External position feedback via DIMETIX FLS-C10 (SSI)

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Camilla Watts
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1 Motivation Especially in applications subject to slip (e.g. storage and retrieval units with friction-wheel drives), drive-independent actual position detection may be useful. This contribution describes the connection of the DIMETIX FLS-C0 laser measuring system as external position feedback system to controllers of the 8400TopLine and 9400HighLine series. 8400TopLine controller with SSI interface DIMETIX FLS-C0 laser measuring system Load with reflector SSI connection to controller (Servo) motor Gearbox Fig. : Example set up with DIMETIX FLS-C0 laser measuring system and Lenze 8400TopLine controller Commissioning_FLS-C0_en.doc/ Page out of 22 Version.0

Commissioning the FLS-C0 laser measuring system For configuring the FLS-C0 laser measuring system there is a convenient configuration tool (DLS / FLS Utility) available for download on the

2 Commissioning the FLS-C0 laser measuring system For configuring the FLS-C0 laser measuring system there is a convenient configuration tool (DLS / FLS Utility) available for download on the manufacturer's website. The laser measuring system can be parameterised via a serial data connection (RS232). Parameter setting is required because SSI communication is not yet activated by default in the laser measuring system. Proceed as follows to activate the SSI communication: Start Requirements: The DIMETIX DLS / FLS Utility configuration tool is installed and started on the PC. A serial RS232 data connection has been established between PC and FLS-C0 laser measuring system. The FLS-C0 laser measuring system is supplied with 24V DC as described in Fig. 2: Fig. 2: Wiring of the serial communication between PC and FLS-C0 laser measuring system Step Establish an online connection between laser measuring system and PC: Click the Connection tab and select the parameters for the serial communication. 7: 9200 Baud, 7 Data bits, Parity even Click CHECK CONNECTION to build up a connection to the connected laser system. Commissioning_FLS-C0_en.doc/ Page 2 out of 22 Version.0

Step 2 Upload the current configuration of the laser measuring system from the device to the PC: Click Read configuration from device to upload the current settings of the laser measuring system to

3 Step 2 Upload the current configuration of the laser measuring system from the device to the PC: Click Read configuration from device to upload the current settings of the laser measuring system to the PC. 7: 9200 Baud, 7 Data bits, Parity even Step 3 Configure the behaviour of the target (stationary target, moving target): Select the Configuration tab. Select "Moving Target" to generate dynamic position values. In the event of an error, transmit the error code with error freezing. Click DOWNLOAD TO DEVICE to transfer the settings to the laser measuring system. Note! In the event of an error, the With Error Freezing function is provided: This function maintains the error state for up to 5 seconds after elimination of the cause of the error before restarting the laser measuring system. This ensures that transient errors will be long enough active in the laser measuring system for reliable detection by the higher-level control systems. Commissioning_FLS-C0_en.doc/ Page 3 out of 22 Version.0

4 Step 4 Go to the SSI tab to configure the SSI data transfer: In the SSI tab, you will find the settings for SSI communication. Step 5 Configure the SSI communication: Select SSI as transmission type. Activate the transmission of the error bit. Be sure to select binary coding. Select 24 bit as data width. In the case of an error, transmit the error code on the position value. Click DOWNLOAD TO DEVICE to transfer the settings to the laser measuring system. Tip! In the case of an error, transmit the error code to the controller. Via a possible data bus communication (e.g. PROFIBUS), the error code can be transferred to the higher-level PLC for further evaluation and display! Commissioning_FLS-C0_en.doc/ Page 4 out of 22 Version.0

Step 6 Configure the start-up behaviour after power-on and the type of measured-value transmission: Click the Stand-alone Mode tab. Activate the laser's auto-start function after power-on.

5 Step 6 Configure the start-up behaviour after power-on and the type of measured-value transmission: Click the Stand-alone Mode tab. Activate the laser's auto-start function after power-on. Zero must be entered as sample time for measured-value recording (fastest possible measured-value acquisition). Click DOWNLOAD TO DEVICE to transfer the settings to the laser measuring system. Step 7 Exit the DIMETIX configuration tool: Exit the program. You can save the laser configuration to a file to restore it quickly the next time. End Commissioning_FLS-C0_en.doc/ Page 5 out of 22 Version.0

6 Commissioning on the 8400TopLine frequency inverter The L-force Engineer software tool is used to configure the 8400TopLine frequency inverter. Proceed as follows to parameterise the SSI communication: Start Requirements: The 8400TopLine frequency inverter is wired according to the corresponding Mounting Instructions. The 8400TopLine frequency inverter is supplied with 24-V control voltage. The L-force Engineer is connected online via a data connection between PC and 8400TopLine frequency inverter. The parameter set in the 8400TopLine inverter corresponds to the parameter set loaded in the L-force Engineer. The DIMETIX FLS-C0 laser measuring system has been commissioned as described in the previous chapter. The DIMETIX FLS-C0 laser measuring system is connected to interface X8 of the 8400TopLine frequency inverter and supplied with external control voltage. DIMETIX FLS-C0 8400TopLine (X8) 9 30VDC 24 30VDCC for heating operation Fig. 3: Wiring of the SSI connection between FLS-C0 laser measuring system and 8400TopLine Commissioning_FLS-C0_en.doc/ Page 6 out of 22 Version.0

7 Step Click the All parameters tab in the L-force Engineer. Go to the Speed/position encoder subgroup and select SSI absolute value encoder: Select the All parameters tab. The parameters relevant for the SSI encoder can be found in the Speed/position encoder => SSI encoder parameter group Step 2 Select the SSI communication parameters in accordance with the characteristics of the FLS-C0 laser measuring system: Select the SSI absolute value encoder (C0422 = 4) as encoder type. Select 25 bit as entire data length (C0426/ = 25). Since the encoder is a linear encoder, the entire 24-bit position value is displayed in the single-turn range (C0426/2 = 24). The position value is transmitted from bit onwards (C0426/3 = ). Bit 0 is the status/error bit of the laser measuring system. The range for multi-turn display must not be used (C0426/4 = 0, C0426/5 = 0). Bit 0 is interpreted as status/error bit of the laser measuring system (C0426/6 = 0). Set C0426/7 = 32 - C0426/ = 7 to be able to check the raw data at the system block LS_MultiEncoderInterface, if necessary. Commissioning_FLS-C0_en.doc/ Page 7 out of 22 Version.0

8 Step 3 Select further SSI communication parameters in accordance with the characteristics of the FLS-C0 laser measuring system: For SSI protocols, the permissible baud rate decreases with increasing cable length. Depending on the length of the encoder cable used and the electromagnetic interference level, a safe bit rate must be set in C0427/0. For the 8400TopLine, only binary coding must be used as coding (C0428/0 = 0). Provide for an appropriate initialisation time for the SSI encoder after power-on (C0430/ = 5000[ms]). Select linearly unipolar as measuring range for laser measuring systems (C0/0 = ). The FLS-C0 transmits the position value in 0.[mm] steps. Depending on the unit selected in the 8400TopLine ([unit]), an appropriate scaling must be selected under the codes C/ and C/2 (see below note). Note! When converting the raw signal of the encoder s act,raw into the incremental value s act,incr, the codes C/ and C/2 are considered according to the following formula: s act, incr. [ incr./ rev. ] C/ C20/ = sact, raw with: C/ = Scaling factor - numerator C/ 2 C20/ 2 C204/ 0 C/2 = Scaling factor - denominator C20/ = Gearbox ratio (numerator) C20/2 = Gearbox ratio (denominator) C204/0 = Feed constant in [units/rev.] The codes C/ and C/2 consider a scaling factor between the raw value and the [unit] value in the controller. Example: In the controller, unit values shall be scaled in [mm]. The FLS-C0 laser measuring system supplies values in a resolution of 0.[mm] as raw signal. The codes C/ and C/2 must be calculated according to the following assignment: C / 0.[ mm] = = C/ 2.0[ mm] 0 Commissioning_FLS-C0_en.doc/ Page 8 out of 22 Version.0

Step 4 Adjust the position value to your system and set the monitoring limits for upper and lower limit position: In C2/, you can select a position offset for adjusting the laser encoder to the

9 Step 4 Adjust the position value to your system and set the monitoring limits for upper and lower limit position: In C2/, you can select a position offset for adjusting the laser encoder to the machine mechanics. In code C2/2 and C2/3 you can select the lower and the upper limit position and use these settings for monitoring purposes (see step 7). Step 5 Change to the FB Editor tab to adapt the signal flow of the application: Change to the FB Editor tab. Change to the representation of the free FB interconnection. Commissioning_FLS-C0_en.doc/ Page 9 out of 22 Version.0

Step 6 Insert the system block LS_MultiEncoder: Insert the system block LS_MultiEncoder. Connect the output LS_MultiEncoder.dnPosition_p to the system input LS_MotionControlKernel. dnmotorrefoffset_p.

In the recommended setting, the SSI telegram is assigned as follows to the outputs of the system block LS_MultiEncoder: bstate dnposition_p wlowword whighword Fig.

10 Step 6 Insert the system block LS_MultiEncoder: Insert the system block LS_MultiEncoder. Connect the output LS_MultiEncoder.dnPosition_p to the system input LS_MotionControlKernel. dnmotorrefoffset_p. Tip! The SSI raw value is provided on the system variables wlowword and whighword. In the recommended setting, the SSI telegram is assigned as follows to the outputs of the system block LS_MultiEncoder: bstate dnposition_p wlowword whighword Fig. 4: SSI telegram assignment to the outputs of the system block LS_MultiEncoder If an error has occurred in the laser measuring system (bstate = TRUE), you can further evaluate the error code on bits 5 of the output word wlowword in the application, e.g. using the following FB interconnection: The arithmetic block L_Arithmetik_x performs a multiplication by a fixed value of 50% (C0338/0 = 3). This deletes the least significant bit (bstate). Set C0472/ = 50%. Latch the error state via a function block L_SignalSwitch_x (sample&hold function). Fig. 5: Supplementation of the FB interconnection to save the error code of the FLS-C0 laser measuring system Commissioning_FLS-C0_en.doc/ Page 0 out of 22 Version.0

Step 7 Implement an error monitoring via the system block LS_SetError_: Insert the system block LS_SetError_. Connect the output LS_MultiEncoder.bFail to the input LS_SetError_.bSetError.

11 Step 7 Implement an error monitoring via the system block LS_SetError_: Insert the system block LS_SetError_. Connect the output LS_MultiEncoder.bFail to the input LS_SetError_.bSetError. This signal indicates a violation of the range limits C2/2 and C2/3 via TRUE level (see step 4). Connect the output LS_MultiEncoder.bState to the input LS_ SetError _.bseterror2. This signal displays the error bit generated by the laser measuring system. Step 8 Parameterise the error responses: Open the parameter list of the system block LS_SetError_ with a click on the corresponding icon. The error response to an exceedance of the range limit is set in C058/. Select no other response than ": Error". The error response for the case that an error bit of the laser measuring system is set is set in C058/2. Select no other response than ": Error". After selecting the corresponding settings, close the parameter dialog. Commissioning_FLS-C0_en.doc/ Page out of 22 Version.0

12 Step 9 Permanently accept the value of the laser measuring system as actual position: Insert a function block L_Not_x and loop it back to itself. Loop back the output L_Not_x.bOut to the input L_Not_x.bIn. Connect the output L_Not_x.bOut to the input LMckInterface_.bHomingSetPos. Step 0 Save the data fail-safe in the 8400TopLine frequency inverter: To save the data fail-safe, click the disk icon on the right-hand side of the toolbar. Click Next to confirm the saving process. End Commissioning_FLS-C0_en.doc/ Page 2 out of 22 Version.0

Relevant codes for 8400TopLine frequency inverters: Code Possible settings: Comments Default Selection C0422 0 0: TTL incremental encoder Encoder type at X8 : 2: 4: 5: Sin/cos encoder Absolute value

13 Relevant codes for 8400TopLine frequency inverters: Code Possible settings: Comments Default Selection C : TTL incremental encoder Encoder type at X8 : 2: 4: 5: Sin/cos encoder Absolute value encoder (HIPERFACE) Absolute value encoder (SSI) Use as free digital frequency input C {[bit]} Configuration of SSI telegram 0 - Subcode : Total telegram length Subcode 2: Number of bits to display one encoder revolution Subcode 3: Start bit of position value (single turn) Subcode 4: Number of bits to display the total number of 5 0 revolutions (only for MT encoders) Subcode 5: Start bit of total number of revolutions 7 0 (only for MT encoders) - Subcode 6: Status bit position in the SSI telegram - Subcode 7: Right shift of raw value C0427 : 2: 3: 4: 5: 6: 7: C : : 00[kbps] 200[kbps] 300[kbps] 400[kbps] 500[kbps] 750[kbps] 000[kbps] Binary coding Gray coding Baud rate on SSI interface For SSI protocols, the permissible baud rate decreases with increasing cable length. Depending on the length of the encoder cable used and the electromagnetic interference level, a safe bit rate must be set in C0427/0. Coding of the SSI telegram C {[ms]} Initialisation time for encoder at X C : No position encoder available Position encoder selection : 2: 3: 4: 5: HTL encoder at terminals DI/DI2 HTL encoder at terminals DI6/DI7 Encoder at X8 (additional setting in C0422 required) Resolver at X7 Encoder from C0495 C : No speed sensor available Speed sensor selection : 2: 3: 4: HTL encoder at terminals DI/DI2 HTL encoder at terminals DI6/DI7 Encoder at X8 (additional setting in C0422 required) Resolver at X7 C0 0 Specification of encoder value range at X8 0: rotatively unipolar : linearly unipolar 2: rotatively bipolar 3: linearly bipolar C 2 C {} Scaling factors for adapting the encoder scaling: - Subcode : Number of [units] in the drive correspond to - Subcode 2: number of encoder units {0.000 [units]} Additional position settings for absolute value encoder: - Subcode : Position offset for adapting the encoder value - to the actual machine mechanics - Subcode 2: Lower limit position for position monitoring - Subcode 3: Upper limit position for position monitoring Note: The position values C2/2 and C2/3 consider the offset value from C2/. Commissioning_FLS-C0_en.doc/ Page 3 out of 22 Version.0

14 Code C202 2 C203 2 Possible settings: Default Comments Selection {} Gearbox ratio motor - load - Subcode : Numerator - Subcode 2: Denominator {} Gearbox ratio motor external position encoder - Subcode : Numerator - Subcode 2: Denominator C {0.000 [units/rev]} C206 2 C : direct : inverted {0.000 [units]} Feed constant The feed constant is selected in application units per gearbox revolution ([units/rev.]). Selection of mounting positions: - Subcode : Motor mounting position - Subcode 2: Mounting position of external position encoder compared to motor mounting position Display code: Position values in application units - Subcode 2: Set position - Subcode 3: Actual position - Subcode 4: Current following error Commissioning_FLS-C0_en.doc/ Page 4 out of 22 Version.0

15 Commissioning on the 9400HighLine servo inverter The L-force Engineer software tool is used to configure the 9400HighLine servo inverter. Proceed as follows to parameterise the SSI communication: Start Requirements: The 9400HighLine servo inverter is wired according to the corresponding Mounting Instructions. The 9400HighLine servo inverter is supplied with 24-V control voltage. There exists a data connection between PC and 9400HighLine servo inverter (e.g. diagnostic adapter) The L-force Engineer is in offline operation. The project in the 9400HighLine inverter corresponds to the project loaded in the L-force Engineer. The DIMETIX FLS-C0 laser measuring system has been commissioned as described in chapter. The DIMETIX FLS-C0 laser measuring system is connected to interface X8 of the 9400HighLine servo inverter and supplied with external control voltage. DIMETIX FLS-C0 9400HighLine (X8) 9 30VDC 24 30VDCC for heating operation Fig. 6: Wiring of the SSI connection between FLS-C0 laser measuring system and 9400HighLine Commissioning_FLS-C0_en.doc/ Page 5 out of 22 Version.0

16 Step Click the All parameters tab for the 9400HighLine servo inverter in the L-force Engineer. Go to the Speed/position encoder subgroup and select SSI absolute value encoder: Select the All parameters tab. Call the parameter group Motor/feedback system => Setting the feedback systems. Step 2 Select an SSI encoder as position feedback system: Select an SSI encoder as position feedback system at X8 (C0422/0 = 4). The real position feedback takes place in the application via the system input FDB_dnActPosIn_p (C0490/0 = 4). Commissioning_FLS-C0_en.doc/ Page 6 out of 22 Version.0

Step 4 Select the SSI telegram length and the baud rate: For SSI protocols, the permissible baud rate decreases with increasing cable length.

17 Step 3 Change to the Application Parameters tab: Select the Application Parameters tab. Click the direct dialog call and select the SSI configuration dialog. Click Cancel to close the dialog. Step 4 Select the SSI telegram length and the baud rate: For SSI protocols, the permissible baud rate decreases with increasing cable length. Depending on the length of the encoder cable used and the electromagnetic interference level, a safe bit rate must be set in C0423/0. The total telegram length is selected via code C0424/0. Commissioning_FLS-C0_en.doc/ Page 7 out of 22 Version.0

Step 5 Configure the error bit in the SSI telegram (SSI partword ): Click SSI partword to configure the error bit (bit 0). Select the error bit position in the SSI telegram (C0435/ = 0).

Step 6 Configure the position value (SSI partword 2): Click SSI partword 2 to configure the position value (24 bits).

18 Step 5 Configure the error bit in the SSI telegram (SSI partword ): Click SSI partword to configure the error bit (bit 0). Select the error bit position in the SSI telegram (C0435/ = 0). The error bit only occupies a data width of bit (C0436/ = ). Select 'binary coded' for decoding (C0437/ = 0). Click Close to end the configuration of the error bit. Step 6 Configure the position value (SSI partword 2): Click SSI partword 2 to configure the position value (24 bits). Determine from which bit onwards the position value will be transmitted in the SSI telegram (C0435/2 = ). The position value is transmitted as a 24-bit value (C0436/2 = 24). Select 'binary coded' for decoding (C0437/2 = 0). Click Close to end the configuration of the error bit. Commissioning_FLS-C0_en.doc/ Page 8 out of 22 Version.0

Use the function block L_TbMulDivLim to convert the raw value of the position into '_e4' format (resolution in 0.000[units]).

19 Step 7 Change to the FB Editor tab: Select the FB Editor tab. Step 8 Create the following FB interconnection to evaluate the position value: Add the system block LS_SsiEncoderX8 to the FB interconnection. Use the function block L_TbMulDivLim to convert the raw value of the position into '_e4' format (resolution in 0.000[units]). Use the user codes C3000/0 and C300/0 to scale the raw value of the position (see step 9). The user code C3002/0 ('_e4' format) can be used for an offset shift of the position raw value. Use the function block L_TbAddSubLim to add the offset value in '_e4' format. The function block L_SdUnitToPos converts the position from '_e4' format into the incremental scaling ('_p' signal). Connect the output dnposout_p to the system input FDB_dnActPosIn_p. Commissioning_FLS-C0_en.doc/ Page 9 out of 22 Version.0

20 Step 9 Calculate the scaling factor C3000/0 and C300/0 according to the following formula: C3000 / 0 resolution Laser = with: C3000/0 = Position resolution of the laser measuring system C300/ 0 resolution ' e4 _' C300/0 = (Fixed) resolution in the 9400HighLine controller for position value in 'e4_' format Example: In the controller, unit values shall be scaled in 'e4_' format (0.000[mm]). The FLS-C0 laser measuring system supplies values in a resolution of 0.[mm] as raw signal. The codes C3000/0 and C300/0 must be calculated according to the following assignment: C3000 / 0 resolution = C300/ 0 resolution Laser ' e4 _' 0.[ mm] 000 = = 0.000[ mm] Step 0 To evaluate error states, supplement your function block interconnection as follows: The function block L_DcDWordToBits provides the error bit of the laser encoder at the output bbit0. Via the function block L_DevApplErr, the bits L_DcDWordToBits.bBit0 and L_Tb5Or2.bOut trip a user error in the 9400HighLine controller. The function block L_Tb5Or2 generates a group error message in the case of limitations for position conversion. The limitations of the function blocks L_TbMulDivLim, L_TbAddSubLim and L_SdUnitToPos are evaluated (see step 8). In the case of an error in the laser measuring system, the error code is latched to SSI_dwDataword_2 via L_TbSelect and will be available for later evaluation (e.g. for transfer via data ports) at L_TbSelect.dnOut. Commissioning_FLS-C0_en.doc/ Page 20 out of 22 Version.0

Step Parameterise the function block L_DevApplErr with the required error texts

Set C5902/ = ('Trip') as error response to a failure of the laser measuring

Set C5902/2 = ('Trip') as error response to an error during position conversion.

Step 2 Build the project in the L-force Engineer: Click the Build icon and

21 Step Parameterise the function block L_DevApplErr with the required error texts and error responses: Click the Parameter List icon in the function block header. Set C5902/ = ('Trip') as error response to a failure of the laser measuring system. Select an unambiguous name as error text. Set C5902/2 = ('Trip') as error response to an error during position conversion. Select an unambiguous name as error text. Click Close to close the dialog. Step 2 Build the project in the L-force Engineer: Click the Build icon and confirm your selection with a click on the Build button. Commissioning_FLS-C0_en.doc/ Page 2 out of 22 Version.0

22 Step 3 Transfer the project to the 9400HighLine servo inverter: Click Online => Go online and confirm the following dialogs as usual by clicking Next. Click Yes to confirm that the connected device is to be stopped and to agree to the download. End Commissioning_FLS-C0_en.doc/ Page 22 out of 22 Version.0

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