L15 - Tools that Simplify Product Sizing, Selection and Design. For Classroom Use Only!

Transcription

1 L15 - Tools that Simplify Product Sizing, Selection and Design For Classroom Use Only!

2 Important User Information This documentation, whether, illustrative, printed, online or electronic (hereinafter Documentation ) is intended for use only as a learning aid when using Rockwell Automation approved demonstration hardware, software and firmware. The Documentation should only be used as a learning tool by qualified professionals. The variety of uses for the hardware, software and firmware (hereinafter Products ) described in this Documentation, mandates that those responsible for the application and use of those Products must satisfy themselves that all necessary steps have been taken to ensure that each application and actual use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards in addition to any applicable technical documents. In no event will Rockwell Automation, Inc., or any of its affiliate or subsidiary companies (hereinafter Rockwell Automation ) be responsible or liable for any indirect or consequential damages resulting from the use or application of the Products described in this Documentation. Rockwell Automation does not assume responsibility or liability for damages of any kind based on the alleged use of, or reliance on, this Documentation. No patent liability is assumed by Rockwell Automation with respect to use of information, circuits, equipment, or software described in the Documentation. Except as specifically agreed in writing as part of a maintenance or support contract, equipment users are responsible for: properly using, calibrating, operating, monitoring and maintaining all Products consistent with all Rockwell Automation or third-party provided instructions, warnings, recommendations and documentation; ensuring that only properly trained personnel use, operate and maintain the Products at all times; staying informed of all Product updates and alerts and implementing all updates and fixes; and all other factors affecting the Products that are outside of the direct control of Rockwell Automation. Reproduction of the contents of the Documentation, in whole or in part, without written permission of Rockwell Automation is prohibited. Throughout this manual we use the following notes to make you aware of safety considerations: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. Identifies information that is critical for successful application and understanding of the product. Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: identify a hazard avoid a hazard recognize the consequence Labels may be located on or inside the drive to alert people that dangerous voltage may be present. Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures.

3 Tools that Simplify Product Sizing, Selection and Design Contents About this lab... 4 Tools & prerequisites... 4 Control Application Details... 5 Lab List... 5 IA Simp Tools: Popular Configuration Drawings... 6 Getting to the IA Simp Tools Web Site... 6 IAB: Sample Files and Popular Configuration Drawings IAB: Selecting the Controller with the Project Design Assistant Other Control Application Details Project Design Assistant Logic General Tour Create a Project Generate Hardware and View Results MA: Selecting Drives & Motors for the Application About This Lab Entering Lab User Credentials Reviewing a Project Reviewing a Completed Axis Exporting a Bill of Materials PW: ProposalWorks Lab Reviewing an Existing Project Combining IAB & MA Reports Additional PW Configuration Generating a Proposal Project IA Simp Tools: Drive and Motion Accelerator Toolkit (DMAT) DMAT Details of 200

4 Appendix: Advanced MA - Sizing and Selecting Drive/Motor Solutions using Motion Analyzer About This Lab Objectives Quick Note Entering Lab User Credentials Creating a Project Before you begin The lab instructor will revert the lab image on each lab computer before each lab session. About this lab This lab session gives you the opportunity to do hands-on learning with some Integrated Architecture (IA) Simplification (Simp) Tools, Integrated Architecture Builder (IAB), Motion Analyzer (MA) and ProposalWorks (PW). This sizing and selection lab will show you how to use a popular configuration drawing, how to select and size the controller using Integrated Architecture Builder (IAB), how to select and size drives and motors using Motion Analyzer (MA), how to combine the results of IAB and MA using ProposalWorks (PW), and know that you can use the Drive and Motion Accelerator toolkit to quickly create application code for the controller and HMI device. If you have extra time or you wish to execute an in depth Motion Analyzer lab, please execute the lab in the Appendix of this document. Tools & prerequisites Software programs required: ProposalWorks V9.0, Integrated Architecture Builder V , Drives and Motion Accelerator Toolkit (DMAT) October 2015 and a web browser Hardware required: Computer with the applications and lab files loaded and access to the Internet Files required: IAB: none MA: Cam Profile.xlsx for the lab in the Appendix ProposalWorks: Uses C:\Program Files (x86)\pst\ra_iab\iab_proj\green Magic Shampoo Labeler IAB.prp and productlist.csv as generated by the IAB and MA portions of this lab. Cam Profile.xlsx in Lab Files folder is used in the Advanced Motion Analyzer lab found in the Appendix. Final files for IAB and PW are also found in a desktop folder called Lab Files. 4 of 200

5 Control Application Details You are project engineer at Green Magic LLC and you have been asked to design the labeling machine for Green Magic Shampoo. The label machine that you have designed is represented in Figure 1. The shampoo bottles enter from the right from the in-feed conveyor controlled by a PowerFlex 525 drive. Next the label is applied by the first Kinetix 5500 drive. Then air bubbles are removed by the sponge wheel controlled by the second Kinetix 5500 drive. Finally the shampoo bottles exit the labeler on the left by an out-feed conveyor controlled by another PowerFlex 525 drive. All of the drives are under the control of a CompactLogix controller and communication between the devices is done via EtherNet/IP. To summarize, your application has one CompactLogix controller, two Kinetix 5500 drives and two PowerFlex 525 drives. You are told to minimize controller cost but allow for possible expansion of the system. You are told to allow for 2 more PowerFlex drives and 3 more Kinetix 5500 drives. At this stage in the project you need to create a Bill of Material of the system that includes both the sizing of the drives as well as controller and network analysis. To do this we will use 3 tools; Integrated Architecture Builder (IAB) and Motion Analyzer (MA), and Proposal Works (PW). First, we will select, validate, and create the control system in IAB. Second, we will select and size the drives and motors in MA. And finally, we will use PW to create the entire bill of material by combining the results of IAB and MA. In addition we will use Popular Configuration Drawings to introduce you to the capabilities of our control products. And finally we will show you the location of the Drive and Motion Accelerator Toolkit, a tool used to quickly create application code for the controller and HMI. Figure 1 - Labeling Machine Lab List Popular Configuration Drawing Lab learn to use these as a starting point in IAB IAB Lab learn how to select and size your controller and validate communication bandwidth MA Lab learn how to select and size drives and motors PW Lab - learn how to combine your IAB and MA results and form a final bill of material Drive and Motion Accelerator Toolkit Lab - learn that you can use this tool to create controller & HMI application code 5 of 200

6 IA Simp Tools: Popular Configuration Drawings Designing a control system can be intimidating. After all a control system is a specialized computer that is programmed to manufacture your product with accurate, precise and repeatable performance. In order to keep up with technology we need tools to help us. We have a group of tools called Integrated Architecture (IA) Simplification (Simp) Tools to help us. This hands-on lab will show you how to use popular configuration drawings to your advantage. As you complete the exercises in this lab exercise, you will: Learn where to find these tools on the web site. Learn about the various types of IA Simp Tools Learn how to use Popular Configuration Drawings Getting to the IA Simp Tools Web Site In a web browser go to Open Web Browser 1. Open the web browser and in the URL box type and the Enter key. 2. Notice how the IA Tools are organized into four system lifecycle categories- Select, Develop, Commission, and Maintain. Each lifecycle phase has sub-categories such as Controllers, Networks, Systems and Visualization. It is under these sub-categories that you will find your IA Tools consisting of Popular Configuration Drawings, Technical Reference Drawings, Quick Start Guides, Sample Code, and Accelerator Toolkits. Take a few minutes to browse these IA Tools and notice the following: 6 of 200

7 Technical Reference Drawings: A Technical Reference Drawing is a drawing that provides an easy to use summary of information, tools and resources available on a specific topic. Examples of Technical Reference Drawings include Ethernet Cheat Sheet, Network Address Translation and KwikLink Lite Media. Quick Start Guides: Quick Start Guides are targeted manuals that takes you through the process of commissioning an automation system from setting up the hardware through writing the application code. Examples of Quick Start Guides include ControlLogix, 1768 CompactLogix, and CompactLogix controllers. Sample Code Website: The sample code website allows you to retrieve samples of code that have been developed by other users and post code that you think others might find helpful. Some example code titles include random number generator, read and write to CompactFlash data storage, convert IEEE floating point to 2 s complement fixed point, and sunrise, sunset and solar azimuth and elevation calculator. Accelerator Toolkits: An Accelerator Toolkit is a collection of example wiring diagrams, CAD drawings, sample application code and documentation collected in one place (DVD and website) on a specific topic. Examples of Accelerator Toolkits include Water Wastewater, Energy Management, and Batch. Popular Configuration Drawings: A Popular Configuration Drawing is a drawing that provides combinations of common automation products and provides performance, capacity, and configuration details. Examples of Popular Configuration Drawings include ControlLogix, CompactLogix, Integrated Motion, Wi-Fi for Industrial Applications and Motor Control Centers. 3. The plant expansion that you are working on today has motion control and a CompactLogix controller. Let s review a Popular Configuration Drawing that has both of these items. If you aren t on the main IA Tools page, then return to Select Controllers. 7 of 200

8 4. Scroll down and select Download [PDF] for CompactLogix 5370 L3. 5. Here you see the CompactLogix 5370 L3 controller with one Ethernet port connected to a Stratix switch (star) and the other Ethernet port connected to a variety of I/O and drives in a linear topology. For each device there is helpful product information like kw rating range for the Kinetix 5500 drives and HP ratings for the PowerFlex drives. Scroll down by one page. 8 of 200

9 6. Now you see the bill of material and summary about the configuration and products. Scroll back up to the top of the document. 7. Take a good look at the table and call out boxes for the CompactLogix 5370 L3 Controller. Here the controller s capabilities are succinctly described. Maximum number of EtherNet/IP I/O nodes and maximum number of CIP Motion axes are provided in the table. These two items are key in sizing a controller. You will find in the next lab section that not only is this Popular Configuration Drawing built into IAB but all the specs listed here are in IAB s embedded rule set. Nice! Close the web browser. Summary IA Simplification Tools are free and are found at Remember that your IA Simplification toolbox consists of Popular Configuration Drawings, Technical Reference Drawings, Quick Start Guides, Sample Code, and Accelerator Toolkits. Use these tools to help you save time with your automation projects. If you have time at the end of the lab, then it is suggested that you come back to this site to browse the other IA Simplification Tools in more detail. You have completed the IA Simplification Tool Popular Configuration Drawing lab. 9 of 200

10 IAB: Sample Files and Popular Configuration Drawings Now we will move onto using Integrated Architecture Builder (IAB). Know that Popular Configuration Drawings are embedded in Integrated Architecture Builder (IAB) as Sample Projects. You can then use these Sample Projects as a starting point for your project or create a new project from scratch. In this section of the lab you will Learn how to navigate to the Sample Files in IAB Learn how to recognize a Popular Configuration Drawing Sample File and open it Learn how IAB has a Device List that contains all the product families represented in the Popular Configuration Drawing Learn how to determine a product s lifecycle status Learn how IAB has embedded rules so that the right processor is selected for your project Open IAB 1. Launch IAB from your desktop by double-clicking on the IAB icon on the computer desktop: 2. If the Connect to the Internet dialog box occurs any time during the lab, select No. 3. The IAB Start Page appears. From the Start Page you have several options from learning about how to use the tool by reviewing a built in lab to creating a new project. In addition you can open existing projects or Sample Project. Select Sample Project. 10 of 200

11 4. Expand CompactLogix and scroll to the bottom. 5. Hover over CompactLogix 5370 L3 Star Linear.iab thumbnail to bring up its description. 11 of 200

12 6. Notice the last sentence. If the Sample File is based on a Popular Configuration Drawing, then it will have its URL reference in its description. This Sample File is the same Popular Configuration Drawing that was used in the previous lab section. 7. You can also switch the Sample Project View from thumbnail view to a list view. Select the list view icon. 12 of 200

13 8. Scroll down and find CompactLogix 5370 L3 Star Linear.iab. Again, any Sample File based on a Popular Configuration Drawing will have its URL reference in its description. Select this file with a left-click of your mouse in the row where the file is described to open it. 9. IAB will open to the Wizard View. Select the Architecture tab. The Architecture View is a graphical view of all the products in your IAB project. For Sample Files based on Popular Configuration Drawings you ll see the publication reference in the description at the top. 13 of 200

14 10. Select the Device List icon. Products in IAB are found in its Device List. 11. The Device List has product categories. Not all the product categories are visible at the same time so there are scroll bar controls on the far left. Let s look at the products available for CompactLogix. Select the CompactLogix tab. 12. The CompactLogix Device List tab has sub-categories. You ll have to scroll or increase the size of the window to see the entire list as it is shown below. Here we see that we have several families of CompactLogix controllers. 14 of 200

15 13. Expand 5370 L1 Controllers by selecting the + sign to the left. There are 4 controllers. Notice to the far right the words Preferred Availability and Active. Starting with IAB v we have Preferred Availability and Product Lifecycle information in IAB. Preferred Availability means this product is stocked at the distribution center and Active means the product is available for sale (not discontinued or near discontinuation.) Also notice we are showing all products and that the PA/Lifecycle Status is Enabled. If the PA/Lifecycle Status in not enabled, or in error, or updating, then the user doesn t have access to the PA/Lifecycle data. However, you are still free to use IAB. There are 4 Lifecycle categories; Active, Active Mature, End of Life (time to do a last time buy and migrate), and Discontinued (not for sale). By using only Active or Active Mature products you can ensure that your control product selections will remain available for sale during the expected lifetime of the automation system that you are building. For example you wouldn t want to specify a product that is listed as End of Life for a new automation project. But it might be perfectly acceptable to buy that same End of Life product as a spare part for an older automation project as you begin to think about modernizing that equipment. 14. The Popular Configuration Drawing that we referenced earlier showed some of the controller limits. Know that IAB knows about these limits and has selection wizards to allow you to select the best controller for the job based on price and capacity. We ll show you this next by using the Project Design Assistant. From Popular Configuration Drawing: 15 of 200

16 IAB: Selecting the Controller with the Project Design Assistant Starting with IAB v , users can select a Logix controller based on function, price, and network capacity by simultaneously comparing up to six controllers through the Project Design Assistant wizard. This hands-on lab will show you how to create a project that is prepopulated with the appropriate controller and I/O for your system. As you complete the exercises in this lab exercise, you will: Learn how to navigate the available options in the Project Design Assistant Define and apply network and device parameters within the Project Design Assistant dialogs View the results of the system you create including Advanced Communication Details and Drive Multiplexing Export the project to ProposalWorks Other Control Application Details We will use IAB to select and size the controller. To properly size the controller we need to know what drive family will be used. Drive selection is done with Motion Analyzer. For the purposes of this lab you already know that you are going to use the PowerFlex 525 and Kinetix 5500 drive families in this application. So that the operator can interact with the machine you are told to include a PanelView Plus 6 with a 10 inch monitor. You are told to include motor overload protection for the PowerFlex 525 drives. You are told to minimize controller cost but allow for possible expansion of the system. You are told to allow for 2 more PowerFlex drives and 3 more Kinetix 5500 drives. Create a New IAB Project 15. Select File > Start Page. 16. The IAB Start Page appears. Select New Project. 16 of 200

17 17. Select Project Design Assistant. Name the workspace Green Magic Shampoo Labeler. Click OK: 18. Select No to the Save Changes to CompactLogix 5370 L3 Star Linear.iab dialog box. 17 of 200

18 Project Design Assistant Logic General Tour 19. Notice that the dialog has four sets of requirements (red arrows): Controller, Local I/O, Distributed I/O, and Other Devices. Click the Redundancy check box under Controller Requirements: Notice that once Redundancy is checked, you can no longer select Safety from the Controller Requirements: 20. The Project Design Assistant has logic in place that recognizes that IAB does not support redundant safety controllers. Uncheck Redundancy under Controller Requirements. 18 of 200

19 21. Click the Extreme Temperature checkbox: Notice that when Extreme Temperature is checked, all of the Local I/O Requirements are grayed out. The Project Design Assistant recognizes that extreme temperature controllers do not support local I/O. 22. Uncheck the Extreme Temperature checkbox. 23. Click the Conformal Coating checkbox. The Project Design Assistant recognizes that conformal coating does not support high speed counters in local I/O and grays out this option: 24. Uncheck the Conformal Coating checkbox. 19 of 200

20 25. Note that for Distributed I/O Requirements that the default I/O platform is Point I/O. Select the pull down menu for Point I/O so that you can see all the I/O platforms supported by the Project Design Assistant. Leave this setting as Point I/O. 26. For non I/O platform devices we have Other Device Requirements. Here you see that we support a variety of products from drives, to computers and motor overload devices. If you choose a device in the Other Device Requirements section that has a Configure button, then you must configure that item in a RAISE configurator before adding it to your project. We ll use this button later when we configure our PowerFlex 525 drive. Scroll up and down to see the various other devices that are supported. Create a Project 27. Now that we had a general tour of the Project Design Assistant, let s begin our project. We want all the devices on linear EtherNet/IP network with a small amount of Local I/O. Match the following values on the Products and Requirements page paying special attention to the items in red. If the IAB dialog box appears, then select OK. 20 of 200

21 28. Next let s add the Kinetix 5500 drives. We don t know the exact drive and motor that we will be using but we need to enter in the number of drives used so IAB can make sure we select the proper controller. Click the arrow up button on the CIP Motion Drives line twice. This will add two 2198-H003-ERS to your project. You must click the button once for each device you want to add. Clicking the arrow down button will remove a device: 29. Now we need to add 2 PowerFlex 525 drives. For the Low Voltage Drives (Compact): Set the quantity to 2 using the up arrow button twice. Set the drive family to PowerFlex 525 using the pull down menu. It is the last item in the list: 30. Now click on the Configure button for the Low Voltage Drives (Compact). This will launch the RAISE configurator. Set the options as shown in the screen shot by first clicking on the red -NO SELECTION. These options will be the first item in each list. When done click on Accept. What is important in IAB is that you add in the correct quantity of drives from the correct drive family. We will determine the specific drive, motors and cables using Motion Analyzer. The values used in IAB are to correctly size the controller for number of CIP connections, number of EtherNet/IP nodes and network capacity. 21 of 200

22 Now your Low Voltage Drive (Compact) selection looks like: 31. Now we need to add 2 Motor Overload devices to protect our two PowerFlex 525 drives. If needed, scroll until you see Motor Overload: Add two 193S-EEPB Motor Overloads. Use the up arrow button twice to set the quantity to two. 32. Now we need to add the Operator Interface. If needed, scroll until you see Operator Interface: One 2711P-T10C4D8 Operator Interface. Use the up button to set the quantity to 1. Use the middle pull down menu to select the PanelView Plus 6 (10 ): 33. We are done entering Other Device Requirements. Click Next to navigate to the Controller Analysis page: Based on the controller requirements 5 of 6 possible Logix controller families can solve this application. The CompactLogix L4X family was eliminated because it doesn t support CIP motion which is required for the Kinetix 5500 drives. 22 of 200

23 When presented with multiple controller families on the Controller Analysis page, uncheck any of the boxes next to the items you would like to omit as controller options for your project. And / Or use the pull down to change the controller catalog number. You may click on the pdf icon to read more about a particular controller. 34. Click the Perform Analysis button: 35. Once the system analysis is complete, you will receive a message indicating a successful analysis. Click OK. The green circle under System Status indicates that the system IAB built from the Project Design Assistant is okay. A yellow circle would indicate a warning, a red circle shows when there is an error, and a gray circle indicates that you have not run the system analysis yet. 36. Here we have the relative cost of the system (we don t know the exact drives we will use, nor did we include the motors) using 5 different controller families. The Info buttons will let us read more details about each controller family. The Preview button will let us view the Bill Of Material (BOM). The Network button will let us review communications details. Comment about pricing: Prices are updated several times a year. If IAB software has been updated from the time that this lab was written, then you may see different prices. Or if pricing in IAB hasn t been updated for a long time, then your price file will expire and you will see no prices in IAB. So for this lab don t be concerned if prices aren t an exact match or if a price appears in red. 23 of 200

24 37. Click the Preview button for the ControlLogix selection to open its bill of materials (BOM) : Note: Prices in IAB get updated twice a year. If your prices don t match, then you are using a computer with a newer price files. Or if not prices are not listed, then your price files have expired (the computer hasn t been updated with new prices in a long time). If Preferred Avail & Lifecycle Status data is not listed, then your computer is updating this data as a background task or the feature is disabled (Options > IAB Options). When the update is completed, then this data will be shown. So for this lab don t be concerned if prices aren t an exact match. 38. The BOM opens and shows a breakdown of the components in your system. Spend a few moments reading through the BOM, then click Close. IAB will navigate back to the Controller Analysis page within the Project Design Assistant. 24 of 200

25 39. The System Performance column shows the project status (after the Perform Analysis button is clicked) and contains a Network button. Click the Network button for the CompactLogix-L30ERM solution to navigate to the advanced Communication Details dialog: You may need to scroll up to see all the values. Look at the items circled in red above. We see that we are using 6 out of 16 possible EtherNet/IP Nodes. The total utilization (motion + I/O +HMI) of the embedded EtherNet/IP channel is 28.1%. You can make any desired changes in this dialog that you deem necessary. Any changes you make in the Communication Details dialog will be accounted for in the Project Design Assistant once you click OK on this page. 40. Let s explore Advanced Communication details as it relates to CIP motion. Look at the items above circled in purple. For the two CIP axes in use we are using 2000 Motion PPS or 28.1% of the motion capacity of the embedded EtherNet/IP module in the controller. In addition, the input and output cycle and the motion task I/O cycle utilization are reported. For proper machine operation none of these values may go over 100%. You either must switch to a more powerful controller and/or communication module or make changes in your controller configuration to reduce the utilization numbers. 25 of 200

26 41. Let s explore what might increase motion resources in our controller. Select the Motion tab. The default Coarse Update Period (CUP) is 2 msec. That means every 2 msec the controller calculates new position values and sends them to the CIP motion drives and the CIP motion drives pass back status and diagnostic information for those drives assigned to Base (x1) update rate. The more CIP motion drives and the faster (smaller) the CUP, the more controller resources are used. You can use less motion resources if you use an Alt(ernate)1 or Alt(ernate)2 update rate. Using an alternate Coarse Update Period (update rate) is also known as drive multiplexing. The alternative update rate will be a multiple of the Coarse Update Period. Also note on this dialog that the number of CIP Position Axes is reported. For our example it is 2. You also can enter in additional information about the motion control program that will be executed by the controller. As you add more motion instructions to execute you will use up more controller resources. As you add items such as virtual axes, you will use more resources. 42. For now let s just explore modifying the CUR and using a feature called Drive Multiplexing. Let s increase the motion demand on the controller. Change the CUR to 4 msec. Select the Results tab. 26 of 200

27 43. Looking at the items circled in red, you can see that we decreased the demand on the controller. You may need to scroll up to see all the numbers. So by doubling the CUP (so communication slows down by 2x) we use ½ the amount of motion resources in the controller and its embedded communication module. So always use the slowest possible CUP to save on controller and communication resources. 44. Let s set the CUP to 2 msec but set up on axis to communicate at the CUP and the other axis to communicate at 2x CUP. This is called Drive Multiplexing. We should see the motion resource numbers change again and to something between the two sets of numbers that we have just seen. Select the Motion tab and set the CUP to 2 msec. 45. Select the I/O Devices tab. Scroll down until you see the two Kinetix 5500 drives. Match the settings shown below so that one drive will update at 2 msec and the other drive will update at 4 msec. 27 of 200

28 46. Select the Results tab. Here we can see that we improved input and output, motion task I/O cycle and Logix controller utilization by using drive multiplexing. So for controllers near their limits, rather than upsizing the controller, Drive Multiplexing maybe a good solution to make the application correctly run. This screen shot is provided so that you can make an easy comparison. 47. Select OK to save and exit out of Advanced Communication Details. This will save our CUR and Drive Multiplexing values. Generate Hardware and View Results 48. You were told to minimize controller cost. However, you were also told to allow for the expansion of the system. You were told to allow for 2 more PowerFlex drives and 3 more Kinetix 5500 drives. From the network analysis section for the 1769-L30ERM, we saw that we are were using 6 out of 16 EtherNet/IP nodes and 2 out of 4 CIP motion position axis. The 2 additional PowerFlex 525 and 3 Kinetix 5500 drives will go against the 16 EtherNet/IP node count and is not a problem (11 out of 16). The additional CIP motion position axes (Kinetix 5500) can t be added. We are out of motion position axes resources (2+3=5 which is greater than 4). So how do we decide on which controller to use? Looking at the Comparison description for the CompactLogix 5370 L1 we can eliminate this controller family because when we expand this system we will go beyond its EtherNet/IP node limit. 28 of 200

29 49. The EtherNet/IP node limit of the CompactLogix 5370 L2 is great enough for our expansion system but can it handle the CIP motion position axes? Click on the pdf icon for the CompactLogix 5370 L2. Go to the table on page 12. Note that the maximum number of CIP motion position axes is 4 but we need 5. So this family of controllers won t work. Close the pdf. 29 of 200

30 50. Select the Info icon to the right of CompactLogix 5370 L3. Go to the table on page 13. Note that the maximum number of CIP motion position axes for the 1769-L33ERM is 8. Close the pdf. Here we see the L33ERM can have 32 Ethernet I/O IP nodes as well as 8 CIP motion position axes. When we expand our system we will have 11 Ethernet I/O IP nodes and 5 motion positions axes. So the L33ERM will work. Hey, that agrees with what we learned in the Popular Configuration Drawing that we looked at earlier! 30 of 200

31 51. We decide on the 1769-L33ERM. It is lower cost than ControlLogix but can handle the expansion requirements. So uncheck the other Family checkboxes. Use the pull down menu and select the 1769-L33ERM and select Perform Analysis: 52. Click OK in the popup dialog. 31 of 200

32 53. Then click on the Generate Hardware/Network button: 54. You will receive a message that your system was successfully generated. Click OK on this dialog to close it: 55. If this dialog box appears, then select OK to the Set Processor dialog. 56. The Project Design Assistant will close and IAB will navigate to its homescreen. Select the Hardware tab. Note: If you double-click on PDS_SS.1, then you can edit your Project Design Assistant selections. You can also specify 1734 safety inputs and outputs. These features were added in IAB v of 200

33 57. Expand all of the items in the Workspace by clicking on the + next to each folder: Note that IAB has added and connected all of the devices you added in the previous lab steps: One 1769 controller w/ I/O One Operator Interface Two Kinetix 5500 Two PowerFlex 525 Two motor overload relays 58. Select the + sign next to 1769 Chassis to see its contents by catalog number. Notice that the generated I/O modules fulfill the Local I/O requirements we specified earlier: You can click on each module to read its description in the lower right to verify the correct modules were selected and created. 33 of 200

34 59. Click on the Architecture View tab to view the entire created system: The IAB Architecture View automatically captures your configuration as you work and presents it in one view. This serves as a logical or physical view of all the networks and all the device that you have in your IAB project. In the Architecture View you can move devices around, redraw networks, add enclosures and area bounding boxes, add text labels and print. 34 of 200

35 60. Click on the Network tab. 61. In the Network View, you see one network at a time and only those devices that are connected to that network. IAB created this linear network via the Product Design Assistant. IAB automatically added a 1783-ETAP (circled in red) to devices that don t have a built in switch to continue the daisy chain. Notice we have a Network tool bar. Use the Help button to learn more. If you don t like the position of a particular device, then select Connect Mode and drag and drop the device to a new position. By default IAB will select cables for you. You will see the default cable selections when we create the bill of material. 35 of 200

36 62. Select Address Info to see IP address assignments. Move the magnification slider bar to the right to make the graphics easier to see. The base IP address used for this network is found in the upper left. In this example the base IP address is The two last octets used by a device is denoted by (.0.2). So in our project the IP address of the CompactLogix is Of course you can change the base IP address and the IP address of a device but that is a subject for another lab. 36 of 200

37 63. Select CIP and Cable Info. 64. Then hover the mouse over the box shown. The number in the box tells you the length of the cable in meters. The color of the box (green = OK, yellow = warning, red = error) tells you if the CIP traffic on the cable is a problem. Here the hover tip tells us the Packet Per Second (PPS) for I/O, HMI and CIP Motion Traffic in each direction. The controller is sending 1110 PPS and the controller is receiving 1110 PPS. PPS information is used to determine when a communication module is overloaded with too much communication traffic. This fingertip data access within IAB is a very nice feature! Come back to our advanced lab to learn more about IAB s controller and communication module capacity checker. Left-click on any blank space in the network view. This will bring up the Information/Tips for Ethernet View in the lower right corner. Here we see the gray network line that indicates copper media running at 100Mbit. Having a network drawing that is color code for media type, speed and cable length is also very useful for project startup and maintenance. 65. Let s save our work. Select Save. 66. Select Project BOM. 37 of 200

38 67. The first time you run the BOM, the Rockwell Software Selection Wizard will run. It will add the recommended software required for the hardware in your IAB project. Give the wizard a few seconds to complete. 68. Click Consolidated BOM. 69. Here you can see that our final selection includes the 1769-L33ERM that will allow for the expansion of our system. Notice the items circled in the red. These items are the software as added by the Rockwell Software Selection Wizard. The drives listed are the drives that we used to determine controller and network capacity. However the actual drives and motor selection will be done using Motion Analzyer. We will fix our final Bill Of Material in ProposalWorks. In ProposalWorks we will import the results of both Integrated Architecture and Motion Analyzer. Then we will delete the drives brought into ProposalWorks by Integrated Architecture Builder. 70. Click Close. Comment about pricing: Prices are updated several times a year. If IAB software has been updated from the time that this lab was written, then you may see different prices. Or if pricing in IAB hasn t been updated for a long time, then your price file will expire and you will see no prices in IAB. So for this lab don t be concerned if prices aren t an exact match. 38 of 200

39 71. Now let s export our Integrated Architecture Project so that it can be used by ProposalWorks. Select File > Export to ProposalWorks File. 72. Enter the file name of Green Magic Shampoo Labeler and select Save. 73. Select No. Please be patient, the export will take some time. 74. Select No to the next pop up dialog box as we will work with ProposalWorks later. 75. Close IAB by selecting File > Exit. 76. If it appears, select Yes to the Save Changes dialog box. Summary As you can see IAB has many features. It has wizards to help you select product. It has built-in validation rules to make sure illegal systems aren t created. It has a network performance tool. It automatically selects cables and software for you. All of these items are to help you quickly specify a control system. You can download IAB from Now it is time to complete the Motion Analyzer section of the lab to select and size your drives and motors. You have completed the IAB portion of this lab. 39 of 200

40 MA: Selecting Drives & Motors for the Application About This Lab As you complete this section of the lab, you will experience the speed and simplicity of using the new Motion Analyzer to size and select motion and drive systems. This session will showcase the web based selection tool. As you complete the exercises in this hands-on session, you will: Log in to the Motion Analyzer website Review a completed project for a Labeling Machine This hands-on lab is ideal for: Individuals who size, select, and optimize motion control applications Mechanical engineers and controls engineers designing machines with motion control Machine users trying to improve an existing machine with motion control System integrators selling motion control Entering Lab User Credentials 1. Open Internet Explorer and manually enter the URL as Note: Don t use the desktop shortcut or the favorites in the browsers as they will point to a different version of Motion Analyzer. That means that the lab instructions and screen shots won t match. 2. Maximize the screen if needed. Click the Login button, enter the following lab user information and click the Submit button: Address: BasicMALab@ra.rockwell.com Password: MotionAnalyzer 40 of 200

41 Reviewing a Project In this example we will use Motion Analyzer to size and select the drive and motor. For the purposes of this lab, you already know that you are going to use the PF525 and Kinetix 5500 drive families in this application. 1. Click on the Library tab at the top of the page. 2. The Library page will appear with a list of the current projects. Click on the Labeling Machine project. Note: This is a read-only project that has been shared with the lab user account for demonstration purposes. For this reason, you will not be able to modify the objects within the project. 41 of 200

42 Component Detail Tab 1. The Project Detail page will appear. There are several tabs for viewing different aspects of your project. Let s take a moment to examine the information contained in the various tabs. The Component detail tab appears when you open an existing project. In the center of the page you will see a list of the Project Components. This particular application contains four axes. 42 of 200

43 2. Expand the Sponge Wheel Axis by clicking the carrot next to the axis name. 43 of 200

44 3. You can now see that the sponge wheel axis contains a motion profile, a transmission, a motor and a drive. These components can be viewed in detail by clicking the View button or the motor/drive text. Along the right side of the page there are buttons for Project Actions. The Project Actions buttons can be used to modify, create or import an axis or motion profile. 44 of 200

45 Summary Tab 1. Click on the Summary tab of the Project Detail page. 45 of 200

46 2. The Summary tab provides a quick overview of information in your project such as the power usage and the number and type of products you have selected. In the Action Items section, you can see a list of tasks which have not yet been completed such as selecting a shunt or power supply or creating a BOM. In the New & Changed In This Project section, you can see a list of the chages that have been made to the project as well as details about those changes. 46 of 200

47 Power Analysis Tab 1. Click on the Power Analysis tab of the Project Detail page. 47 of 200

48 2. The Power Analysis tab is where you go to see the power utilization for your application. If your application requires them, you can add capacitor modules, shunts and power supplies here. The power analysis graph shows the DC Bus voltage level for the system throughout the velocity profile for the axis. 48 of 200

49 Customer/Site Tab 1. Click on the Customer/Site tab of the Project Detail page. 49 of 200

50 2. The Customer/Site tab is where you can update customer, industry and site information. 50 of 200

51 Selected Products Tab 1. Click on the Selected Products tab of the Project Detail page. 51 of 200

52 2. The Selected Products tab contains product catalog numbers and descriptions for the particular drives and motors you have selected in your project. You can save these products to a Product List or Export the Bill of Materials to another program such as Microsoft Excel. 52 of 200

53 Reviewing a Completed Axis Now that you have had the chance to review a completed project, let s take a closer look at the components of a completed axis. 1. Click on the Component Detail tab of the Project Detail page. 2. Click the View button for the Sponge Wheel Axis. 53 of 200

54 3. The Components tab of the Sponge Wheel Axis page will appear. Let s take a look at this page in more detail. Along the top half of the page is the Power Requirements section. This is where you select the Voltage and Phase for the application. In the center of the page you will find the axis components. This application contains load and profile information as well as information for a belt drive transmission. You can also view the Voltage Tolerance by clicking on the Voltage Tolerance drop down button. 54 of 200

55 4. Click on the Sponge Wheel Profile. 55 of 200

56 5. The Profile page will appear. This page is used to edit the motion profile information for an axis. In the interest of time, the load and profile information has already been entered for you for the various application axes. Take a moment to explore the profile plots. Click the next to the various plots to examine the profile information. Use your mouse to drag the plot and your mouse s wheel to auto-adjust (zoom) the plot scales. 6. You can also click on each segment to view your segment points as shown below. 56 of 200

57 7. You can select to edit the motion segments or the additional loads. Click on the Additional Loads edit button and a segment of your profile to view the added load. 57 of 200

58 8. When you are finished exploring the Profile page, click on the Return to Axis Without Saving button. Click OK to proceed. 9. Click on the Belt Drive transmission. 58 of 200

59 10. The Transmission Properties page appears. Here you can edit the properties for any transmission components in your application. For convenience, the transmission properties for the application have already been entered. The button is used to calculate the inertia value for the application. 59 of 200

60 11. When you are finished exploring the Transmission Properties page, click on the Continue to Axis button. 60 of 200

61 12. Since a drive and motor have already been selected for the application, let s take a look at the performance plots for this solution. Click on the Performance tab of the Sponge Wheel Axis page. 61 of 200

62 11. The Sponge Wheel Axis Performance page will appear. The Torque/Speed Curve appears first. Here you can see where the particular segments of the motion profile fall relative to the Torque/Speed curve. You can see the curve for additional drives or motors by clicking on the Size Up and Size Down buttons. 62 of 200

63 If a gearbox is selected for the application, you could also see how changing the gearbox impacts the Torque/Speed results. 12. Click on the Power/Speed and Thermal buttons to see the other Performance plots for the application. 13. When you are finished browsing the application performance plots, click on the Continue to Project button at the top of the page to return to the Home page. 63 of 200

64 Exporting a Bill of Materials 1. Click on the Selected Products tab of the Project Detail page. 64 of 200

65 2. Click on Export BOM to export the Bill of Materials for this application. 3. For convenience, the exported Bill of Materials file has already been saved for the Proposal Works section of the lab. Click the Cancel button in the dialog box that appears. You have completed Motion Analyzer section of the lab. Close your browser and its tabs. Now it is time to complete the Proposal Works section of the lab. 65 of 200

66 PW: ProposalWorks Lab We will now combine and consolidate the IAB and MA output information into one PW project file. This hands-on lab will show you how to create a proposal project using information generated from other PST applications while including new items into your project. As you complete the exercises in this lab exercise, you will: Learn how to create new Equipment List Organize your Bill of Materials based on project list Generate a Consolidated BOM Navigate through the Proposal Outline and Document sections Generate a final proposal document Reviewing an Existing Project We will use PW to combine the outputs from IAB and MA into one project file followed by adding additional items needed for this proposal project. We will use the report generated from IAB and merge the MA export into one PW file. Once each BOM has been imported successfully, we will add the other items in a separate Equipment List and navigate through PW to generate the final proposal document. Open PW 1. Launch PW from your desktop by double-clicking on the PW icon on the computer. 2. If the Connect to Internet dialog box occurs, select No. 66 of 200

67 3. From the home page, go to File Menu > Open. 4. We will want to use the file report generated from IAB. The Green Magic Shampoo Labeler IAB.prp file will be located at the following location: C:\Program Files (x86)\pst\ra_iab\iab_proj Browse to the location and select Green Magic Shampoo Labeler IAB.prp. Select Open. 67 of 200

68 The IAB BOM project information will now be displayed. You won t see all the graphics for the products but don t be concerned. Combining IAB & MA Reports 1. Since we will also be importing the BOM project information from MA, we want to have the ability to distinguish between each set. Go to left side of the ProposalWorks screen and click on the Proposal Outline tab. 2. Click once on the Equipment List section to select. Double click on the header to have the ability to alter the text. Type IAB as your new header. Double click here 68 of 200

69 3. Now that we have made this change, let s take a moment and save our work before we move forward with the project. To save the project, select File > Save. Note: You may also save the project by clicking on the ProposalWorks as well. icon located at the upper right hand corner of 4. Since we used MA to select the drives for this exercise, we can remove the drives selected during the IAB exercise. To remove the drives, click on the Filter icon. The Filter option allows us to quickly and easily search the BOM based on keywords or catalog number criteria. To search for the drives, select the Filter icon and type the keyword drive in the field below. 69 of 200

70 The following results will be displayed as a result of the keyword drive used. Don t be concerned if the graphics don t appear. Click on the X to the right of the word drive and type the keyword powerflex. The following results will be displayed as a result of the keyword powerflex used. Don t be concerned if the graphics don t appear. 70 of 200

71 5. Now that we located the PowerFlex 525 Drives we need to remove them. To remove these items, simply rightclick on the location for the graphic and select Delete. Don t be concerned if the graphics don t appear. 6. The following warning message will appear. Click on Yes to finalize process. 71 of 200

72 7. Repeat this process for the remaining PowerFlex drive. With your new skills, change the filter to drive and delete the two Kinetix 5500 drives. To clear the Filter results, click on the Filter icon and click on the Clear Filter option. 8. We will now add the MA project information into ProposalWorks. We will create a new Equipment List to store the MA project information. ProposalWorks has the ability to store sets of Bill of Materials into different Equipment Lists. To create a new Equipment List, go the Proposal Outline section. From the dropdown menu select Equipment List followed by clicking on the green plus symbol. 9. Double click on the Equipment List 2 header and rename to MA. 72 of 200

73 10. The export from MA will be in.csv format. To import this information into PW, go to the Generate Documents icon on the upper right corner followed by selecting the CSV option under Import Options. 11. A new window will appear. Browse and search for the productlist.csv file in C:\Program Files (x86)\pst\ra_iab\iab_proj that was generated by the MA portion of the lab. Click on Open to finalize the selection process. 73 of 200

74 12. The items from MA project will now be imported into the Equipment List titled MA. Don t be concerned if you don t see the graphics. Be patient as the products are being added. Select OK to the Success dialog box. Notice how we now have motion products in the Equipment List. 13. Let s organize the information by including a group header. To include a group header, click right above the first item in the MA Equipment List. The red line denotes the insertion point. Don t be concerned if you don t see the graphics. 74 of 200

75 14. Now right click where the red line is and select the Group option. A group header will now be placed in the Equipment List. Don t be concerned if you don t see the graphics. 15. Double click on the header and rename to MA Project Export. Don t be concerned if you don t see the graphics. Additional PW Configuration There are other items needed for this system. IAB and MA were used to create the majority of IA project but we will want to use PW to select the control, signaling and wiring selections needed to complete this project. To minimize confusion on where these items should belong, you will want to create a new Equipment List specifically for these items. 1. To create a new Equipment List, go to the Proposal Outline section. From the dropdown menu select the Equipment List option followed by clicking on the green plus symbol. 75 of 200

76 2. Rename the header from Equipment List 2 to PW. Do you remember how to do this? Double-click on Equipment List 2 and then type in the new name of PW. The Proposal Outline section should now look as follows: We will add three items to our project. All items will be configured and placed in the PW Equipment List. The remaining items will be wired into the embedded I/O of the controller. To complete this process, you will need to quote a 30mm 800T 2-position illuminated selector switch, 30 mm illuminated push button, and an IFM module with the appropriate cable to connect to our previously selected I/O. 3. Go to left side of PW and click on the Product Library tab. The Product Library houses product configurators for both Rockwell Automation and Encompass Partner. Users may either search for product configurators by either navigating through the Product Library directly or entering keywords or catalog number criteria to search for the appropriate product configurator. 76 of 200

77 4. Type the keywords 30 mm selector switch in the Keyword Filter section. 5. The application calls out for an 800 T 2-position illuminated selector switch. Search for the title of the appropriate configurator and double click to launch the product configurator. The product configurator will now launch on the screen. 77 of 200

78 6. Product configurators take the information from product selection tables/guides and make it easier to select a product. To select a product, answer each attribute from top to bottom. As you make your selections, the configurator will construct a catalog number per your application. Select your options so that the configurator has the following result. 7. Notice that the Accept button is now available to be selected. Select the Accept button to finalize the selection process. 78 of 200

79 The 800T catalog number will also be displayed in the Equipment List. 8. We will now configure the push button for the application. Go to the Product Library and type 30 mm push button as the keywords and 800t as the catalog number. 9. Search for the illuminated push button configurator. Select and double click on the 800T Momentary Contact, Illuminated configurator. 79 of 200

80 10. The 800T configurator will now appear on the screen. Answer the questions in the configurator as seen below: 11. Click on the Accept button to finalize the configuration process. The conigured 800T will now be displayed in the Equipment List. 12. Let s now configure the needed IFM module and cable. From the IAB project BOM, we will use some of the information to appropriate select the IFM module. Go to the Product Library. Clear the catalog number filter and type 1492 as the keyword. Double click on the 1492 Wiring Systems Modules configurator. 80 of 200

81 13. Match the selections in the configurator as seen below. The cable can also be selected from within the same configurator. This will launch a second configurator. To configure the cable, select the Pre-Wired Cable Connector Selection attribute. 81 of 200

82 14. Once you have selected this option, you will see the second configurator screen. Make the following selections as listed below. Once the selections have been made, click on the Accept button to finalize the selection. 15. You will have to click on Accept once more. Both products will now be displayed in the Equipment List. Notice that the cable is linked to the main IFM product. 82 of 200

83 Generating a Proposal Project Since we have three sets of BOMs, we will want to provide the customer with a nice Consolidate BOM for the project as well. Go to the left side of ProposalWorks and click on the Proposal Outline tab. 1. From the Proposal Outline use the dropdown menu to select Consolidate BOM. Once you have selected this option, please click on the green plus symbol to add to the Proposal Outline. 2. A Consolidated BOM will now appear on the screen. 83 of 200

84 3. We will want to add documentation to the proposal before we compile and send to customer. To view what documentation is available, click on the Documents Menu icon. From within this view, you will have the ability to view and add documents to your proposal document. Product supplements such as product details, certifications, user manuals, etc can be located within the Product Supplements tab. Just double click on a particular item listed in the Available Product Supplements area to view it. Also know that the items in the list depend on if you are connected to the Internet or not. 4. For demonstration purposes double-click on any supplement and view it. It may contain hyperlink/s. Explore the hyperlinks if there are any. Close the supplement when you are done. 5. We will want to include some Product Details and Certification documents to our proposal. To quickly search for all possible product details, make sure the Keyword field is clear and use the second dropdown to select Product Details Supplements. Note: Your supplement list may vary as items are added over time. 84 of 200

85 6. The filter allowed to only display the Product Details and Certifications for all items in the project. To include these documents in our proposal document, click on the main header and drag towards the Proposal Outline section. 7. These supplements will now be included in the document. Note: Your supplement list may vary as items are added over time. 85 of 200

86 8. We will want to include a cover page to the proposal document as well. Click on the Document Library tab. Under the Samples section there will be a DIST Proposal Cover Page Sample. Drag and drop that item right above the IAB header in the Proposal Outline. 9. Before we generate the final document, we will need to fill out some user and customer information. Click on the User menu followed by clicking on the Profile tab. You will need to enter your information in this location: Enter in your contact information. 86 of 200

87 10. We will now enter the customer information. This information will be used when we generate the final report. Click on the Customers button. Click on the green plus sign. 11. Enter the following customer information and click on the Save icon to save the customer information. 87 of 200

88 12. Make sure that the newly created customer contact has been selected before proceeding further. 13. Go to the Project menu and fill out the selections for Description, Project ID and Bid Due Date. Use today s date for the Bid Due Date: 88 of 200

89 14. We are now ready to export the project to Word. To export the project, click on the Generate Documents icon to view the export options. We will want to export the proposal document in Word format. Select the Word option from the Export Options section. 15. The following Proposal Output Options window will appear. The left pane is a mirror image of the information you had placed on the Proposal Outline section. The right pane are the available options to be selected for the export. Green checkmarks indicate that those options will be selected and generated in the final document. The user has the opportunity to select which options to export into the final report. Since we want all options that are currently selected, all we have to do is select the Generate button: 89 of 200

90 16. Once you click on the Generate button, a Word document will be generated with all the components that you had selected and placed on the Proposal Outline section. Please give the software time to generate the report. Feel free to look through the generated Word document. To do this click on the Word icon in the system tray (bottom of your screen) and scroll through the document. Close the Word document when you are done. Close ProposalWorks. If asked, save your changes to the files. Summary In the lab we used PW to combine the BOM generated by IAB and MA to make a final proposal. Then we added in some additional missing products to complete our solution. In addition we found out how PW can be used to collect up project documentation such as certifications and wiring diagrams. Now that the bill of material is finalized, let s move onto an IA Simplification Tool that will help us write the application code for the controller and the PanelView Plus graphic terminal (HMI). You have completed the PW portion of this lab. 90 of 200

91 IA Simp Tools: Drive and Motion Accelerator Toolkit (DMAT) So far in this lab we have only used product selection tools. But at some point you will have to program these automation products. So do we have a tool to help with application code? Yes. The tool is called the Drive and Motion Accelerator Toolkit or DMAT. It provides example HMI and logic code along with a wizard. The wizard can be used to customize the code for your application. However we are running out of time in this lab so we will just end with a tour of the DMAT. However, we will show you where you can download this free tool. DMAT Details The Drives and Motion Accelerator Toolkit (DMAT) provides tools to assist with all facets of your design task, from selecting components and developing drawings, to writing code, laying out HMI screens, starting up your machine - and even troubleshooting. 1. Open the Drives and Motion Accelerator Toolkit software using the icon located on the desktop. 91 of 200

92 2. Move the mouse over the first menu item, INTRODUCTION AND OVERVIEW. Notice that documentation is provided in a variety of media from presentations to videos. In addition there is a detailed Quick Start Manual. 92 of 200

93 3. Move the mouse over the menu item called DISCRETE DEVELOPMENT TOOLS. Notice that this menu item provides links to all the DMAT toolkit files including BOM files, CAD drawings file, controller logic files, HMI applications, and examples. The DMAT Wizard uses these files to assemble the output files. You may also use these files to add additional drives or build your application manually without the DMAT Wizard. 4. Move the mouse over the items under Help and Other Information to view the additional files included in the DMAT. Notice that this menu item provides a wealth of information including how to control EMC noise that often comes with the use of pulse width modulated drives. 93 of 200

94 5. Mouse over the menu item called Wizard Development Tool. The Drives and Motion Accelerator Toolkit (DMAT) Wizard will create an initial Bill of Materials, assemble a system drawing set, and create a Studio 5000 Logix Designer project file with a preconfigured controller, network, drives and initial system program logic. In addition, you are introduced to several Rockwell Automation system configuration tools that provide assistance in sizing your motor/drive combinations for a variety of load, transmission, and application types. Using the DMAT Wizard can reduce the 5 Development Hours to 5 minutes! 94 of 200

95 6. Now we will show you where you can get this free tool. In your web browser go back to Under Develop select Systems. 7. Scroll down until you see Drives and Motion Accelerator Toolkit. Using the download link the DMAT can be installed on your PC. In this lab the software is already installed and ready for use. Final Summary IA Simplification Tools, IAB, MA and PW are all free software. Use Popular Configuration Drawings as a baseline architecture. Use IAB to select your controller and verify network performance. Use MA to select and size your drives and motors. Use PW to combine your bill of materials from IAB and MA, add any missing product, and generate the final proposal. Use the Drive and Motion Accelerator Toolkit to quickly create controller and HMI application code. IA Simplification Tools are found at You can download IAB and PW from The cloud version of MA can be found at There are labs available for both PW and IAB to help you get started. For IAB, start with the Basics-Lab.pdf found by selecting File > Start Page > Labs > Basic Functionality. For PW, watch the videos under the Help section. MA has a built in lab as well. The DMAT has its own Quick Start manual. You have completed the lab. However, the Appendix has an Advanced Motion Analyzer lab if you wish to continue. 95 of 200

96 Appendix: Advanced MA - Sizing and Selecting Drive/Motor Solutions using Motion Analyzer About This Lab As you complete this section of the lab, you will experience the speed and simplicity of using the new Motion Analyzer to size and select motion and drive systems. This session will showcase the web based selection tool. As you complete the exercises in this hands-on session, you will: Log in to the Motion Analyzer website motionanalyzer.rockwellautomation.com Configure a customer application for a winder machine with a paint and drying section. This hands-on lab is ideal for: Individuals who size, select, and optimize motion control applications Mechanical engineers and controls engineers designing machines with motion control Machine users trying to improve an existing machine with motion control System integrators selling motion control Objectives XMO is an OEM material handling company specializing in metal fabrication for buildings and transportation. Their products may use metals such as iron, titanium, steel, silver, copper, aluminum, and alloys such as stainless steel, silicon, and bronze. XMO is commissioning a new production line with a winder machine, a paint section, and a drying section. You were asked to size each axis in the production line and provide a bill of material for this project. XMO is familiar with Rockwell Automation and its products. In the project requirement, they specified that all axes should be driven by Kinetix 5700 drives on a shared DC bus. The drive system can use a dual axis inverter where applicable and also share control power from a single source. The power requirement will be three phase 480V with a tolerance of ±10%. To reduce cabling, they have looked into using single cable technology and decided on the VPL servo motors for the paint and drying sections. Since the winder axis will be crucial, they have talked about using the Kinetix VP Continuous Duty motors connected to their preferred gearbox manufacturer, Stober. The gearbox gear ratio can be between 4-8:1. The drive system cabinet will be located at least 20 meters from the motors. The preferable length for the motors is anything between meters. The drive system will be housed in an area with ambient temperature of 104 F. You are to provide a bill of material for this application. Quick Note Some of the images of data entry may use units that your user account may not be set to. This is done to bring attention to the importance of entering correct data to the tool, and making sure your user units are selected correctly. 96 of 200

97 Entering Lab User Credentials 1. Open Internet Explorer and manually enter the URL as Note: Don t use the desktop shortcut or the favorites in the browsers as they will point to a different version of Motion Analyzer. That means that the lab instructions and screen shots won t match. 2. Maximize the screen if needed. Click the Login button, enter the following lab user information and click 3. Click the Login button, enter the following lab user information and click the Submit button: Address: labuser##@ra.rockwell.com where ## is the two digit number given to you by your instructor. Password: Rockwell2017 Note: You can also utilize your own log in information for this lab or create a new account. 97 of 200

98 Creating a Project Logging in to Motion Analyzer will take you to the home page. You can create new applications (projects), access existing application data, or simply browse for drive, motor, independent mover system, or gearbox product information. Let s begin by starting a new project. 1. Click on the Start A New Project button in the main page. 2. The Create a Project window will appear. Enter a name for your project and a description in the Project Name and Project Description tabs. Click Create Project to create your axes. 98 of 200

99 3. You can enter your customer s information in the Customer Information section. The Use section allows you to include filters specific to Industry or Application related projects. The Site section relates to the Altitude and Ambient Temperature of your machine s location. All these sections can be entered at a later time in the project. Click Go to project to continue. Note: It is important to include the SITE information when sizing. The ambient temperature does have an effect on thermal capacity calculation of your axis, therefore having the correct information entered would allow Motion Analyzer to provide a correct solution. 99 of 200

100 Component Detail Tab 1. The Project Detail page will appear. There are several tabs for viewing different aspects of your project. The current tab will display the axes associated to this project. You can also change the name of your project in this page. 2. Click on the Edit icon to change the name of your project. In this example, my project name is changed to MA Advanced. 100 of 200

101 3. Click on the Edit icon to accept your change. 4. Select Create New Axis, Use Application Template to create the first axis of the project. 5. The Select Motion Type window will open. This is where you will select the load type of your axis. For the paint axis, we will be selecting a rotary motor, however the load will be moving linearly. We will be utilizing a mechanism which translates the rotary motion of the motor into linear motion of the load. The motion profile is entered for the load, so in this example, we will be entering linear motion profile data. Select the LINEAR AXIS WITH MECHANISM type. 101 of 200

102 6. You will get this notice. Note: You are using new motion analyzer profile editor. If you wanted to use the earlier available profile editor, you could uncheck the Use New Editor selection. 7. Click OK to confirm and continue. 102 of 200

103 Create a Motion Profile Here is the motion profile that has been specified for your application. Let s look at how to enter this information into the Profile page in Motion Analyzer. 1. The profile editor will first ask you for starting conditions. We will leave the entry tabs as is and select Get Started. Note: If you were dealing with an axis with an inclination angle, you can enter the value in degrees in the Inclination tab. 2. The profile editor page will be open. Take some time to look at the page, check the available options in the Profile Plot section, and review your unit options. 103 of 200

104 3. Click on ADD and select Index to insert the first segment of your motion profile. 4. The segment editor section will open and you can edit your segment to the specified points. 5. You will enter the distance, time, and jerk of your first segment. Enter 10 inches and 1.5 seconds for your Motion Distance and Motion Time respectively. Makes sure the units are in inches and seconds before entering the values. 104 of 200

105 6. To allow for a smooth ramp-up to speed, include a 50 % jerk to the plot for both ACCLEREATION JERK and DECELERATION JERK 7. The segment entries should match the image below 105 of 200

106 106 of 200

107 8. Your segment should look the following: 9. We will now add the CAM segment in your profile. Click on ADD and select Cam. 10. Our CAM table will be import from a file. On your desktop look for the file CAM Profile in a folder called Lab Files. Open it and copy the texts starting at the 3 rd row. The image below shows portion of your CAM table. 107 of 200

108 11. In the profile editor window, click on IMPORT FROM LOGIX EDITOR. 12. Paste the copied text into the cam table Import window. 108 of 200

109 13. Click Import Data after pasting the table data. 14. Your CAM segment will show the following table: 109 of 200

110 15. We will now select the master and slave unit conversion to scale our plot. For the Master Conversion and the Slave Conversion, enter 1 second and 5 inches respectively. Don t forget to press enter on your keyboard to accept the changes. 16. Your segment should look the following: 110 of 200

111 17. The third segment will return us to our starting position. Click ADD and select Index to insert the third segment of your motion profile. 18. You will enter the distance, time, and jerk of your third segment. Enter -10 in and 1.5 seconds for your Motion Distance and Motion Time respectively; and enter 50 % for your ACCELERATION JERK and DECELERATION JERK. Your entries should look as below: 111 of 200

112 19. The last move segment will be your dwell segment. Click ADD and select Cruise/Dwell to insert the dwell segment of your motion profile. 20. Enter 2 seconds for your dwell Motion Time. Note: You can select your Data Entry Permutation to be Time or Distance entry for a DWELL move. For an ACCEL or DECEL move, the Data Entry Permutation offers Time Distance or Time Velocity entry. You can also specify your motion type whether you are performing Incremental or Absolute motion. Note: You have entered your motion segments to represent your overall motion profile. However your profile did not include any load to this point. We will insert both a mass and friction coefficient as loads on your profile. 112 of 200

113 21. To include a load, click ADD and select Mass to insert load acting on the profile. 22. The load to be move throughout the profile is a constant load. Click on the Permutation drop down and select Constant for an unchanging load. Note: If each segment had a different load value, you would leave the Permutation at Variable and enter your segment loads. 23. Enter a load mass of lbs. in the Full Load tab, then click Apply Changes. 113 of 200

114 24. The next load to enter is our Friction Coefficient. Click ADD and select Friction Coeff to insert the coefficient of friction acting on the profile. 25. Click on the Permutation drop down and select Constant for an unchanging friction coefficient. 114 of 200

115 26. Enter 0.2 in the Full Load tab, then click Apply Changes. 115 of 200

116 27. Your profile plot should display as below: 28. You can remove certain graphs from the Profile Plot by unchecking the View Y AXIS boxes. Remove Jerk from Motion, and Load Mass and Applied Force from Segment Loads by unchecking the View checkbox. 29. You can add certain graphs from the Profile Plot by checking the View Y AXIS check boxes. Include the Mass from Additional Loads by checking the Y AXIS box. 116 of 200

117 30. Select the EDIT circle to return to the Motion Profile. 31. You ve completed the Motion Profile edits. Click SAVE AND CONTINUE TO AXIS. You ve just finished editing the motion profile of your Paint axis. In the next section, you will edit the mechanical components associated with this axis. 117 of 200

118 Axis Components Now that the load and profile information has been entered, let s begin entering the data for the mechanism. The Components page will include a Profile which defines how our load is moved by the system; Linear Mechanism which translates the rotational motion from the motor into linear motion; Transmission which may be a belt drive, chain & sprocket, spur gear, our some sort of coupling; Gearbox; Motor which can be a custom induction motor, an RA partner product, or an Allen Bradley motor; and finally a Drive. 1. We will start by changing the name of our axis and setting the power requirements of the incoming power. Click on the EDIT icon and change Axis 1 to Body Dipper 2. Click the Voltage and phase dropdowns and select 480 and 3 respectively. 3. Click the Voltage Tolerance dropdown and enter 10 in both fields. 118 of 200

119 4. To edit our linear mechanism, click on DEFINE CUSTOM in the LINEAR MECH. Component. 5. Select Lead Screw from the PICK A TYPE dropdown options. 6. Click OK to confirm your selection. 7. Your lead screw mechanism will require a name, we choose Lead Screw for our example. Enter a name and click OK to proceed. If you choose to not enter a name, Motion Analyzer will provide a default name. 119 of 200

120 8. Change the units of the Lead (per Rev) to m/rev and enter m/rev in the entry tab. Also enter 95 % in the Efficiency entry tab. 9. Click on the Inertia Calculator icon to calculate the inertia of the lead screw. 120 of 200

121 10. The Inertia Calculator tool provides the inertia of an object based on size and material. Select Solid Cylinder and Steel as Type and Material respectively, and enter Element 1 as Name. 121 of 200

122 11. Set your units for Length and Diameter to mm by clicking on the units icon and selecting the new unit. 12. Enter 250 and 16 for length and diameter respectively. Your entry should look as below: 122 of 200

123 13. Click Save to load the element. 14. Your element will be loaded and you can apply this calculation to your object inertia. Click Apply to enter the inertia value into the Inertia tab. 123 of 200

124 15. Click inside the Inertia field. The lead screw linear mechanism should display as below: 16. Click Save to add this mechanism to your axis component list. 17. Once the linear mechanism has been saved, click CONTINUE TO AXIS to proceed to the other components of your axis 124 of 200

125 18. You will be returned to the axis components page. Your completed components are the Profile and the Linear Mechanism. We will add a transmission to this axis. Click on DEFINE CUSTOM for the Transmission component. 19. You will be returned to the axis components page. Your completed components are the Profile and the Linear Mechanism. We will add a transmission to this axis. Click on DEFINE CUSTOM for the Transmission component. 125 of 200

126 20. Provide a name for your custom transmission. In our example, we choose Coupling for name. Click OK to proceed. Note: For the axis components, you can leave the name entry blank and click ok. Motion Analyzer will provide a standard name for the components. 21. From the Transmission Properties dropdown, select the Coupling transmission type. 22. Enter the following information into your Parameters fields. 126 of 200

127 23. Click Save to save your changes and select CONTINUE TO AXIS to proceed to the axis components page. 24. You will be returned to the axis components page. Your completed components are the Profile, the Linear Mechanism, and a Transmission. We will select the specified customer motor and drive families to the axis components as solution filters. On the Components page, scroll right to access the motor and drive components. 127 of 200

128 25. Click ADD Motor on the Motor component. 26. Click on Browse Products to select one or more motor families in the motors product page. 128 of 200

129 27. The Motors product page will open. Scroll through the page to see all the motor choices you have. 28. Scroll back up to the top of the page. In the Rockwell Automation section, Click VIEW 6 MORE to view all Rockwell Automation motor products. 129 of 200

130 29. The Rockwell Automation motor products will be displayed. You can select one or multiple motor families when searching for solution or comparing motor products. 130 of 200

131 30. Click Select on the VP Low Inertia Servo Motor to select the customer specified motor family. A checkmark will appear once you select the motor family. 31. Select Save Selections to Axis to add the selected motor family to your motor components 32. Select OK to proceed adding the selected motor family to your axis components 131 of 200

132 33. You will be returned to the axis components page. Your completed components are the Profile, the Linear Mechanism, a Transmission, and a Motor family filter. We will select the specified customer drive family to the axis components as solution filters. On the Components page, scroll right to access the drive component. 34. Click ADD Drive on the DRIVE component. 132 of 200

133 35. Click on Browse Products to select one or more drive families from the drives product page. 36. The Rockwell Automation drives products page will be displayed. You can select one or multiple motor families when searching for solution or comparing motor products. Click on VIEW 7 MORE to see more offerings. 133 of 200

134 37. We will select the Kinetix 5700 Servo Drive family. Click Select on this family. 134 of 200

135 38. Select Save Selections to Axis to add the selected drive family to your axis components. 39. Select OK to confirm your selection. 40. Your completed components are the Profile, the Linear Mechanism, a Transmission, a Motor family filter, and a Drive family filter. On the Components page, scroll right to see the motor and drive filters. 135 of 200

136 41. You have added a filter for single family for both your motor and drive components. When filtering for solution, limiting the filters to a few product families may translate to shorter solution search time. Click on SEARCH FOR SOLUTIONS. 136 of 200

137 42. The SOLUTIONS LIST page will open and will start searching for compatible solution results. 43. Once the solution search is completed, you will be presented with multiple combination results. Note: The solutions list offers multiple motor/drive combination. You can filter by Profile Match, Inertia Ratio, etc for a solution that meets your specific needs. 137 of 200

138 44. Click on View Torque Speed Curve on the first solution to view the torque speed curve. 45. The torque speed curve of the first solution will be displayed. You can click anywhere away from the plot to return to the Solutions List window. Return to the Solutions List window. 138 of 200

139 46. Click on Filter Solutions by Product Family dropdown 47. Because we limited our solution search to a single motor and drive family, you will not see other family product combinations listed. You can use this feature to filter your solutions further. Click Select to select the first solution. 139 of 200

140 48. Your selected solution will be added to your axis components. Review the Components page for the selected solution. 49. You ve selected a dual axis inverter allowing you to connect an additional axis on this single Kinetix 5700 servo drive. 140 of 200

141 Performance The completed axis components are shown. Scroll to view that we ve completed the PROFILE component, defined the LINEAR MECHANISM and TRANSMISSION components, and selected our MOTOR and DRIVE components. Notice that at the axis components page, any change made is automatically saved by Motion Analyzer. You can create snapshot as starting point and can restore the snapshot after making changes to your axis. 1. We will review the performance of our selected solution to confirm performance. Click on the Performance tab 141 of 200

142 2. The Torque/Speed curve will be displayed. Take time to review this solution, explore the Drive and Motor tabs to view application to component performance. 3. Return to the Summary tab by clicking Summary. Review the Power/Speed and Thermal plots by clicking on Power/Speed and Thermal respectively. 142 of 200

143 Note: If the thermal plot does not display properly, refresh your webpage. 4. Return to the Torque/Speed plot by clicking on Torque/Speed 5. You can size up/down on your motor and drive to view the performance of different motor/drive combinations. Click Size Down and Size up on the Motor and Drive to view the changes on your Summary and on your Torque/Speed plot. Note: Any changes made in the Summary will not take effect until you apply the new motor/drive combination after sizing up/down. 143 of 200

144 6. Return to the Components pages by clicking on Components. 7. In the axis components page, Click SET CONFIGURATION to configure the complete catalog number of your motor. 144 of 200

145 8. The selected motor family will be displayed with multiple configurations to choose from. Click on the horizontal display icon to view more items. 9. Assuming the customer requested a motor with the following features: IP rating 66, Keyed shaft, 24 Vdc brake, and a multiturn absolute feedback. Use the filter to find a close match. Click on the Options dropdown to view your filter options. 145 of 200

146 10. Select the checkboxes for Keyed shaft and 24 Vdc brake. Click on the Options dropdown to retract the filter options. Notice how your number of items decreased. 11. Click on the IP Ratings dropdown to view your filter options. 12. Select the checkbox for IP66. Click on the IP Ratings dropdown to retract the filter options. 13. Click on the Feedback dropdown to view your filter options. 146 of 200

147 14. Select the checkbox for Multi-Turn Absolute. Click on the Feedback dropdown to retract the filter options. Notice how your number of items decreased. 15. Select the following motor by clicking on its Select checkbox. 16. Click OKAY to return to axis. 17. At the axis components page, scroll right to view your selected motor. 147 of 200

148 18. Click Select Cable to add a motor cable to your axis. 19. The customer prefers a Continuous flex cable with minimum 20 meters length. Select Continuous from the FLEX TYPE dropdown. 148 of 200

149 20. Change the units of the CABLE LENGTH entry tab to m, and enter 20 in the tab to show cables 20 meters and longer. 21. We will select the 23 meters long cable to give our customer an extra 3 meters additional length. Click Select to select the shown cable. 149 of 200

150 22. The cable will be added to your MOTOR component as an accessory as shown below: 23. You ve completed the configuration of the paint axis called the Body Dipper. This axis has the same configuration as the second axis, the drying section. Since we ve completed the work, we will duplicate this axis. 150 of 200

151 Duplicating and Merging an axis Duplicating an axis reduces time to recreate an exisiting blah blah 1. In the axis components page, click DUPLICATE to duplicate the axis. 2. Rename this copy as Dryer. Note: You can duplicate an axis or axis component for up to 20 copies, and you can choose to duplicate to the current project, to library, or to a previous existing project. 151 of 200

152 3. Click YES, DUPLICATE THIS AXIS to confirm your selection. 4. Once the axis is duplicated, you are returned to the project page s Component Detail tab. 152 of 200

153 5. Since we are using a matching dual axis inverter for both our body dipper axis and dryer axis, we can merge the two axes to use a single dual axis inverter. Select MERGE EXISTING to merge the dryer axis with the body dipper axis. 6. Click on the Select an Axis dropdown option 7. Select the shown axis 153 of 200

154 8. Select JOIN AXES to merge the two axes to the dual axis inverter. 9. Your completed configuration should look as shown: 154 of 200

155 Application Template Motion Analyzer s application templates let you enter pre-configured mechanism application data. The templates include the Winder/Unwinder and the Press Roll Feed (constant time). We will use the winder/unwinder template to create our winder axis. 1. From the project Component Detail page, click Create New Axis, Use Application Template to open the Motion Type/Motion Profile Options/Define Application Template window. 2. Select the CENTER DRIVEN WINDER application template. 155 of 200

156 3. The application template will be loaded and open with a blank template as shown below. Use this template to enter required inputs to calculate the load profile for Winder or Unwinder applications. Note: The direction of pull from a web tension application determines whether to use wind or unwind. For a Winder or Unwinder application, two index moves are created: maximum diameter, minimum rotation speed (maximum torque for center driven) and minimum diameter, maximum rotation speed (minimum torque for center driven). Note: The maximum torque condition is the worst case for winding temperature so the move time for this index is made large enough to dominate the temperature calculations. The maximum speed case is included to check that the specified speed can be reached. Note: The Mirror option is used only when a Wind and Unwind axis share a DC power rail. The two axes are first sized as normal (for example, Profile Mirror is unchecked). The Winder is then set to Profile Mirror. This matches the two axis motion profiles as if they were connected by the web. This is necessary only to check the system sizing. In this mode the motor winding temperature of the Winder axis will be underestimated. 156 of 200

157 4. Click on Wind and Center Driven to select the center driven winder. Note: The roll in a center driven winder is driven directly via a shaft at its center of rotation. For a Center Driven application, rotary load is selected and the roll is modeled as Inertia and Torque in a Multi-segment profile. 157 of 200

158 5. There are about ten information tab to enter. Review below to know what the field information is. Note: Input data and description: Empty Diameter - Minimum reel diameter, when the roll is completely unwound. Full Diameter - Maximum reel diameter, when the roll is completely wound Empty Inertia - Inertia of the reel when it is completely unwound Full Inertia - Inertia of the reel when it is at full diameter or completely wound Maximum Web Tension - Maximum allowable web tension for the material. The value is used for sizing purposes Minimum Web Tension - Minimum web tension for the application. It is used to calculate the Tension Ratio Maximum Web Speed - Design speed of the material running through the machine Acceleration Time - Shortest required acceleration time from zero to maximum web speed Deceleration Time - Shortest required deceleration time from maximum web speed to zero Jerk - if the acceleration and deceleration follows a smooth S-curve. If a value is not entered, acceleration is considered trapezoidal 158 of 200

159 6. Copy the following data into your template. Make sure the units match. 7. Click SUBMIT to enter your application template information 8. Select YES, CLEAR THIS PROFILE to insert your application template information as a new motion profile. 159 of 200

160 9. You should be seeing the populated plots of your motion profile as you scroll through the page. 10. Click the magnifying icon on the Position Plot to automatically zoom the plots 160 of 200

161 11. Click on the dropdowns for the Jerk, Acceleration and Velocity plots. 161 of 200

162 Your completed profile should resemble the following: 162 of 200

163 12. The winder application template automatically provided a torque, inertia, position, velocity, acceleration, and jerk plot. Let s look at the torque and inertia plots to understand how the calculations are done. 13. Click SAVE to save your application motion profile. 163 of 200

164 14. Once the profile finishes saving, click CONTINUE TO AXIS to access your axis components. 15. Your axis Components will look as below: 16. Rename the axis to Winder, set the power requirement to 3 phase 480 volts, and set the voltage tolerance to ±10 %. 164 of 200

165 17. The axis Components page should look the following: 18. We are going to add a motor and drive family. Click on Add Drive. 165 of 200

166 19. Click on Browse Products to open the drives product page Note: If you know the product catalog number, you can start entering the first few letters or numbers associated with the product. Motion Analyzer will provide products with similar catalog number as you continue entering the letters or numbers of your product. 166 of 200

167 20. In the drives products page, select the Kinetix 5700 Servo Drive family by clicking on Select or in the checkbox by the product 21. Click Save Selections to Axis to add the item as a filter to the DRIVE component of your axis. And click OK to continue to axis. 22. Click on Add Motor to open the motor catalog options 167 of 200

168 23. Click on Browse Products to open the motor products page Note: If you know the product catalog number, you can select the Select a family dropdown to select a motor family, then select a product from the chosen family. 168 of 200

169 24. In the motors products page, select the VP Continuous Duty Servo Motor family by clicking on Select or in the checkbox by the product 25. Click Save Selections to Axis to add the item as a filter to the MOTOR component of your axis. And click OK to continue to axis. 169 of 200

170 26. For this axis, we will use a gearbox. Click Add Partner Gearbox 170 of 200

171 27. The customer requested for a specific manufacturer. From the SPECIFY PARTNER GEARBOX, click on the Select a manufacturer dropdown and select Stober Drives. 28. Click on Browse for Families, Products or Configuration to open the gearbox products page 171 of 200

172 Note: You can enter the manufacturer s gearbox manually by entering characters contained in the catalog number. Motion Analyzer will prefill options. You can also select the Select a family dropdown to select a motor family, then select a product from the chosen family. 172 of 200

173 29. The manufacturer s products page will be displayed. Click on VIEW 12 MORE to see the remaining of the products 30. Scroll through the Gearboxes product page to see your options. In the filter section, click on Commonly Used filter dropdown list. 31. Type 5 in the Low entry tab, select the Planetary type and In-Line configuration. Your filters list should look as follows: 173 of 200

174 32. From the listed products, select the PA-Series product family. 33. Click Save Selections to Axis and select OK to continue 174 of 200

175 34. In the axis Components page, you should be able to see all your filters applied to their components as shown: 35. Click SEARCH FOR SOLUTIONS and allow Motion Analyzer to query for matching combinations. The search should take some time. 175 of 200

176 36. Once your SOLUTIONS LIST is populated, you should be able to view all combinations provided by the tool. The list will show the pages with different combinations and the current sorting is based on Profile Match. You can also see that this sorting may not be applicable as you may need to look at inertia for each combination. 37. Let s sort the list by lowest to highest inertia. Click twice on the Inertia Ratio column. 176 of 200

177 38. The SOLUTIONS LIST page is now sorted by Inertia Ratio. Select the solution indicated on the list by clicking Select 177 of 200

178 39. Your selected solution will populate the axis components as shown here: 40. We will review the performance of your selected solution compared to the application requirements. Click on Performance 178 of 200

179 Torque/Speed Curve The Torque/Speed tab (label 1) contains the Torque-Speed graph for the selected components combination. This graph is created dynamically, which means that if the supply voltage changes in the Motor or Drive tab, the graph will change accordingly. The Power/Speed tab (label 2) contains the Power-Speed graph for the selected components combination. This graph is typically used for Variable Frequency Drive (VFD) applications where power is more appropriate than torque as a measure of performance. The Thermal tab (label 3) displays the output of drive and motor thermal models that reside in the drive firmware. The Selected Solution portion (label 4) of the detailed solution view provides an overall summary of the performance characteristics for the various components of the system. It also contains tools to adjust system performance and efficiency. Notice that for this particular motor and drive combination, you are given a warning that Extended Speed Active Shunt is necessary when speed of the motor exceeds the inverter safe maximum speed. The shunt recommendation will be viewed on the power analysis page. The drive, motor, and gearbox continuous and peak utilizations are displayed 179 of 200

180 1. To limit the speed on our motor, we will first size down the gear ratio of our gearbox. Click on the size down icon to lower our ratio to Notice that the warning disappears when the motor is not exceeding the inverter safe maximum speed. Also notice the inertia ratio went higher. 180 of 200

181 Note: The Motion Analyzer database contains the Input Pinion Inertia for every available gearbox. To obtain a correct inertia ratio, Motion Analyzer software adds the Input Pinion Inertia to the Reported Motor Inertia, which decreases the application inertia and increases the motor inertia. To correctly calculate the inertia ratio, the Input Pinion Inertia must be removed from the Reported Application Inertia and added to the Reported Motor Inertia. 3. Click Apply to save this new selection. 181 of 200

182 4. Return to the Components page by clicking on the Components tab. 5. Click on SET CONFIGURATION to select the configuration of your motor. 182 of 200

183 6. Select the shown configuration by clicking Select 7. Click OK to return to the axis page 183 of 200

184 8. We will look for cable to include into our axis. Click Select Cable 9. This particular motor will require a dual cable, one for power and one for feedback. We will look for cables 22 meters or longer for a standard power cable and continuous flex feedback. The table is already sorted in meters. Go to the next page by clicking on the icon. 184 of 200

185 10. Select the displayed cable by clicking Select. 11. Your power cable is added to your motor component. Return to the COMPATIBLE CABLE window by clicking Select Cable 185 of 200

186 12. Click the Choose Flex Type dropdown list and select Continuous 13. Go to the next page of the COMPATIBLE CABLES by clicking on the icon. 14. Select the shown cable by clicking Select 186 of 200

187 15. Your completed axis configuration should look as shown here: 16. Continue to the project by clicking on CONTINUE TO PROJECT 187 of 200

188 Power Analysis Tab In the Components view of your axis, you selected a motor, gearbox, and drive solution. However, if there are power components needed for your application, you ll select them in the Power Analysis page. You can analyze the drive module/system activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters. 1. Your project component detail should be seen as below: 2. Click on the Power Analysis tab. 188 of 200

189 3. The Power Analysis tab is where you go to see the power utilization for your application. If your application requires them, you can add capacitor modules, shunts and power supplies here. The power analysis graph would show the DC Bus voltage level for the system throughout the velocity profile for the axis. 4. Select Auto Configure to configure axis power options. Both the power supply module, shunt, and capacitor module have automatic and manual selection options. 189 of 200

190 5. The Power Analysis page will display the power detail of your winder axis as shown. 190 of 200

191 6. Scroll through the SELECTED AXIS DETAIL section to view your power utilization and shunt power 7. After reviewing the power supply, and shunt or capacitor requirement; click on your Body Dipper / Dryer axes module. 191 of 200

192 8. You should be able to select Auto Configure to configure axis power options for this dual axis inverter. 192 of 200

193 9. Your analysis page should display your power requirements. Don t forget to scroll through the SELECTED AXIS DETAIL section to view your power utilization and shunt power. 193 of 200

194 10. The Kinetix 5700 drive family is designed for machines with high axis-counts, high-power requirements, and highperformance motion applications. Kinetix 5700 servo drive systems require a DC-bus supply when sharing axis inverters in a common DC-bus configuration. Click on Share to stack your axis inverter modules in a single cluster. 11. Add the dual axis inverter to the single axis inverter cluster by clicking Add to Group 194 of 200

195 12. To share the 24V control DC-bus power between your DC-bus supply and axis inverter modules, select the Share Control Power checkbox. 13. Select Save to save your selection. 195 of 200

196 14. Motion Analyzer will automatically gather information for your power requirement. Once complete, your Power Analysis page should look as shown. Scroll through the SELECTED SHARED DC BUS DETAIL section to view the shunt continuous power utilization histograms. 196 of 200