Generic Motion Control

Transcription

1 Motion control Speed and precision to meet the highest demands. Integrated technology functions for maximum flexibility. Cutting-edge centralized or decentralized drive architectures for modular machine manufacturing. Safety functions and "Plug & Play" in the power transmission system enable solutions that will set you in motion. 84

2 Generic Motion Control 85

3 ACOPOSmulti65m Decentralized servo actuator ACOPOSmulti65m - Sophisticated machine modularity The strong trend towards modularity The ACOPOSmulti drive system has always been extremely modular. The next logical step was to merge inverters with the motor to create servo actuators that can deliver power directly where it is needed. This allows configurable modules to become easily connected mechatronic devices. It also makes it possible to reduce delivery times, free up valuable floor space and simplify commissioning. With the ACOPOSmulti65m servo actuator, B&R has now introduced a motor-mounted inverter with IP65 protection onto the market that meets all of these demands. Not only compact, but also safe The ACOPOSmulti65m servo actuator essentially combines the following components: The servo motor as a power converter The built-in position sensor The choice of an optional gearbox The servo drive not only saves space since it is built directly on the servo motor, it also includes the safety technology. The ACOPOSmulti65m servo actuator delivers maximum performance by using the latest technology for power devices with minimal power loss as well as a motor series that is optimized for this application. With three different sizes, the servo actuators cover the entire spectrum, with a torque range of 1.8 to 10.5 Nm and a power range of 500 W to 2 kw. For applications that demand more power, an optional fan assembly can be retrofit for a performance boost of up to 100%. Also ideal for modular machine engineering is the possibility to connect X67 modules directly to the ACOPOSmulti65m servo actuator. This paves the way for implementing machine modules as self-sufficient finished and testable production units. The range of X67 modules provides all the functionality you need. The portfolio contains digital, analog and mixed I/O modules as well as stepper motor modules with IP67 protection. Integrated safety In addition to the proven wired safety functions STO (Safe Torque Off) and SS1 (Safe Operational Stop 1 time-monitored), a network-based ACOPOSmulti65m servo actuator variant will also be available in the future as an option. This will allow users to access the following functions that have already been certified for ACOPOSmulti: STO, SOS, SS1, SS2, SLS, SMS, SLI, and SDI. The interesting part about this is that the safety functions can be individually selected as needed. In contrast, wired variants only allow the collective selection of the STO and SS1 safety functions. Homogeneous and compatible The ACOPOSmulti65m servo actuator features the well-known functionality from the ACOPOSmulti drive system and can therefore be integrated homogeneously into the drive solution. Optimum machine and system configurations based on the ACO- POSmulti65m servo actuator. In addition to its topological flexibility, it simplifies and optimizes modular machine manufacturing, allowing efficient production strategies to be implemented in the process. Decentralized and flexible In terms of topology, the ACOPOmulti65m servo actuator can be employed in a simple line or tree structure. In a line structure, the node number is assigned automatically. However, this can be done without opening the housing if an address setting is required, for example to save space for options or extensions. The connection to the drive group is made using a hybrid connector. It contains all power and signal lines relevant to the operation of the servo actuator as well as the POWERLINK network. The highly effective IP65 protection allows it to be mounted directly on the machine. The control cabinet would then only have to contain the power supply modules, high-powered inverter modules and the necessary electromechanical components. The result is a drastic simplification of wiring for modular machine architectures as well as for handling optional machine functions; the latter can easily be connected with the requisite dimensioning of the power supply to the machine's main line using hybrid cabling. LL Highlights The servo actuator is available in three sizes ranging from 1.8 to 10.5 Nm Can be delivered with or without an add-on gearbox Seamless integration in the ACOPOSmulti drive system Reduced wiring Integrated safety technology (STO, SS1 safety functions) Additional optional safety functions (STO, SOS, SS1, SS2, SLS, SMS, SLI and SDI) are available 86

4 ACOPOSmulti65m Interfaces and connectors LL ACOPOSmulti65m 1 Hybrid cable connection 1 2 Hybrid cable connection 2 3 2x trigger inputs 4 POWERLINK connection for external X67 nodes 5 24 VDC output for external X67 nodes 6 SafeMC module (optional) 7 Node number switches (integrated in hybrid plug) 87

5 ACOPOSmulti65m Typical topologies Decentralized architecture with the ACOPOSmulti65m Decentralized architecture with the ACOPOSmulti65m, ACOPOSmulti65 and the 8CVE connection box 88

6 ACOPOSmulti65m Dimensions for medium size (in mm)* *Preliminary data 89

7 ACOPOSmulti ACOPOSmulti safety technology The safe power transmission The safe power transmission system consists mainly of a safe inverter module, a motor and safe evaluation of the position or speed. If these conditions are all met, then safety of the monitoring functions is ensured up to the encoder shaft. It can be assumed that the real threat is posed not by the encoder shaft, but the load side of the motor shaft. Slip/breakage at the connection between motor and encoder shaft The motor and position encoder are normally connected via a clamp connection and not a keyway connection. If the motor manufacturer does not guarantee mechanical fault prevention, then slipping or breakage of the connection between the motor and encoder shaft must be assumed. A large slip has the same effect as a break, and a small slip has the effect of a static offset. A static offset of ε electrical > ± 90 will cause uncontrolled acceleration of the motor. If a safety function is active at the time, then the movement will be detected as soon as it exceeds the permissible limit values and changed to a safe state. Safety is therefore maintained. When a shaft offset is ε electrical < ± 90, the encoder position will not correspond to the position on the load side of the motor shaft. The speed at the two points is the same, however. An activated SLS safety function "Safely Limited Speed" would detect this error on the shaft connection because the current speed is correct. Subsequently, there is no impact on safety. If there is a break or too large of a slip at the connection between the motor and encoder shaft, then neither the encoder position nor the encoder speed will match the load side anymore. A violation of the speed limit while SLS "Safely Limited Speed" is active would not be detected, meaning that safety is no longer guaranteed. 90

8 ACOPOSmulti Mechanical fault prevention! Shaft break monitor via safe encoder system It is possible to prevent breakage or slipping of the connection between motor and encoder shaft by mechanical oversizing. However, this design approach is not enough by itself. There are additional organizational and fault-preventing steps that need to be taken in the production processes. Implementing this fault prevention allows you to ensure safety all the way down to the motor shaft only then can the machine manufacturer view the motor as a "safe" actuator. Safe monitoring of the mechanical connection between motor and encoder shaft via software Starting with Safety Release R1.4, the SafeMC module offers the option of monitoring the mechanical connections between motor and encoder shaft via software. If shearing of the encoder during standstill can be prevented (e.g. encasement in the motor), then these methods certified by TÜV Rheinland can be used to detect any errors on the connection between the encoder and motor shaft that are relevant for the safety functions SOS, SS1, SS2, SLS, SDI and SLI. Monitoring is not suitable for the safety function SLP/SMP. It is currently not possible to solve this problem with today's technology. Prerequisite for using safe monitoring of the encoder connection without mechanical fault prevention The application must meet the following mandatory requirements before using the certified safe monitoring of the encoder connection: Use of Safety Release R 1.4 Use of synchronous motors Encoder must be integrated in position control Encoder must be protected against shearing when at a standstill (e.g. encasement in the motor housing) Safety functions that require a safe absolute position cannot be used (SLP and SMP) Monitoring for position lag errors, speed errors and set position change (Alive Testing) must be enabled in the safe application and sufficiently strict limits must be monitored. LL Conclusion As a system supplier, B&R helps its customers ensure safety down to the load-side motor shaft and offers stock motors with mechanical fault prevention. In addition, implementing safety-oriented monitoring of the connection between the motor and encoder shaft made it possible to use motors with standard encoder mounting (i.e. without mechanical fault prevention) for safety applications with the limitations mentioned above. 91

9 ACOPOSmicro Powerful solutions across the board ACOPOSmicro servo and LinMot linear motors Reduced energy, service and maintenance costs thanks to longer lifespan and fewer components per axis The use of ACOPOSmicro servo and LinMot linear motors instead of pneumatic cylinders makes it possible. In particular, the large amount of energy required to generate compressed air due to significant energy loss (e.g. motor and compressor loss, pressure loss through reduction valves and leaks) has a negative impact on the TCO of a machine and increases the demand for electrical linear axes. Linear motors provide more precise positioning, thus improving the accuracy of repeated machine movements. Higher clock speeds, by up to a factor of 2, increase the production capacity of the plant and reduce production costs. Packaging machines, handling devices, or pick and place applications are just a few examples where pneumatic cylinders, linear axes driven by servo motors, cam gears, or multi-jointed applications can be replaced by linear motors. In summary, the integration of electrically driven linear axes into B&R's automation technology catalog opens up a new world of innovative and flexible machine designs. The ACOPOSmicro servo with a LinMot encoder interface A new member of the ACOPOSmicro family is the new ACOPOSmicro with a LinMot encoder interface. The combination of maximum performance in minimum space is a major highlight of this series. The footprint of the ACOPOSmicro double axis module takes up only 100 cm² in the control cabinet, thereby allowing extremely compact multiaxis applications. 4 The ACOPOSmicro product family can be operated in a nominal voltage range from 18 VDC to 80 VDC. State-of-the-art semiconductors ensure a low amount of heat loss eliminating the need for expensive cooling concepts that can be difficult to implement. Furthermore, the intelligent power supply module with a network connection offers completely new options for diagnostics In addition to its 2 trigger inputs and 24 VDC output, the ACOPOSmicro servo with LinMot encoder interface also features a Safe Torque Off function and a POWERLINK interface. The integrated POWERLINK hub also greatly simplifies bus cabling. Configuration takes place in B&R Automation Studio and is exactly the same as for all other ACOPOS drive products. LL Features LL Highlights Compact design Flexible application Low power dissipation Uniform design for servo and stepper 1 Motor connections 2 24 VDC power supply and digital I/O 3 POWERLINK interface 4 Power element supply 5 Encoder inputs 6 Node number switches for POWERLINK 7 Insert for labeling 92

10 ACOPOSmicro Technical data Short description 80VD100PS.C18X-01 80VD100PD.C Servo motor module Connection for linear motors with LinMot encoder 24 VDC supply Input voltage 24 VDC ±25% CPU power consumption In preparation Power element supply Input voltage 24 to 64 VDC ±25% Undervoltage cut-off <18 VDC Overvoltage cut-off >95 VDC Motor connections Amount 1 2 Rated switching frequency 5 khz Rated voltage VDC ±25 % Rated current 8 A eff Max. current/module In preparation Max. current/motor In preparation Encoder inputs Amount 1 2 Type LinMot Enable input Amount 1 Input circuit Sink Rated voltage 24 VDC Trigger inputs Amount 2 Input circuit Sink Rated voltage 24 VDC Input filter Hardware <10 μs Digital output Amount 1 Continuous current 1 A Max. switching frequency 100 Hz Rated voltage 24 VDC Protective measures / safeguards Overload / short-circuit protection Interfaces POWERLINK Integrated hub Design 2x RJ45 socket Mechanical characteristics Mounting / cooling Screw mounting with heat spreader on mounting plate or cold plate Dimensions without heat spreader Width 65 mm Height 134 mm Depth 95 mm 93

11 Motion control Mixed doubles - Cross cutters made easy By combining the two new function blocks MC_BR_CrossCutterControl and MC_BR_RegMarkCapture002, implementing sheeter applications with registration mark correction has never been so easy. The perfectly coordinated interfaces have been streamlined down to the essential parameters to guarantee quick and clearly organized implementation. MC_BR_CrossCutterControl Programming a cross cutter to separate products is as easy as using the MC_BR_CrossCutterControl function block and supplying it with the length of the cutting area and the length of the product being cut. Simply reset and set a special input to temporarily interrupt the cutting procedure. The function block offers several options for complex applications, such as the following: Choosing a start mode: Immediately At a defined master position Restart after a prior movement stop Specifying a custom cam profile for implementing a special pushout movement Specifying a percentage of a super-synchronous speed during the cutting process Direct specification and application of a compensation value which is determined by a higher-level registration mark control MC_BR_RegMarkCapture002 Simply cutting the product with one set length is often not sufficient for a cross cutter application. In most cases, the cut has to be made at a defined position between two products. This is generally done using registration marks or similar identifiers that are then evaluated by a sensor. The function block MC_BR_RegMarkCapture002 is specially designed to effectively detect and evaluate registration mark signals in cross cutter applications. Once a registration mark is detected the function block calculates a value which the function block MC_BR_CrossCutterControl must subsequently use to compensate its cut for the product that was just measured. 94

12 Motion control Precision switching and flexible connections Shorter and shorter cycle times or increasingly precise dosing specifications demand ever-faster reactions depending on specific axis positions. New function blocks are now available for precisely these applications, which are seamlessly integrated into the B&R automation solution. The use of standard software, standard hardware and a single engineering tool eliminates the need for independent and separately connected drum sequencer controllers. MC_BR_DigitalCamSwitch The MC_BR_DigitalCamSwitch function block switches a digital signal on/off in response to defined axis positions. A total of up to 64 switch on/off positions can be specified in five parameter sets each. It is also possible to switch between parameter sets during runtime. There are three ways of further processing the digital signal: The status is taken from a function block output and simply linked to a digital output module. The status is used directly on an ACOPOS servo drive or a virtual ACP10SDC axis. The signal is output directly via a plug-in module in the ACOPOS servo drive. MC_BR_GenericDigitalCamSwitch Similar to the MC_BR_DigitalCamSwitch function block, this function block also switches a digital signal on/off in response to switching positions. However, there are some differences: Any position in the system can be used that is available in a variable. The switching edges are not dependent on cycle time. This means, for example, that switching edges can also be located within one task class cycle. Linking the outputs of this function block with an X20DS4389 digital signal processor module makes this possible. In turn, resolution of less than a few microseconds can be achieved for signal output. In addition, switching delays are compensated for and a hysteresis is defined for the switching points. 95

13 Motion control Encoderless control A trend in modern drive technology is the increased use of the field-oriented control principle on motors without position sensor or rotary encoder, referred to "encoderless control". This makes it possible to guarantee dynamic operation of an axis and to improve the effectiveness of the drive across the entire operating range. This aspect will continue to gain importance in future designs, not only for environmental reasons, but also due to the cost savings achieved throughout the life cycle of the machine. The basic principle of field-oriented control requires knowledge of the exact position of the field pointer in the motor. This information can be determined using suitable sensors for the position or speed. In many cases, however, it's desired to avoid these speed sensors or position encoders so that the existing measurement values (stator current) and reference values (stator voltage) can be used instead. The result is not only cost savings for the positioning sensor, but also the elimination of an encoder cable and evaluation unit. Availability is also increased while saving space and weight of the drive at the same time. However, it must also be noted that the elimination of a precision positioning sensor also carries a few disadvantages. The benefits of this mode are lower investment costs (sensors, cables and evaluation unit can be saved), lower maintenance costs due to higher availability and due to the non-existent positioning sensor a more compact motor design. The elimination of the exact positioning sensor results in restrictions on the position accuracy, in the usable torque, in efficiency and other characteristic features. Despite this, it opens up a multitude of new application areas previously too challenging for a conventional variable frequency drive and now able be implemented with this new mode of operation. Smart system integration Unlike the real encoder, the so-called position observer the core functionality of the encoderless control operating mode delivers the estimated electrical rotor position based on measurement signals, reference values and system parameters. Unknown values in the system are calculated using respective intelligent algorithms or existing identification processes. The rotor position calculated in this manner is converted to a mechanical position by the firmware allowing it to then be processed in the ACOPOS system as a virtual actual position. + AC1xx plug-in module Pos mech. Mode A Mode B ACPFirmware ACPFirmware ACP Firmware Driver Current posit. [unit] PCTRL SCTRL ICTRL ACP Controller structure Pos el. ACP Firmware Position monitor Mirroring the observed actual position like this ensures that the program is no different for the user whether a position sensor is used or not. All of the familiar and well-proven ACOPOS functions such as homing, phasing, two encoder closed loop control, offsets, function blocks from the Smart Process Library, set value generation, set current filter, torque limitation, etc. can be used as usual. In addition, it is possible to use the observed actual position as an additional source of information, for monitoring purposes for example, when using a position sensor. 96

14 Motion control Controller Optimization Tool The existing autotuning function for servo drives in the ACOPOS drive family provides excellent results. Furthermore, B&R's new "Controller Optimization Tool" make it possible to simplify the fine tuning of controller parameters that is frequently necessary for more complex systems. The first step is to calculate the frequency response using an automated identification method. Because the "Controller Optimization Tool" are fully integrated in B&R Automation Studio (see image), the measured frequency response is loaded from the drive and displayed graphically. A proposal for setting controller parameters is calculated based on robust algorithms. At the touch of a button, the controller settings can be transferred to the drive and its effects checked in the measured frequency response of the closed loop. If the required level of dynamics is not reached, a variety of different set current filters can be easily adapted and evaluated based on the graphic display and the cursor measurement function. The integrated stability control ensures that the identified parameters lead to a stable overall system. This makes it possible to graphically design and test the speed and position control loop. Optimize intuitive servo drives. Universal and intuitive The "Controller Optimization Tool" is based on the autotuning function for servo drives and therefore covers the same area of operation. This includes horizontal and vertical axes with both synchronous and induction motors. Resonance frequencies of mechanical components are moving toward smaller values due to the rapid advance of direct drives in drive technology. In such cases, the "Controller Optimization Tool" is an ideal tool to achieve the maximum dynamic range and accuracy. LL Highlights More information about the driven mechanics: The frequency response matches the fingerprint of a drive axis. This makes it easier to locate vulnerabilities in the power transmission system. Intuitive operation: Graphical representation makes it much easier to configure set current filters, among other things. Verification of the calculated controller parameters: Measuring the frequency response of the closed loop enables the configuration to be verified immediately. Graphical support for both speed and position controller Quick and easy set-up thanks to intuitive support Full integration in B&R Automation Studio 97

15 GMC software A new approach to controller programming Generic Motion Control User layer operation PLCopen Functional range for industries Motion Control CNC Robotics Actuators Servo Stepper Inverter Hydraulics Generic Motion Control combines all important functions into a single homogeneous system. The integration of technology functions continues to blur the boundary between classical control tasks on the one hand and path control on the other. The functionality of the integrated interpreter from GMC has been expanded to meet these challenges. Data exchange made easy The exchange of data is essential whether between technology functions at the PLC level or for movement and path control. Easy configuration The GMC interpreter provides full access to PLC variables, data types and functions. Configuration is as easy as loading the respective declaration files from the Automation Studio project. The definitions can be used in all programs loaded in the interpreter, as well as the built-in functions from the configured GMC languages. Programming with structures Defining structures and using them for variables in G-code programs opens up a wide range of new possibilities for designing motion programs. This enables a much clearer organization of subprograms. Structured variables that were generated in a CNC program are initialized with the same initial values as in the PLC environment, which allows seamless integration into the PLC environment. 98

16 GMC software IEC-ST: CNC/Robotics/PLC programming from one source Programming a CNC device with traditional G-code or using special dialects to program robots is a thing of the past. The configurable GMC interpreter also offers the possibility to process IEC-ST programs. This opens up unprecedented opportunities for programming CNC, robotics and PLC. Interpreted IEC-ST programs The default language of automation technology, IEC Structured Text (ST), can now also be used with the GMC interpreter. The interpreter executes IEC-ST programs sequentially in contrast to the cyclic execution of a traditional PLC program, which was programmed in a standard Automation Studio task. This also does away with the strict time constraints that must normally be accounted for in all functions. Sequential programs are also much easier to design, to read and to maintain. Programs processed by the GMC interpreter correspond exactly to the syntactic definitions from Automation Studio and ultimately behave the same. Application examples for interpreted ST: Centralized control for sequential CNC programming Complex motion programs Subprograms with PLC function blocks Integration of all PLC libraries HMI interface operation Debugging PLC functions using the interpreter... Monitoring and diagnostics The full range of monitoring and diagnostics functions is available for CNC as well as ST programs. This includes functions as step into, breakpoints, variable test, variable set and variable watch among others. Support for the IEC-ST syntax in the interpreter opens up unforeseen possibilities for uniform design of CNC, robotic and PLC programs. Strong typing The introduction of IEC-ST also brings support for "strong typing". This means that the consistency of data types is tested strictly for mapping and transfer parameters. The goal of this is to prevent any potential conversion errors or inaccuracies before they happen. Potential problems are identified and reported when a program is loaded. In the past, weak typing was used for CNC programs, which also allowed implicit type conversion between different data types. The perfect mix IEC-ST and CNC programs are able to execute one another. This introduces new possibilities, such as implementing programming logic in ST and processing programs in classic CNC G-Code. Special interpreter features for ST To implement technology functions in the best possible way, the GMC interpreter also contains some advanced features for IEC-ST programs, such as path-synchronous processing of functions and function blocks and data-logging for restoring programs (restart). Interpreter-specific attributes in the IEC declarations make it possible to determine software validity, path synchronization, logging behavior, etc 99

17 Encoder interfaces SinCos encoder with SSI interface ACOPOS encoder interface 8AC Users now have the entire bandwidth of combined encoder interfaces at their disposal thanks to the support of encoders that, in addition to incremental information provided via symmetrical analog sine/cosine signals, also offer additional absolute value information about an SSI interface. ACOPOSmulti encoder interface 8BAC A major advantage of this combined encoder interface is the mechanical flexibility granted when selecting an absolute position encoder since this interface is offered by many manufacturers. Compared to a classic SSI absolute interface, the presence of the additional sine/cosine signals represents a significant improvement in the resolution of the position signal and thus the speed signal. Additionally, elimination of the digital transfer dead times also brings further improvements to the dynamic behavior of the drive. Unlike purely incremental sine/cosine interfaces, the additionally provided SSI absolute value interface also does away with the need for homing procedures which means quick and easy system startup. LL Highlights Maximum mechanical flexibility when selecting a position encoder Significant increase in resolution compared to a classic SSI absolute interface No homing necessary 100