RMCWin. WalkThrough. This document is intended for walking through RMCWin with customers over the telephone/internet.

Transcription

1 RMCWin WalkThrough This document is intended for walking through RMCWin with customers over the telephone/internet. Figure 1. Typical RMC100 and RMCWin installation. PC running RMCWin Setup and Diagnostics RS 232 Serial Ethernet PLC or Industrial PC Machine Control Sequencing Fault Monitoring HMI Communication: Ethernet Modbus Plus PROFIBUS-DP DI/O Serial RMC100 Position Control Velocity Control Pressure Control Output: ±10 Volts Step/Direction Feedback: MDT SSI Quadrature Analog Actuators and Feedback Copyright 2004, Delta Computer Systems, Inc. www.

2 Starting the RMC100 Controller RMC100 Startup Guide Starting the RMC100 Controller Index/specification/general/ power Contents/Using RMCWin/Setup Options/Selecting a Serial Port to Use Contents/Communication Types/RS-232/Wiring. Contents/Using RMCWin/Connecting to an RMC/Communication Drivers/TCP/IP Direct to RMC- ENET Configuration Connect and Verify a Feedback Device Index/wiring/topic for your transducer type. 1. Connect power to the RMC100 controller. Note: The RMC100 controller requires 24 VDC at various current levels up to 750 ma, depending on the communication and transducer interface modules used. 2. Connect the PC to the RMC100 controller using one of the following two methods. Connect a standard null-modem DB-9 RS-232 serial cable from the PC to the RMC100 controller. If the serial port is configured correctly, the Offline message in the lower right corner of the RMCWin status bar will change to Online and a pop-up message window will indicate that RMCWin can communicate with the RMC100 controller. If the display indicates Offline and an RMC100 controller is connected and has power, try changing the serial port by double-clicking on COM in the lower right corner of the RMCWin status bar. The Options dialog box appears. From the Communication tab in the Options dialog box, select the correct com port. If the display indicates Closed after starting RMCWin, another program may be using the serial port. Try closing other programs that may be using the serial port. If the RMC100 is equipped with an Ethernet communications module and the PC is equipped with a TCP/IP interface (such as an Ethernet adapter or modem with TCP/IP installed), you may wish to connect the PC to the RMC100 via Ethernet for noticeably faster communication. Plug an Ethernet cable into the RMC100 Ethernet module. Use a regular patch cable when using a hub or router and a crossover cable when connected directly from the PC to the RMC. On the Tools menu, click Options, and then click the Communication tab. Under Communication Driver, click TCP/IP Direct to RMC-ENET. Select the desired RMC. If the IP address of the RMC is all zeros, you must configure the RMC100 Ethernet by clicking the Configure button and entering the correct settings. See the help for more details. Click OK. This section describes wiring and testing connections to feedback devices, such as MDTs (Magnetostrictive Displacement Transducers) and quadrature encoders. See the Wiring section in this document for detailed wiring feedback module diagrams. The online Help also provides wiring information. In all cases, shielded twisted pair wiring must be used. Note: Always turn off power to the RMC100 and the feedback device when connecting wiring from the device to the RMC100 controller. 2

3 Index/configuration/MDT Index/configuration/SSI Index/configuration/analog transducer Index/configuration/quadrature Decide which axis on the selected RMC100 you want to use and connect the wiring from the feedback device to that axis according to the wiring diagrams in the Wiring section of this document. After connecting the wiring, re-apply power to the RMC100 and feedback device. When power is re-applied the RMC100 controller should indicate that it is online in the RMCWin lower right status bar. The RMC100 needs to be configured properly before it will communicate with some types of transducers. MDT: First, in the RMCWin Tools menu, select Module Configuration. Select the slot for the axis you are configuring, and click on Slot Option. Select either Standard or Short blanking period. This setting is transducer dependent, and is available in the transducer datasheet. Next, double click on the CONFIG parameter in the Parameter area to display the MDT Axis Configuration Word dialog box. Select the transducer type you are using. Click OK and then click the to initialize the RMC100 SSI: In the RMCWin Tools menu, select Module Configuration. Select the slot for the axis you are configuring, and click on Slot Option. Complete the necessary information for your transducer type and your application. Analog Transducers: First, in the RMCWin Tools menu, select Module Configuration. Select the tab for the axis you are configuring, and click on Slot Option. Select the option corresponding to the type of application you have. Next, double click on the CONFIG parameter in the Parameter area to display the Analog Axis Configuration Word dialog box. Select the voltage or current range for your transducer. Click OK and then click the to initialize the RMC100. Quadrature Encoders: Double click on the CONFIG parameter in the Parameter area to display the Quadrature Axis Configuration Word dialog box. Select the polarity of the Fault, Limits, Index (Z) and Home (H) inputs and the action of the Homes status bit depending on your application. Click OK and then click the to initialize the RMC100. In the Status area of the RMCWin display, the value of COUNTS should now change. Move the axis manually and look for a corresponding change in the displayed value of COUNTS, in the status area. If COUNTS do not change, the most common problem is incorrect wiring. Refer to the online Help topics. Connect and Verify an Actuator Index/drive/Drive Index/stepper/wiring This section describes wiring and testing drive output connections and testing actuator motion. For most types of actuators, Drive output wiring consists of a ±10V drive output and a common. For stepper motors a Step and a Direction signal are used. Note: Always turn off power to the RMC100 and the actuator/amplifier when connecting wiring from the actuator to the RMC100 controller. Use the same axis number for the actuator as you did for the feedback device. Connect the wiring from the actuator to that axis. Refer to the appropriate wiring information in the online Help, or in the specification sheets. After connecting the wiring, re-apply power to the RMC100, the feedback device, and the actuator. 3

4 Starting the RMC100 Controller RMC100 Startup Guide The axis is not currently initialized, but it reads counts and you may see a slight movement when the drive output is connected. Test the drive output in either of these ways: 1. Unplug the drive output from the system and check output voltages from the RMC. Use the open loop ( O ) command described in the following section. 2. Connect the drive output from the RMC100 to the actuator and supply output voltages to see if the actuator moves. This method is described in the following section. Test Actuator Motion Connecting drive output from the RMC100 to the actuator and supplying output voltage is the quickest method of testing actuator motion and direction. If there is no movement, remove the connector and verify that the actuator receives a voltage. Note: Read this section completely before executing any commands on the RMC. Note: Verify the Simulate bit is NOT set in the CONFIG word. In the Command area of the RMCWin display, select the correct axis and enter the following (see Figure 2): MODE 0x0001 ACCEL 10 DECEL 10 SPEED 0 COMMAND VALUE 100 These values cause the output voltage to change to 100 mv at a rate of 10 mv/ms. Figure 2. Initial values to verify drive. Note: Be prepared to stop the system with the button or ALT+K. Both issue a Kill (K) command, which will set the drive output to 0 volts. Send an open loop command by typing O and then ENTER in the Command field or by pressing ALT+SHIFT+O. You should see the value of DRIVE in the status area of the RMCWin display change to 100. You should be able to measure roughly 100 mv with a voltmeter on the drive output connector. Observe the COUNTS value in the RMCWin display Status Area, and note whether the value is increasing or decreasing. One of three things could have happened at this point: 1. The actuator moved and the COUNTS increased. In this case you are ready to go to the next section and set the SCALE. 4

5 2. The actuator moved and the COUNTS decreased. In this case you must use the Reverse Drive Mode bit in the CONFIG parameter to reverse the direction. Double click on the CONFIG parameter, check the Reverse Drive Mode option in the dialog box (see Figure 3). Click OK, and then click the the RMC100. to initialize Figure 3. Setting Reverse drive mode. 3. The actuator does not move. In this case check the output voltage, check that the actuator is enabled, verify the Simulate bit is not set in the CONFIG word, increase the voltage and repeat the process above. Note: It is essential that the COUNTS increase when a positive output voltage is specified with the O command. If this condition is not met, you will not be able to control the axis in closed loop. At this point the drive has moved in one direction. Verify that it moves in the opposite direction with the following steps: 1. Click or press ALT+K to turn drive voltage off. 2. In the COMMAND area of the RMCWin display, select the drive axis and enter a -100 for the COMMAND VALUE (-100 mv). 3. Send an open loop command by entering ALT+SHIFT+O. You should see the value of DRIVE in the status area of the RMCWin display change to -100 and the drive should move in the opposite direction. Setting the Scale Index/scale/scale and offset calibration utility Contents/Transducer Types/Your Transducer Type/Scaling It is important to specify the measurement units to be used. Setting the SCALE converts the information from the transducer into meaningful measurement units. Most transducer types use this parameter with the Prescale Divisor bits in the CONFIG parameter to convert from the change in transducer counts to a change in the actual position. Refer to the online Help topics at left for more information. Note: SCALE is a signed number. If you want your system s position units to increase when the COUNTS decrease, set the SCALE to a negative value. 5

6 Tuning the System RMC100 Startup Guide Tuning the System Contents/Starting Up the RMC/Setup Details/Tuning a Position Axis Once the system is set up, it must be tuned in order to operate. Tuning gets the system to move in a controlled manner, with minimal oscillation, overshoot, or lag error. Tuning allows the system to achieve the best efficiency and stability. See the Tuning section in this document for instructions on how to tune your system. Saving Configuration Settings Index/step-by-step startup. Scroll to Step 10. Make sure you save your configuration settings or they may be lost! There are three ways to save configuration settings. 1. Save settings on the controller in FLASH. Certain types of configuration settings may only be set via RMCWin on the PC and stored in FLASH. To save configuration information to FLASH, click the button or issue an Update Flash (U) command. 2. Save settings on disk on the PC. 3. Save settings on the PLC. The PLC can then send this information to the controller on startup. After performing the startup, save your configuration settings. See the appropriate online Help topic for more information. Step-by-Step Example Appendix D contains a step-by-step, illustrated example of setting up and tuning a hydraulic cylinder. Read this to see the practical details of setup and to learn how to use the plots to tune the axis. This will help you to quickly set up and control a hydraulic system! Communications Index/digital I/O/communication Index/step-by-step startup. Scroll to Step 9. After setting up and tuning your system, it is ready to be programmed and integrated into the rest of your application. The RMC100 offers numerous communication options for this purpose. The purpose of communications is to issue commands and read back status information. Available RMC100 communications modules include Modbus Plus, PROFIBUS-DP, Serial, and Ethernet. A simple communications interface between the RMC100 and the system controller or Programmable Controller (P/C) is also provided by the Digital I/O module. See the RMC Modules section of this document for a short overview of each, and the communications section of the online Help for more detailed information. 6

7 Tuning After setting up your system, it must be tuned in order to control it. The better tuned a system is, the better it follows the desired trajectory and holds position. Tuning procedures differ depending on the type of system. This section contains procedures that may work for the following systems: A Hydraulic Position Axis or Motor in Velocity Mode A Motor in Torque Mode A Position/Pressure System Please read the "General Tuning Guidelines" before continuing to any of the tuning procedures. General Tuning Guidelines Index/tuning/overview Index/go Index/plots/using Index/stored commands/using Index/plot time Keep these general guidelines in mind throughout the tuning procedure. There is no substitute for experience when tuning an axis. The procedures offer some guidelines, tips, and suggestions for tuning your system. While the steps will work for many systems, they may not be the best for a particular system. The tuning procedure is a reiteration of the following general steps. Use these steps throughout the tuning procedure: Make a move. Use the Go (G) command for making moves. View the plotted move. See the Plots topic for more information. Viewing the plot will help you determine which parameters must be changed. Change a parameter. To do this, edit the parameter in RMCWin and then click to initialize the RMC100 with this value. Repeat these steps using the same move until the parameter is at the desired value. See the Stored Commands topic for repeating moves. Use the Sum of Errors Squared in the RMCWin plotting utility to determine how the last parameter change affected the system. The Sum of Errors Squared indicates how closely the Actual Position is tracking the Target Position. If this number decreases significantly, the last parameter change was good. If this number increases significantly, the last parameter change was bad. Remember, that in order to use the Sum of Errors Squared to compare moves, the moves must be identical. Begin the tuning procedure with long, slow moves and low Accelerations. This will prevent you from losing control of and potentially damaging the system. To obtain the greatest tuning precision, use the shortest Plot Time possible. This will spread the move across the entire plot window and allow you to see precisely how the system is responding. See the Plot Time topic in the online help. You may want to turn off some of the Auto Stop bits. The Auto Stop turns off the Drive if an error occurs. In the initial stages of tuning, a Following Error or other error may occur, causing an undesired halt. Setting these bits to "Status 7

8 Tuning RMC100 Startup Guide Only" will make the RMC ignore the errors so you can tune the axis. This may not be possible on some systems because of safety concerns. Remember to set these bits to either "Soft Stop" or "Hard Stop" when you have gained sufficient control of the axis. When changing the parameters, remember that they are not updated in the RMC until the Set Parameters (P) command is issued. They are not stored into the RMC FLASH memory until the Update FLASH command is issued. Tuning a Position Axis Index/tuning/position The following procedure may be used to tune many hydraulic position axes and motors in velocity mode. 1. Set all Gains and Feed Forwards to zero This is done by editing the values in the main RMCWin window. Then click the to initialize the RMC Set the Null Drive The drive it takes to hold the axis in position is referred to as the Null drive. If the axis tends to drift significantly when you give it an Open Loop drive of 0, you should set the null drive. This drive is then always added to the total drive output and helps the RMC100 accurately follow the motion profile. To set the null drive, issue a P command to hold the axis in position in closed loop, then issue the N command. 3. Check Dead Band If your system has a large dead band, you will need to set the Dead Band Eliminator value. To find your dead band, give increasing amounts of drive to the system with the Open Loop command. The value of drive at which the system starts to move is your dead band. If this value is approximately 400 or greater, the Dead Band Eliminator should probably be used. If it is less, it is left to the discretion of the designer. 4. Adjust the Proportional Gain The Proportional Gain must be adjusted to gain some control over the system for continuing the tuning procedure. Adjust the Proportional Gain by slowly increasing it and making moves. When the system gets close to final position reasonably quickly, continue to the next step. If the system begins to oscillate, decrease the gain. 5. Adjust the Feed Forwards In many hydraulic systems the feed forward parameters (Extend Feed Forward and Retract Feed Forward) are the most important parameters for position tracking during a move. Make a long move without any oscillation or overdrive. Then issue the Set Feed Forward command. This command will automatically adjust the Feed Forward parameter for the direction of that move. 6. Adjust the Acceleration Feed Forwards The Acceleration Feed Forward terms help eliminate following errors while accelerating. It is particularly useful for systems moving large masses with relatively small cylinders. Such systems often have a delay before the start of 8

9 movement. The Acceleration Feed Forward terms can help compensate for this delay. Look for following errors during acceleration and deceleration. Increase the Extend and Retract Acceleration Feed Forward terms until the errors disappear. For large masses the Acceleration Feed Forward may be in the tens of thousands. 7. Readjust the Proportional Gain Proportional Gain affects the responsiveness of the system. Low gains make the system sluggish and unresponsive. Gains that are too high make the axis oscillate or vibrate. Slowly increase the gain. When you see a tendency to oscillate as the axis moves or stops, reduce the gain by 10 to 30 percent. At this point, if you have gained sufficient control of the system, you may want to increase the speed, accel and decel of your moves and further adjust the proportional gain. A value of proportional gain that may seem good at low speeds and accels, may not work at higher speeds. 8. Adjust the Integral Gain The Integral Gain is helpful for getting into position and for tracking during long, slow moves. It will not significantly affect tracking during short, fast moves. Many hydraulic systems do not require a large Integral Gain. However, it is usually desirable to have some Integral Gain (5 to 50 units) to help compensate for valve null drift or changes in system dynamics. Some systems may require larger Integral Gain, in particular if they are moving a large mass or are nonlinear. Too much Integral Gain will cause oscillations and overshoot. 9. Adjust the Differential Gain Differential Gain may greatly enhance performance on many hydraulic systems. It is used mainly on systems that have a tendency to oscillate. This happens when heavy loads are moved with relatively small cylinders. Differential Gain will tend to dampen out oscillations and help the axis track during acceleration and deceleration. This will positively affect short, fast moves. Important: If you use Differential Gain, you may be able to increase the Proportional Gain somewhat without causing the system to oscillate. If the drive output during the constant velocity portion of the move is smooth, the Differential Gain is perhaps not set high enough. The drive output may look "fuzzy." This indicates that the drive is responding to the minute errors of the axis. Note that not all systems allow the differential gain to be set high enough for the drive to be "fuzzy". A disadvantage of Differential Gain is that it amplifies position measurement noise. If there is too much noise or the gain is too high, this can cause the system to chatter or oscillate. 10. Increase System Speed Gradually increase the Speed and Acceleration values while making long moves. Look for following errors, overshoot, or oscillations. If an overdrive error occurs, there is not enough drive capacity to drive the axis at the requested Speed or Acceleration. Should this occur, reduce the Speed and/or Acceleration and Deceleration. 9

10 Tuning RMC100 Startup Guide If a following error occurs during acceleration and deceleration and adjusting the Gains and Acceleration Feed Forward does not help, the Acceleration and Deceleration ramps are too steep for the response of the system. If the actual position lags or leads the target position during the entire constant velocity section of the move, adjust the Feed Forwards. Should the system seem a little sloppy, try adjusting the Proportional Gain. If the Drive is not high, the gains can probably be increased for better control. If the Drive is too high, or an overdrive error occurs, the system is not capable of performing the requested move. The Speed, and/or Accelerations may need to be decreased. If the system vibrates while in position, the Dead Band value may need to be increased. However, if the oscillation is not caused by a deadband in the system then this will not help! A rule of thumb is to set the Dead Band Eliminator value to half of the peak-to-peak oscillation of the drive output while in position. The final tuning of the system should be made at the speed of intended operation. 10