Product Demo Instructions MP2600iec Demo Instructions: v03 Applicable Product: MP2600iec with MotionWorks IEC Pro Yaskawa Electric America 2121 Norman Drive South Waukegan, IL 60085 1-800-927-5292 Page 1 of 29
Application Overview This document provides detailed instructions on how to demonstrate the features of the MP2600iec controller with the sales demo case. Instructions on invoking various features with the help of the HMI and an OPC server are given. Products Used: Component Product and Model Number Servopack Motor Controller Software HMI Third Party Devices SGDV-OCC02A SGMAV 01 MP2600iec MotionWorks IEC Pro Proface Advosol OPC client driver Page 2 of 29
Objective: The MP2600iec sales demo provides demonstrations of the following features: Gearing with virtual master and external encoder master High Performance Moves Safety Circuit Implementation Simple Indexing Torque Control Mode Jog Control Rotary Table Operation Registration Latch Electronic cam with virtual master and external encoder master Adaptive Tuning and advanced auto tuned performance OPC interface This document will detail how to operate the demo to demonstrate the functionality listed above. Page 3 of 29
Setting up the demo application using MotionWorks IEC Pro: 1. Open the MotionWorks IEC software. Select File->Open Project. Figure 1: Open a Project 2. Select the MP2600iec_SalesDemo project file. This will load the code for the demo into the MotionWorks IEC software. 3. Click on the Hardware tab at the bottom of the Project Tree Window shown below. Figure 2: Project Tree Window Page 4 of 29
4. Right click on the Resource folder highlighted above and click on settings. This will display the following menu. Figure 3a: Setting IP address in project 5. The network architecture for the three devices: MP2600iec controller, PC with MotionWorks IEC project, and the HMI is as shown below in Figure 3b. Figure 3b: Network Architecture Page 5 of 29
6. Ensure that the CN11A and CN11B communication ports on the MP2600iec are set appropriately. Also make sure that a non zero entry is made in the default gateway field. Check section called Setting up the demo application on page 10 for information about logging in to the web server. Figure 3c: Ethernet Configuration page on web server 7. Launch the Hardware Configuration. The Hardware Configuration will be used to set user units and configure the axes on the demo case. Figure 4: Hardware Configuration Page 6 of 29
8. Once the Hardware Configuration launches, connect to the controller on the demo case to go online. Figure 5: Going online 9. When prompted to choose between offline configuration and the auto discovered configuration on the controller, choose Offline configuration. This loads the configuration that was saved as part of the demo application. Once connected and online, save the configuration. This step saves the configuration to the controller. Once the configuration has been saved, disconnect the Hardware Configuration from the controller and cycle power on the demo case. 10. Switch to MotionWorks IEC and Make the project. This will check the code for errors and warnings. Click the Project Control Dialog button to download the IEC application code to the controller. Figure 6: Project Control Dialog Window Page 7 of 29
11. When the following menu appears, select More. This will open the window that will prompt the user to download the project to the flash memory of the controller. 12. Select Permanent as Bootproject and download. Figure 7: Resource window to download the project Figure 8: Save to flash (BootProject) Page 8 of 29
13. Once the IEC application has been downloaded, perform a warm start. Figure 9: Warm start 14. Now the controller should be in the Running state and the demo should be functioning. Figure 10: PLC running Page 9 of 29
Setting up the demo application using the web server 1. Log on to the web server of the controller using the blue panel as shown at the left of the page below. The UserName is Admin and the Password is MP2600 Once you have logged in, additional menu items will appear. 15. Go to the project archive page. Scroll down to the bottom and delete all user files in the project archive. Figure 11: Project archive page 16. To install the demo application, browse to find the demo archive on the PC and send to the controller. Figure 12: Installing a new project archive 17. The new archive has been loaded once the page refreshes. Reboot the controller and it will run the MP2600Demo project. Page 10 of 29
Servo Power On: Before running any of the modes, the servo must be enabled by flipping the DI0 switch up. Turning on this switch will also clear any alarms. If an alarm is encountered during operation, disable the axes and re enable it using DI0. Units Position Velocity Acceleration Deceleration : degrees : degrees/second : degrees/second/second : degrees/second/second Figure 13: HMI Main menu Page 11 of 29
Gearing: To demonstrate the gearing functionality: 1) Flip the DI1 switch up. 2) Select gearing from the HMI main menu. 3) Select the master axis for the gearing demo 4) For virtual master a) Start master move (master speed can be observed on the HMI) b) Gear Engage. This will make the servo axis move at a velocity dictated by the gear ratio. The gear ratio can be monitored on the HMI c) Change the gear ratio using the analog input knob. d) Slave (servo) axis speed can be monitored on the HMI. e) Disengage gear to break the gear relation. f) Stop master to stop the master s motion. Disengage the gear before stopping the master 5) For external encoder master a) Rotate external encoder (master speed can be observed on the HMI) b) Gear Engage. This will make the servo axis move at a velocity dictated by the gear ratio. The gear ratio can be monitored on the HMI c) Change the gear ratio using the analog input POT. d) Slave (servo) axis speed can be monitored. e) Disengage gear to break the gear relationship. 6) Back to main menu on HMI and flip off DI1 Page 12 of 29
Figure 14: Gearing menu Page 13 of 29
High Performance Moves: In this mode the axis will go through a series of moves that showcase the capabilities of the servo. 1) Choose performance from the HMI main menu. 2) To activate this mode flip on the DI2 switch. 3) Servo status, absolute position, position error, actual servo speed and any servopack alarms can be monitored on the HMI. 4) Back to main menu and flip off DI2 Figure 15: High performance move screen Page 14 of 29
Indexing: In this mode, the axis performs simple indexing using parameters supplied through the HMI. 1) Choose Indexing from the HMI main menu. 2) Flip DI3. 3) Enter distance (<360 degrees), Speed, Accel, Decel and dwell. 4) Press Next. 5) Enter the number of indexing moves required. 6) Start Indexing starts the indexing move. The moves may be interrupted any time using stop indexing. 7) Back to main menu on HMI and flip off DI3. Figure 16: HMI indexing screen Page 15 of 29
Torque Control Mode: To activate the torque control mode: 1) Choose torque from the main menu on the HMI. 2) Enter the command torque limit. 3) Enter the velocity limit for the torque mode move. 4) Flip switch DI4 up. In this mode, the axes will be receiving an open loop torque command. 5) Actual speed and torque can be monitored on the HMI. 6) Manually prevent the axis from moving (if the limiting torque and velocity are low values.) 7) On preventing the axis from moving it can be seen that the actual torque applied by the servo ramps up to equal the commanded torque. 8) Back to main menu and flip off DI4. Figure 17: Torque Control screen Page 16 of 29
Velocity Control/Jog: To activate this mode: 1) Turn DI5 on. 2) Choose Jogging from the main menu of the HMI. 3) Enter CMD Speed on the HMI. 4) FWD/REV jogs the motor in forward/reverse directions at the commanded speed. To stop jogging in a direction press the selected direction again. 5) The actual axis speed can be monitored on the HMI. 6) Back to main menu and flip off DI5. Figure 18: Jog screen Page 17 of 29
Tuning: This mode showcases the out of the box adaptive tuning capability of the Sigma-5 servo. 1) Make the load: servo inertia ratio 1:1 by leaving only one disc on the motor shaft. 2) Choose Tuning from the main menu on the HMI. 3) Press out of the box parameters. 4) Cycle control power. 5) After the controller and servopack boot up, turn the servo on. 6) Connect using SigmaWin+. 7) Choose trace settings as shown in figure below. 8) Start tracing. 9) Press start move on the HMI. 10) The axis moves at 3000 rpm with a 100 ms accel and decel. The move can be stopped by pressing stop move on the HMI. 11) The performance plot from SigmaWin+ can be studied. It can be seen that the settling time is around 220 ms. 12) Repeat steps 7 10 using an inertia ratio of 20:1 by having all discs on the motor shaft. The settling time with the changed inertia ratio also is around 150 ms which shows the out of the box capability of the Sigma-5 to adaptively set gains in the face of changing loads. 13) To see advanced auto tuning performance press advanced auto tuned parameters on the HMI. 14) Cycle control power. After the system powers on, start tracing using SigmaWin+. 15) It can be seen from the plot that position error while accelerating and decelerating are vastly reduced. Following error at steady state conditions are zero. The settling time is 50 ms. Overshoot is also reduced. Page 18 of 29
Figure 19: Tuning HMI screen Figure 20: Trace setup in SigmaWin+ Page 19 of 29
Figure 21: Adaptive tuning results Figure 22: Advanced auto tuned results Page 20 of 29
Rotary Table: In this mode, the axis acts as a rotary table mechanism. There are three preset positions that it will travel to upon command from user input. The user also can select the mode of travel (direction) for the table. The table can rotate in the positive only direction, negative only direction, or take the shortest path to its destination. 1) To start rotary table mode, turn DI7 switch on. 2) Choose Rotary Tbl on the main menu on the HMI. 3) Select the direction of travel from the HMI. To select a new direction, press the current direction once again to disable it and then select the new direction. 4) Select the target position on the HMI. 5) The axis moves to the target position. Position can be monitored on the HMI. 6) Back to the main menu on the HMI and flip off DI7. Figure 23: Rotary table screen on HMI Page 21 of 29
Latch Control: In this mode the axis will move at a constant velocity until receiving a latch input. Once the input is received, the axis will complete a registration distance before stopping. 1) Choose Registration on the main menu of the HMI. 2) Input a Feed speed on the HMI. 3) Enter a registration distance (<360 degrees.) 4) Start axis. 5) While the axis is in motion, flip SI4 to simulate the latch sensor. 6) The axis should move the registration distance, stop and restart looking for the next latch input. 7) Parts done displays the number of registration moves completed. 8) The axis can be stopped at any time by pressing Stop Axis. 9) Back to the main menu. Figure 24: Registration screen Page 22 of 29
Safety: The safety feature built into the Sigma-5 can be seen from the safety section. The safety category can be seen on the HMI.The safety input can be monitored through the controller as a bit. 1) Press the E-Stop on the demo case. The HBB lamp lights up. Figure 25: Safety screens Page 23 of 29
Camming: Manually position the servo axis such that a distinguishing mark on the load disc coincides with a mark on the demo that can be used as a zero point. Make sure that the two cam files: TWCam.csv and OWCam.csv are loaded in the controller. They can be verified by logging into the controller s web server and checking the project archive. The axes will have to be enabled for camming to start. 1) Flip DI6 on. 2) Select Camming from the main menu on the HMI. 3) Choose the cam profile. Make sure the light for the selected profile blips on for an instant. Press Next. 4) Choose the cam master. 5) If virtual master is chosen a) Start master starts the virtual master motion. Make sure the lamp glows. b) If the ready to engage lamp is on, Cam engage will engage the cam relation and servo will start motion. c) Cam shift will implement a shift in the profile. d) Pressing Cam scale will implement a 200 % scale. If the scale button is pressed again the profile is scaled back to 100 %. e) Disengage the cam to break the virtual master servo axis relation. f) Stop master will stop the virtual axis motion. Disengage the cam before master is stopped. g) Repeat steps 3 5g for demonstrating the second cam profile. 6) If external encoder master is chosen, a) Manually rotate the external encoder axis. b) If the ready to engage lamp is on, Cam engage will engage the cam relation and servo will start motion. c) Cam shift will implement a shift in the profile. d) Pressing Cam scale will implement a 200 % scale. If the scale button is pressed again the profile is scaled back to 100 %. e) Disengage the cam to break the virtual master servo axis relation. f) Repeat steps 3, 4 and 6 for demonstrating the second cam profile. 7) Flip DI6 off. Page 24 of 29
Figure 26: Camming HMI screens Page 25 of 29
Figure 27: Demo case IO Page 26 of 29
OPC connectivity: Go to: C : KWSoftware>Opc21 Start the OPCConfig application (OPCConfig.exe). Select the Resource and rename it MP2600 as shown below. Set the IP address of the controller port to which the server needs to communicate (192.168.2.1) Figure 28: OPC configurator Page 27 of 29
Click on settings and set the IP address and timeout settings. Figure 29: OPC configurator settings From C :> KWSoftware> Opc21 run the PcosOPC application (PcosOpc.exe). This starts the server on the user PC. Once the server is running on the PC, it can be seen in the toolbar of the PC screen. Figure 30: Server running on PC Make sure the OPC client software files exist on the demo PC. Run the MP2600iec sales demo.exe file from the bin folder. This opens the OPC application written in Visual Basic. Figure 31: VB application with Advosol based OPC client Page 28 of 29
1) Connect the OPC server. 2) Make sure all DIs on the demo case are off. 3) Servo on will enable the servo. 4) Step Move Start will make the axis go through a series of moves first in the forward direction and then in the reverse direction. 5) Step Move Stop will stop the step moves when the current cycle is over. 6) Cam Move Start will start cam based motion for the axis. Cam motion can be stopped by pressing Cam Move Stop. 7) Actual position, velocity and torque can be monitored in the application. 8) Click Disconnect to disconnect the application from the OPC server. Page 29 of 29