
Used to position the motor
relatively to its current
position.
PX
Main Position
Used to set the value of the
position counter.
RM
Reference Mode
Used to specify the use of
an external reference.
SP
Speed for PTP Mode
Used to set the maximum
speed for the point-to-point
motion mode.
ST
Stop Motion
Stops the software motion.
Target Radius
Sets the target radius in
counts. The target radius is
the maximum error allowed
for the positioning of the
motor.
Unit Mode
Used to select the drive
control algorithm. Either
torque control, speed
control, micro-stepper, dual
feedback position, or single
loop position.
TR[1]
UM
DESCRIPTION
Table 2-3. Commands used in the JS2.ehl program.
G 34. Slower
G 48. The Part Feeder moves in the same direction as the Flat Belt
Conveyor (i.e., from left to right).
STUDENT ASSESSMENT
The following points should be checked to assess the student's work:
22
G
The setup is wired according to the diagram presented in Figure 2-1 of the
student manual.
G
The wiring ducts are used appropriately to maintain a tidy setup.
G
The Digital Servo Drive, the Linear Guide, and the Conveyor Optical Encoder
are correctly connected.
G
The Digital Servo Drive is properly tuned for use with the Flexible
Manufacturing System (Advanced Applications).
SERVO CONTROL