MOTION CONTROLLER(SV13/22) (REAL MODE) Programming Manual, type A173UHCP,A273UHCPU MOTION CONTROLLER (SV22) (VIRTUAL MODE) Programming Manual type A173UHCPU, A273UHCPU
INTORODUCTION Thank you for purchasing the Mitsubishi Motion Controller. This instruction manual describes the handing and precautions of this unit. Incorrect handling will lead to unforeseen events, so we ask that you please read this manual thoroughly and use the unit correctly. Please make sure that this manual is delivered to the final user of the unit and that it is stored for future reference.
For Safe Operations 1. Prevention of electric shocks WARNING Never open the front case or terminal covers while the power is ON or the unit is running, as this may lead to electric shocks. Never run the unit with the front case or terminal cover removed. The high voltage terminal and charged sections will be exposed and may lead to electric shocks. Never open the front case or terminal cover at times other than wiring work or periodic inspections even if the power is OFF.
3. For injury prevention CAUTION Do not apply a voltage other than that specified in user's manual or the instruction manual for the product you are using on any terminal. Doing so may lead to destruction or damage. Do not mistake the terminal connections, as this may lead to destruction or damage. Do not mistake the polarity (+/−), as this may lead to destruction or damage. The servo amplifier's heat radiating fins, regenerative resistor and servo amplifier, etc.
CAUTION Use wires and cables within the length of the range described in user's manual or the instruction manual for the product you are using . The ratings and characteristics of the system parts (other than control unit, servo amplifier, servomotor) must be compatible with the control unit, servo amplifier and servomotor. Install a cover on the shaft so that the rotary parts of the servomotor are not touched during operation.
(3) Transportation and installation CAUTION Transport the product with the correct method according to the weight. Use the servomotor suspension bolts only for the transportation of the servomotor. Do not transport the servomotor with machine installed on it. Do not stack products past the limit. When transporting the control unit or servo amplifier, never hold the connected wires or cables. When transporting the servomotor, never hold the cabled, shaft or encoder.
CAUTION When coupling with the synchronization encoder or servomotor shaft end, do not apply impact such as by hitting with a hammer. Doing so may lead to encoder damage. Do not apply a load larger than the tolerable load onto the servomotor shaft. Doing so may lead to shaft breakage. When not using the unit for a long time, disconnect the power line from the control unit or servo amplifier. Place the control unit and servo amplifier in static electricity preventing vinyl bags and store.
(6) Usage methods CAUTION Immediately turn OFF the power if smoke, abnormal sounds or odors are emitted from the control unit, servo amplifier or servomotor. Always execute a test operation before starting actual operations after the program or parameters have been changed or after maintenance and inspection. The units must be disassembled and repaired by a qualified technician. Do not make any modifications to the unit.
CAUTION Do not place fingers or hands in the clearance when opening or closing any opening. Periodically replace consumable parts such as batteries according to user's manual or the instruction manual for the product you are using. Do not touch the lead sections such as ICs or the connector contacts. Do not place the control unit or servo amplifier on metal that may cause a power leakage or wood, plastic or vinyl that may cause static electricity buildup.
Revisions *The manual number is given on the bottom left of the back cover. Print Date *Manual Number Revision Jun.,2001 IB(NA)-0300029-A First edition This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual.
CONTENTS 1. GENERAL DESCRIPTION ....................................................................................................... 1- 1 to 1- 6 1.1 System Configuration ........................................................................................................................ 1- 2 1.1.1 A273UHCPU System overall configuration ................................................................................ 1- 2 1.1.2 A173UHCPU(-S1) System overall configuration ...............................
5. MECHANICAL SYSTEM PROGRAM....................................................................................... 5- 1 to 5- 4 5.1 Mechanical Module Connection Diagram ........................................................................................ (1) Block ........................................................................................................................................ (2) System ...............................................................................................
6.3.2 Synchronous encoder control change ...................................................................................... 6-36 (1) Current value change by the CHGA instruction................................................................ 6-36 7. TRANSMISSION MODULE ..................................................................................................... 7- 1 to 7-31 7.1 Gear ..................................................................................................................
8.1.2 Parameter list ............................................................................................................................ 8- 5 (1) Unit setting......................................................................................................................... 8- 5 (2) Roller diameter (L) / Number of PULSES per roller revolution(NL) ................................... 8- 5 (3) Permissible droop pulse value ..........................................................................
8.4.2 Settings when creating cam data ............................................................................................. (1) Cam No. ........................................................................................................................... (2) Resolution......................................................................................................................... (3) Stroke/cam No. change point ............................................................................
10. AUXILIARY / APPLIED FUNCTIONS..................................................................................10- 1 to 10- 4 10.1 Current Value Change / Speed Change........................................................................................ 10- 1 10.1.1 Current value change by CHGA instruction and speed change by CHGV instruction ............ 10- 1 10.2 Improved Current Value Management .......................................................................................... 10- 3 11.
1. GENERAL DESCRIPTION 1. GENERAL DESCRIPTION The A273UHCPU/A173UHCPU(-SI) (hereafter referred to as "servo system CPU") features two operating modes (REAL and VIRTUAL) at motion controllers where the operating systems (OS) shown below have been installed: • SW2SRX-SV22U • SW2SRX-SV22A .......... Abbreviated to “SV22” This manual explains the mechanical system program required to operate the motion controller in the VIRTUAL mode.
1. GENERAL DESCRIPTION 1.1 System Configuration 1.1.1 A273UHCPU System overall configuration The following system configuration assumes use of the A273UHCPU.
1. GENERAL DESCRIPTION NOTES (1) A servo system CPU can be connected to a maximum of four motion extension base unit. (2) The motion extension base units which can be used are indicated below. • A255B (control power supply not required) • A268B (control power supply required) (3) When using a teaching unit A31TU-E with dead-man switch, a dedicated connecting cable A31TUCBL03M is required between the CPU module and A31TU-E connector.
1. GENERAL DESCRIPTION 1.1.
1. GENERAL DESCRIPTION 1.2 Summary of REAL and VIRTUAL Modes (1) REAL mode (a) The REAL mode is used to execute direct control by the servo program at systems using servomotors. (b) To utilize the REAL mode, positioning parameter settings must be designated ,and a positioning sequence program must be created. (c) The procedure for REAL mode positioning control is as follows: 1) A REAL mode servo program "start request" is issued with a SVST instruction in the positioning sequence program.
1. GENERAL DESCRIPTION (2) VIRTUAL mode (a) The VIRTUAL mode is used to execute synchronous processing (with software) using a mechanical system program comprised of a virtual main shaft and mechanical module. This mode permits the synchronous control for conventional positioning by main shaft, gear, and cam, etc., to be replaced by a servomotor positioning control format.
2. PROCEDURE FOR VIRTUAL MODE POSITIONING CONTROL 2. PROCEDURE FOR VIRTUAL MODE POSITIONING CONTROL The procedure for VIRTUAL mode positioning control is discussed in this section. 2.1 System Start-Up The procedure for a VIRTUAL mode system start-up is shown below. Reference Section Reference Manual SW2SRX-GSV22PE, Motion Controller (SV13/22 REAL Mode) SW0IX-CAMPE Operating Manual Programming Manual (type A273UH/A173UH) START Chapter 4 Register SW2SRX-GSV22PE, SW0SRX-CAMPE Section 6.
2. PROCEDURE FOR VIRTUAL MODE POSITIONING CONTROL Reference Section (1) Designate cam data settings (11) Section 8.4 Reference Manual Motion Controller (SV13/22 REAL Mode) Programming Manual (type A273UH/A173UH) SW2SRX-GSV22PE, SW0IX-CAMPE Operating Manual Chapter 22 Write setting data to hard disk or floppy disk, then end SW0IX - CAMPE operation Section 21.2 Section 6.
2. PROCEDURE FOR VIRTUAL MODE POSITIONING CONTROL Reference Section (2) Motion Controller (SV13/22 REAL Mode) Programming Manual (type A273UH/A173UH) Start-up servo by peripheral device Execute zeroing test by JOG/manual pulse generator operation REAL Mode VIRTUAL Mode Reference Manual Sections 7.19 to 7.21 SW2SRX-GSV22PE/ SW0IX-CAMPE Operating Manual Section 12.2 Sections 12.4 to 12.6 Adjust cam setting axis (bottom dead center, stroke amount adjustments, etc.
2. PROCEDURE FOR VIRTUAL MODE POSITIONING CONTROL 2.2 Operation The preparation procedure for VIRTUAL mode operation is shown below. 2.2.1 Operation with incremental system The operation procedure when an incremental system is used is shown below. Reference Section Reference Manual Motion Controller (SV13/22 REAL Mode) Programming Manual (type A273UH/A173UH) START Switch power supply unit ON REAL Mode Turn the "PLC READY" signal (M2000) ON Section 4.
2. PROCEDURE FOR VIRTUAL MODE POSITIONING CONTROL 2.2.2 Operation with an absolute (absolute position) system The operation procedure when an absolute system is used is shown below. Reference Section Reference Manual Motion Controller (SV13/22 REAL Mode) Programming Manual (type A273UH/A173UH) START Switch the power supply unit ON Turn the "PC READY" signal (M2000) ON Section 4.1 Execute an "all-axes servo START request" (switch M2042 ON) Section 4.
2. PROCEDURE FOR VIRTUAL MODE POSITIONING CONTROL 2.3 Differences Between The REAL and VIRTUAL Modes Portions of the positioning data, positioning device, and servo programs, etc., used in REAL mode operations are different when used in VIRTUAL mode operations. The Motion Controller (SV13/22 REAL Mode) Programming Manual (type A273UH CPU/A173UHCPU(-S1)) should be read after acquainting yourself with these differences. 2.3.1 Positioning data Positioning data used in the VIRTUAL mode is shown in Table 2.
2. PROCEDURE FOR VIRTUAL MODE POSITIONING CONTROL 2.3.3 Servo program (1) Servo program area (a) The same servo program No. cannot be used in both the REAL and VIRTUAL modes. For VIRTUAL mode operations, the servo program's range must be designated in advance. (The range setting is executed at an IBM PC running the SW2SRXGSV22PE software.) (2) Servo instructions (a) The zeroing, speed control (II), speed/position switching functions, and highspeed oscillation functions are inoperative in the VIRTUAL mode.
2. PROCEDURE FOR VIRTUAL MODE POSITIONING CONTROL 2.3.4 Control change (current value change & speed change) When a control change is executed in the VIRTUAL mode, the drive module's feed current value and speed will change. Control changes are not possible for the output module. The differences between control changes in the REAL and VIRTUAL modes are shown in Table 2.4 below. Table 2.
3. PERFORMANCE SPECIFICATIONS 3. Performance Specifications Table 3.1 gives the performance specifications of the PCPU. Table 3.
3. PERFORMANCE SPECIFICATIONS Table 3.
4. SERVO SYSTEM CPU DEVICES 4. SERVO SYSTEM CPU DEVICES The servo system CPU devices for which positioning control is carried out using the VIRTUAL mode and the applications of these devices are explained in this chapter. The signals which are sent from the PCPU to the SCPU indicate the PCPU device refresh cycle and the signals sent from the SCPU to the PCPU indicate the PCPU device fetch cycle. 4.1 Internal Relays 4.1.
4. SERVO SYSTEM CPU DEVICES POINTS (Note-1) : When the VIRTUAL mode is used do not set M4000 to M5599 in the latch range. (Note-2) : The virtual servo motor axis status signals/command signals occupy only the areas of the axes set in the mechanical system program. The area of an axis that is not set in the mechanical system program can be used by the user.
4. SERVO SYSTEM CPU DEVICES 4.1.2 Axis statuses Axis Device Number No.
4. SERVO SYSTEM CPU DEVICES 4.1.3 Axis command signal Axis Device Number No.
4. SERVO SYSTEM CPU DEVICES 4.1.4 Virtual servo motor axis statuses Axis Device Number No.
4. SERVO SYSTEM CPU DEVICES 4.1.5 Virtual servo motor axis command signals Axis Device Number No.
4. SERVO SYSTEM CPU DEVICES 4.1.6 Synchronous encoder axis statuses Device Number Axis A173UHCPU No.
4. SERVO SYSTEM CPU DEVICES 4.1.
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4.
4.
4. SERVO SYSTEM CPU DEVICES (1)PLC READY flag (M2000)................................. Signal sent from SCPU to PCPU (a) This signal notifies the PCPU that SCPU operation is normal. It is switched ON and OFF by the sequence program. 1) When M2000 is ON, positioning or zeroing (REAL mode only) functions can be executed by the servo program specified by the sequence program, and JOG operations can be executed by the sequence program.
4. SERVO SYSTEM CPU DEVICES (d) When M2000 turns OFF, the following processing is executed. 1) Processing details • The PCPU READY flag (M9074) is turned OFF. • Operating axes are decelerated to a stop. POINT The PLC READY flag (M2000) switches OFF when a servo system CPU "STOP" status exists. When the RUN status is resumed, the status which existed prior to the STOP will be re-established. ON M2000 OFF RUN→STOP switching STOP→RUN switching (2) Virtual servomotor START accept flags (M2001 to M2032) ....
4. SERVO SYSTEM CPU DEVICES 2) When executing positioning by switching the JOG instruction ON, the START accept flag will switch OFF when positioning is stopped by a JOG instruction OFF. 3) The START accept flag is ON when the manual pulse generator is enabled (M2051 to M2053:ON), and is OFF when the manual pulse generator is disabled (M2051 to M2053:OFF). 4) The START accept flag is ON during a current value change being executed by a sequence program CHGA instruction.
4. SERVO SYSTEM CPU DEVICES (3) PC link communication error flag (M2034) ........................................................................ Signal sent from PCPU to SCPU This flag comes ON when an error occurs during personal computer linking communication. When M2034 comes ON the error code is stored in the personal computer link communication error code storage register (D9196). The devices dedicated to personal computer communication are indicated below. Table 4.
4. SERVO SYSTEM CPU DEVICES (4) Speed switching point designation flag (M2040) ........................................................................ Signal sent from SCPU to PCPU The speed switching point designation flag is used when a speed change is designated at the pass point in constant-speed control.
4. SERVO SYSTEM CPU DEVICES (6) All-axes servo START command (M2042) ..... Signal sent from SCPU to PCPU This signal is used to enable servo operation. • Servo operation ENABLED ............ When M2042 is switched ON, the servo OFF signal is OFF, and there are no active servo errors. • Servo operation DISABLED ........... When M2042 switches ON, the servo OFF signal is ON, or a servo error is detected.
4. SERVO SYSTEM CPU DEVICES (8) REAL/VIRTUAL mode status flag (M2044) ........................................................................ Signal sent from PCPU to SCPU This flag verifies that switching between the REAL and VIRTUAL modes is completed, and verifies the current mode. • OFF when the REAL mode is in effect, and switching from the VIRTUAL to REAL mode is completed. • ON when switching from REAL to VIRTUAL mode is completed.
4. SERVO SYSTEM CPU DEVICES (11) Motion slot module error detection flag (M2047) ........................................................................ Signal sent from PCPU to SCPU This flag indicates whether the status of modules mounted at the base unit and extension base units is normal or abnormal. • ON.............. Status of mounted module is abnormal • OFF ...........
4. SERVO SYSTEM CPU DEVICES (14) START buffer full (M2050) .............................. Signal sent from PCPU to SCPU (a) This signal switches ON when the PCPU fails to process the specified data within 65 seconds following a positioning START (SVST) instruction or a control change (CHGA/CHGV) instruction from the sequence program. (b) A M2050 reset must be executed from the sequence program. (15) Manual pulse generator enabled flag (M2051 to 2053) .........................................................
4. SERVO SYSTEM CPU DEVICES (17) Cam data/limit switch output data batch-change completion flag (M2057) ................................................................................. Signal from PCPU to SCPU (a) This flag is used to confirm normal completion of cam data/limit switch output data changes. 1) The flag turns ON at normal completion of cam data/limit switch output data changes. 2) Turning M2056 OFF also turns M2057 OFF.
4. SERVO SYSTEM CPU DEVICES (20) Synchronous encoder current value changing flags (M2101 to M2112) ............................................................................. Signals from PCPU to SCPU The synchronous encoder current value changing flag is ON while the current value of the synchronous encoder is being changed using the control change (CHGA) instruction of the sequence program. Use this flag as an interlock for the synchronous encoder current value change program.
4. SERVO SYSTEM CPU DEVICES (d) The automatically decelerating flag list is given below. Axis No. Device No. Axis No. Device No. Axis No. Device No. Axis No. Device No.
4. SERVO SYSTEM CPU DEVICES POINT (1) Even during a stop, the ON status of the start acceptance flag (M2001 to M2032) indicates that the speed change "0" request is accepted. Check with this speed change "0" flag. (2) During interpolation, the flags corresponding to the interpolation axes are set. (3) In any of the following cases, the speed change "0" request is invalid.
4. SERVO SYSTEM CPU DEVICES (f) The speed change "0" accepting flag does not turn ON if a speed change "0" occurs after an automatic deceleration start. Automatic deceleration start V Speed change "0" t Start acceptance flag (OFF) Speed change "0" accepting flag (g) Under position follow-up control, the speed change "0" accepting flag turns ON if a speed change "0" occurs after an automatic deceleration start to the "specified address".
4. SERVO SYSTEM CPU DEVICES 4.2 Data Registers 4.2.1 Data register list A273UHCPU Device Number D0 (! Valid) Application Real Axis monitor device (20 points × 32 axes) ! Real mode ..........Axis A173UHCPU (-S1) Device Number Virtual ! D0 Virtual mode........Output module D640 D704 Application Real Virtual ! ! Control change register (2 points × 32axes) ! ! Common device (96 points) ! ! Back up ! Back up ! Axis monitor device (20 points × 32 axes) Real mode ..........
4. SERVO SYSTEM CPU DEVICES 4.2.2 Axis No.
4. SERVO SYSTEM CPU DEVICES 4.2.3 Control change registers Axis No.
4. SERVO SYSTEM CPU DEVICES 4.2.4 Virtual servo motor axis monitor devices Axis No. Device Number 1 D800 to D805 2 D810 to D815 3 D820 to D825 4 D830 to D835 5 D840 to D845 6 D850 to D855 7 D860 to D865 0 Feed current value 1 8 D870 to D875 2 Minor error code 9 D880 to D885 3 Major error code 10 D890 to D895 4 Execution program No.
4. SERVO SYSTEM CPU DEVICES 4.2.5 Current values after virtual servo motor axis main shaft's differential gear Axis No.
4. SERVO SYSTEM CPU DEVICES 4.2.6 Synchronous encoder axis monitor devices Axis Device Number No.
4. SERVO SYSTEM CPU DEVICES 4.2.8 Axis No. Cam axis monitor devices Device Number Signal Name 1 D1240 to D1249 (! Valid) Refresh Cycle 2 D1250 to D1259 3 D1260 to D1269 4 D1270 to D1279 Signal Name Real Virtual Signal Direction 5 D1280 to D1289 0 Unusable 7 D1300 to D1309 1 Execution cam No.
4. SERVO SYSTEM CPU DEVICES 4.2.
4. SERVO SYSTEM CPU DEVICES (1) JOG operation simultaneous start axis setting registers (D710 to D713) .................................................................................... Data from SCPU to PCPU (a) These registers are used to set the virtual servomotor axis No. and directions of the axis whose JOG operation will be started simultaneously.
4. SERVO SYSTEM CPU DEVICES (3) Manual pulse generator 1-pulse input magnification setting registers (D720 to D751)............................................................ Data from SCPU to PCPU (a) This register is used to set the magnification (1 to 100) per pulse of the input pulse count from the manual pulse generator for manual pulse generator operation. 1-Pulse Input Magnification Setting Register Correspondi ng Axis No.
4. SERVO SYSTEM CPU DEVICES (4) Manual pulse generator smoothing magnification setting area (D752 to D754) ...................................................... Data from SCPU to PCPU (a) These devices are used to set the smoothing time constants of manual pulse generators.
4. SERVO SYSTEM CPU DEVICES (5) Limit switch output disable setting registers (D760 to D775) .................................................................................... Data from SCPU to PCPU (a) These registers are used to disable the external outputs of the limit switch outputs on a point by point basis. Set the corresponding bit to 1 to disable the limit switch output and turn OFF the external output.
4. SERVO SYSTEM CPU DEVICES (6) Limit switch output status storage registers (D776 to D791) .................................................................................... Data from PCPU to SCPU (a) The output states (ON/OFF) of the limit switch outputs set on the peripheral device and output to the A1SY42 and the AY42 are stored in terms of 1 and 0. • ON .................. 1 • OFF.................
4. SERVO SYSTEM CPU DEVICES (7) Servo amplifier type (D792 to D799) .......................... Data from PCPU to SCPU The servo amplifier types set in system settings are stored when the servo system CPU control power supply is switched on or reset.
4. SERVO SYSTEM CPU DEVICES 4.3 Special Relays/Special Registers List 4.3.1 Special relays Device No. Signal Name M9073 PCPU WDT error flag M9074 PCPU READY completed flag M9075 TEST mode ON flag M9076 External emergency stop input flag M9077 Manual pulse generator axis setting error flag M9078 TEST mode request flag M9079 Servo program setting error flag ! Valid) (! REAL VIRTUAL Signal Direction Refresh Cycle ! ! SCPU←PCPU END Fetch Cycle (1) PCPU WDT error flag (M9073)...........
4. SERVO SYSTEM CPU DEVICES (4) External emergency stop input flag (M9076) .......................................................................... Signal sent from PCPU to SCPU This flag status indicates whether the external emergency stop input to the power module's EMG terminal is ON or OFF. • OFF .............. External emergency stop input is ON. • ON ................ External emergency stop input is OFF. (5) Manual Pulse Generator Axis Setting Error Flag (M9077) .....................................
4. SERVO SYSTEM CPU DEVICES 4.3.2 Special registers ! Valid) (! Device Number D9180 D9181 D9182 Signal Name Unusable D9183 Test mode request error information D9184 PCPU WDT error factor D9185 D9186 D9187 Error program No.
4. SERVO SYSTEM CPU DEVICES (2) PCPU WDT error cause(D9184).....................Data from the PCPU to the SCPU When PCPU error occurs, the code of cause will be stored. Error Code 1 Error Cause Operation when Error Occurs PCPU software fault 1 2 PCPU operation cycle time over 3 PCPU software fault 2 30 PCPU/SCPU hard ware fault AC servo motor drive module CPU fault 100 Indicates the slot No.(0 to 7) where the AC motor drive module with the fault is loaded.
4. SERVO SYSTEM CPU DEVICES (3) Manual pulse generator axis setting error information (D9185 to D9187) ...................................................................................
4. SERVO SYSTEM CPU DEVICES (5) Error item information (D9190) ........................... Data sent from PCPU to SCPU When the servo program setting error flag (M9079) switches ON, the error code corresponding to the erroneous setting item will be stored. Error Code 900 901 902 904 905 906 Error item data Error Description The servo program designated by the SVST instruction does not exist. The axis No. designated by the SVST instruction is different from the axis No. designated by the servo program.
4. SERVO SYSTEM CPU DEVICES (7) REAL/VIRTUAL mode switching error information (D9193 to D9195) .......................................................................... Data sent from PCPU to SCPU When a mode switching error occurs in real-to -virtual or virtual-to-real mode switching, or a mode continuation error occurs in the virtual mode, its error information is stored. Refer to Section 10.6 for details of the stored error code. (8) PC link communication error codes (D9196) ............................
5. MECHANICAL SYSTEM PROGRAM 5 MECHANICAL SYSTEM PROGRAM This section discusses the VIRTUAL mode's mechanical system program. This program consists of a mechanical module connection diagram and the mechanical module parameters. • The mechanical module connection diagram shows the virtual mechanical system consisting of connected virtual mechanical modules. • The mechanical module parameters are the parameters used at the mechanical module connection diagram for control of the mechanical modules.
5. MECHANICAL SYSTEM PROGRAM 5.1 Mechanical Module Connection Diagram The mechanical module connection diagram shows a virtual system consisting of mechanical modules. The mechanical module connection configuration is shown in Fig. 5.1 below.
5. MECHANICAL SYSTEM PROGRAM (1) Block The term "block" refers to a single series of elements between and including a virtual transmission module (gear connected to the virtual main shaft) and an output module. Refer to Table 5.1 to determine the number of mechanical modules which can be connected in one block. (2) System The term "system" refers to all the blocks which are connected to a single virtual main shaft. One system can consist of up to 8 blocks.
5. MECHANICAL SYSTEM PROGRAM 5.2 Mechanical Module List Summaries of mechanical modules used in VIRTUAL mode mechanical module connection diagrams are given in Tables 5.1. For details regarding each mechanical module, see Chapters 5 to 8. Table 5.
6. DRIVE MODULE 6. DRIVE MODULE The drive module drives the virtual axis. There are 2 types of drive module: • Virtual servo motor......................See Section 6.1 • Synchronous encoder .................See Section 6.2 6.1 Virtual Servo Motor The virtual servo motor is used to control the virtual axis by servo program or by JOG operation. Virtual servo motor operation and parameters are discussed below. 6.1.
6. DRIVE MODULE (b) START by JOG operation An "individual" or "simultaneous" START can be executed at the JOG (Note-1) operation. 1) Individual START ............Each axis can be started by a forward/reverse (Note-2) JOG command . Program example for virtual axis 1 individual START Mechanical system program Virtual servo motor M4802 Forward JOG Reverse JOG M4803 2) Simultaneous START......The simultaneous START axis Nos.
6. DRIVE MODULE (2) Procedure for stopping before completion To stop virtual servo motor operation before positioning is completed, switch the stop/rapid stop command ON in the sequence program. (There are no external stop causes (STOP, FLS, RLS) for the virtual servo motor.) (3) Control items (a) During positioning control, the virtual servo motor backlash compensation amount is processed as "0".
6. DRIVE MODULE (5) Operation mode when error occurs The operation method when major errors occur at the output modules of a given system can be designated as shown below. Control occurs as shown below, based on the parameter settings (see Table 6.1) of the virtual servo motor which is connected to the virtual main shaft. (a) Continuation ........ Output module operation continues even if a major output module error occurs.
6. DRIVE MODULE (6) Virtual servo motor axis continuous operation By setting the virtual servo motor stroke limit upper and lower limit parameters such that the upper stroke limit = lower stroke limit, the stroke limit can be disabled thereby allowing operation to continue indefinitely. When the stroke limit is disabled it is also possible for the startup of the feed current value to take place in a direction that exceeds 32 bits. In such a case the feed current value is converted to a 32 bit ring address.
6. DRIVE MODULE [Control contents] (1) If a speed change is made to a negative speed, control is carried out as indicated in the previous table in accordance with the control mode during startup. (2) The command speed during return becomes the absolute value of the changed speed. If the speed limit value is exceeded the minor error 305 will result and control will use the speed limit value. (3) The following hold true when the servo is in the stand by status at the return position.
6. DRIVE MODULE [Operation example of constant-speed control] The diagram below shows an example of operation when a reverse return request is carried out in relation to constant-speed control.
6. DRIVE MODULE 6.1.2 Parameter list The virtual servo motor parameters are shown in Table 6.1. Parameters shown in this table are explained in items (1) to (4) below. For details regarding the virtual servo motor parameter setting procedure, refer to the SW2SRX-GSV22PE/SW0IX-CAMPE Operating Manual. Table 6.1 Parameter List No.
6. DRIVE MODULE Error Code 106 Contents Operation Command position is outside of the stroke limit range at startup. Does not start Error Code Contents Operation 207 Feed current value is outside of the stroke limit range during startup. 208 The feed current value of another axis is outside of the stroke limit range when circular interpolation starts.
6. DRIVE MODULE (3) Command in-position range The term "command in-position" refers to the difference between the positioning address (command position) and current feed value. The "command in-position" signal switches ON when the difference between the command position and the feed current value enters the setting range ([command in-position] − [feed current value] ≤ [command in-position range]). The command in-position range is checked constantly during positioning control.
6. DRIVE MODULE 6.1.3 Virtual servo motor axis devices (internal relays, data registers) (1) Virtual servo motor axis status Axis Device Number No.
6. DRIVE MODULE (Note-1) (a) Positioning START completed signal (M4000+20n) 1) This signal switches ON when a positioning START is completed at the axis designated by a SVST instruction in the sequence program. This signal is inoperative during JOG and speed control operations. This signal can be used for M-code readouts, etc., when positioning is (Note-2) started.
6. DRIVE MODULE (b) Positioning completed signal (M4001+20n) 1) This signal switches ON when positioning is completed at the axis designated by a SVST instruction in the sequence program. This signal will not switch ON when JOG or speed control operations are started, or when they are stopped while in progress. This signal can be used for M-code readouts when positioning is completed.
6. DRIVE MODULE (c) Command in-position command (M4003+20n) 1) This signal switches ON when the absolute difference between the command position and the current value is less than the "command inposition range" designated by the virtual servo motor parameter setting (see Section 6.1.2).
6. DRIVE MODULE (e) Error detection signal (M4007+20n) 1) The error detection signal comes ON when a minor error or major error is detected in a virtual servo motor or output module connected to a virtual servo motor. The ON/OFF status of the error detection signal is used to distinguish whether or not an error exists. 2) When the error detection signal comes ON the corresponding error code is then stored in the error code storage area. (Note-1) (Note-2) • Minor error code ...
6. DRIVE MODULE (2) Virtual servo motor axis command signals Axis Device Number No.
6. DRIVE MODULE (Note) (a) Stop command (M4800+20n) 1) The stop command is used to stop operation at an axis where motion is in progress, and it becomes effective at the leading edge (OFF→ON) of the signal. (Operation cannot be started at axes where the stop command is ON.) ON Stop command (M4800+20n) OFF Stop command at specified axis V Control when stop command is OFF Designated speed STOP t Deceleration stop processing 2) The stop command can also be used during speed control.
6. DRIVE MODULE (b) Rapid stop command (M4801+20n) 1) This command is used to execute a rapid stop at an axis which is in motion, and it becomes effective at its leading edge (OFF→ON). (Operation cannot be started at axes where the rapid stop command is ON.
6. DRIVE MODULE POINT The sequence program features an interlock function which prevents the forward (M4802+20n) and reverse (M4803+20n) JOG start commands from being switched ON simultaneously. (d) Completed signal OFF command (M4804+20n) This command is used to switch the "positioning START completed signal" (M4000+20n) and the "positioning completed signal" (M4001+20n) OFF in the sequence program.
6. DRIVE MODULE (f) External STOP input invalid command at START (M4809+20n) This command is used to designate a valid/invalid setting for the external STOP input. • ON ......... The external STOP input will be invalid, and axes where the STOP input is ON can be started. • OFF ....... The external STOP input will be valid, and axes where the STOP input is ON cannot be started.
6. DRIVE MODULE (3) Virtual servo motor axis monitor device Axis Device Number No.
6. DRIVE MODULE REMARKS (1) (Note-1): n Virtual axis No. n Virtual axis No. n Virtual axis No. n Virtual axis No. (2) (Note-2): (3) (Note-3): The "n" in D800+10n represents the number corresponding to the virtual axis No. 0 1 8 9 16 17 24 25 1 2 9 10 17 18 25 26 2 3 10 11 18 19 26 27 3 4 11 12 19 20 27 28 4 5 12 13 20 21 28 29 5 6 13 14 21 22 29 30 6 7 14 15 22 23 30 31 7 8 15 16 23 24 31 32 For details regarding the drive module error reset command, see Section 6.1.3.
6. DRIVE MODULE (4) Current value after virtual servo motor axis main shaft differential gear Axis No.
6. DRIVE MODULE REMARKS (1) (Note): n Virtual axis No. n Virtual axis No. n Virtual axis No. n Virtual axis No. The "n" in D806+10n represents the number corresponding to the virtual axis No. 0 1 8 9 16 17 24 25 1 2 9 10 17 18 25 26 2 3 10 11 18 19 26 27 3 4 11 12 19 20 27 28 4 5 12 13 20 21 28 29 5 6 13 14 21 22 29 30 6 7 14 15 22 23 30 31 7 8 15 16 23 24 31 32 (b) Error search output axis No. storage register (D808+10n) .....
6. DRIVE MODULE 6.2 Synchronous Encoder The synchronous encoder is used to execute virtual axis operation by pulse inputs from an external source. Synchronous encoder operation and parameters are discussed below. 6.2.1 Synchronous encoder operation (1) Operation START A synchronous encoder axis START occurs when the reception of the pulse inputs from the external synchronous encoder begins.
6. DRIVE MODULE (b) Pulse input reception at an external signal input occurs as follows 1) Reception of pulse inputs from the external synchronous encoder begins when the clutch is switched ON.
6. DRIVE MODULE REMARKS (1) (Note-1): For details regarding the REAL/VIRTUAL mode switching request flag and the REAL/VIRTUAL mode switching status flag, see Section 4.1. (2) For details regarding switching between the REAL and VIRTUAL modes, see Chapter 9. (3) (Note-2): The synchronous encoder input START signal is input to the A273EX/A172SENC "TRA" terminal. For details regarding the A273EX/A172SENC "TRA" terminal, refer to the Motion Controller [A173UHCPU/A273UHCPU] User's Manual.
6. DRIVE MODULE (6) Operation mode when error occurs The operation method when major errors occur at the output modules of a given system can be designated as shown below. Control occurs as shown below, based on the parameter settings (see Table 6.4) of the synchronous encoder which is connected to the synchronous encoder main shaft. (a) Continuation ....... Output module operation continues even if a major output module error occurs.
6. DRIVE MODULE 6.2.2 Parameter list The synchronous encoder parameters are shown in Tables 6.4. For details regarding the synchronous encoder parameter setting procedure, refer to the SW2SRX-GSV22PE/SW0IX-CAMPE Operating Manual. Table 6.4 Synchronous Encoder Parameter List No. 1 2 Setting Item Encoder No. Operation mode when error occurs Default Value Continuation Setting Range 1 to 12 Continuation/Clutch OFF (a) Encoder No.
6. DRIVE MODULE 6.2.3 Synchronous encoder axis device (internal relay, data register) (1) Synchronous encoder axis device Device Axis No.
6. DRIVE MODULE REMARKS "n" in M4640+4n, M4641+4n and M4642+4n indicates the value corresponding to the synchronous encoder No. n Synchronous encoder No. 0 P1/E1 1 P2/E2 2 P3/E3 n Synchronous encoder No. 6 P7/E7 7 P8/E8 8 P9/E9 3 P4/E4 4 P5/E5 5 P6/E6 9 10 11 P10/E10 P11/E11 P12/E12 (1) (Note-1): For details regarding drive module major and minor errors, see Section 11.3. For details regarding output module major and minor errors, see Section 11.5.
6. DRIVE MODULE (3) Synchronous encoder axis monitor device Axis No.
6. DRIVE MODULE (4) Current value after synchronous encoder axis main shaft differential gear Device Axis No.
6. DRIVE MODULE 6.3 Virtual Servo Motor/Synchronous Encoder Control Change This section provides explanations regarding virtual servo motor current value changes, speed change JOG speed changes, and synchronous encoder current value changes. Current value changes are carried out using the CHGA instruction and speed changes are conducted using the CHGV instruction/DSFLP instruction.
6. DRIVE MODULE (a) JOG speed setting register (D960+2n) ...... Data sent from SCPU to PCPU 1) The JOG speed which is used at JOG operations is stored in this register. 2) The JOG speed setting range is 1 to 10000000 PLS/s. 3) The JOG speed setting stored in this register is adopted at the leading edge (OFF→ON) of the JOG START signal. Even if the JOG speed setting is changed while a JOG operation is in progress, the JOG speed will remain unchanged. 4) For details regarding JOG operation, see Section 7.
6. DRIVE MODULE 6.3.2 Synchronous encoder control change (1) Current value change by the CHGA instruction A program example is given below. Synchronous encoder current value change program (when encoder No. 1 is changed to a value of 20000 PLS) Command M2044 Encoder No. setting Setting of the current value change M2001 CHGA E1 K2000 (a) The change in the Current value and speed are set using the devices described below. • Indirect setting .......
7. TRANSMISSION MODULE 7. TRANSMISSION MODULE There are the following four types of transmission module. • Gear................................... Section 7.1 • Clutch................................. Section 7.2 • Speed change gear .......... Section 7.3 • Differential gear ................. Section 7.4 The following describes the device range and procedure for indirect setting of items by devices among transmission module parameters.
7. TRANSMISSION MODULE (2) Device data fetch When the data of a device that has been set indirectly is switched from the REAL to VIRTUAL mode, first acquire everything as default values and thereafter carry out fetch control during virtual mode operation for the corresponding module. Shown in the table below are the fetch timing of each device and the refresh cycle of the set device.
7. TRANSMISSION MODULE 7.1 Gear The operation of the gear and the parameters required to use a gear are explained here. 7.1.
7. TRANSMISSION MODULE (1) Gear ratio (a) The gear ratio is the setting which determines the number of output pulses that are transmitted to the output shaft for every pulse from the drive module. (b) The gear ratio is determined by the settings for the number of gear teeth at the input shaft (GI) and the number of gear teeth at the output shaft (GO).
7. TRANSMISSION MODULE 7.2 Clutch There are two types of clutch: the smoothing clutch and the direct clutch. These two clutches operate in the same way; the difference is that with the smoothing clutch, acceleration and deceleration processing by smoothing processing is executed when the clutch is switched ON and OFF but this does not happen with the direct clutch.
7. TRANSMISSION MODULE REMARKS (1) Clutch ON/OFF status • Clutch ON status..........The status in which PULSES input to the clutch are output to the output shaft. • Clutch OFF status........The status in which PULSES input to the clutch are not output to the output shaft.
7. TRANSMISSION MODULE 2) If the input to the clutch (drive module travel value × gear ratio) changes after completion of smoothing, smoothing processing is executed at that point also.
7. TRANSMISSION MODULE 2) Since the amount of slip remains constant even if the drive module speed changes, the clutch ON/OFF position can be controlled without any influ-ence from speed changes.
7. TRANSMISSION MODULE 7.2.1 Explanation of clutch operation There are five clutch modes: • ON/OFF mode • Address mode • Address mode 2 • One-shot mode • External input mode Each of these modes is explained below. (1) ON/OFF mode (a) In this mode, the clutch is turned ON and OFF in accordance with the ON/OFF status of the clutch ON/OFF command device. 1) When the clutch ON/OFF command device comes ON, the clutch is set to the ON status.
7. TRANSMISSION MODULE (d) See Appendix 2 for details about the refresh cycle of the clutch ON/OFF status device. END END processing Sequence program operation END 0 END 0 0 END 0 ON Clutch ON/OFF command device OFF Clutch status device OFF ON Max. 7.1ms Max. 7.1ms Max. 7.
7. TRANSMISSION MODULE (c) Make sure that the clutch ON/OFF command device is turned ON/OFF, and the status in which the clutch ON/OFF address can be accepted is established, before the current value of the virtual axis reaches the clutch ON/OFF address. In the address mode, a delay occurs from the time the clutch ON/OFF command device is turned ON/OFF until the clutch ON/OFF address can be accepted. See Appendix 2 for details about the delay times.
7. TRANSMISSION MODULE (e) See Appendix 2 for details about the refresh cycle of the clutch ON/OFF status device. END 0 END processing Sequence program operation END 0 END 0 ON/OFF mode Mode setting device value 0 0 Address mode 1 ON Clutch ON/OFF command device END OFF OFF ON Min. 3.5 ms required Min. 3.
7. TRANSMISSION MODULE (3) Address mode 2 Control switches to that of the address mode 2 as soon as the "mode setting device" value changes to "2: Address mode 2". (a) While the "clutch ON/OFF command device" is ON, the following control is exercised according to the current clutch status. 1) When the current clutch status is OFF When the address set in the "clutch ON address setting device" is reached, the clutch turns ON. After that, the status in 2) is established.
7. TRANSMISSION MODULE (c) Clutch ON/OFF control is exercised per calculation cycle. If both the ON and OFF addresses are passed through during one calculation cycle, internal control is performed properly but the clutch status device remains unchanged. 1) When the clutch status is OFF and both ON and OFF addresses are passed through Clutch OFF address Clutch ON address Drive module current value Clutch status Clutch status device (OFF) Calculation cycle Number of pulses in this area is transmitted.
7. TRANSMISSION MODULE (4) One-shot mode (a) Control switches to that of the one-shot mode as soon as the "mode setting device value" changes to "3: One-shot mode clutch ON command enable" or "4: One-shot mode clutch ON command disable".
7. TRANSMISSION MODULE (c) While the "mode setting device value" is "4", the clutch ON/OFF command device is invalid, and the clutch remains OFF. However, when the "mode setting device value" is changed from "3" to "4" during execution of the clutch ON/OFF processing started by turning ON the clutch ON/OFF command device, the clutch ON/OFF processing in execution is performed till the end and the clutch ON/OFF command is then made invalid from the next time on.
7. TRANSMISSION MODULE (e) Clutch ON/OFF control is exercised per operation cycle. For the specified travel value at which the clutch status turns from OFF to ON to OFF during one operation cycle, internal control is performed properly but the clutch status device remains unchanged. Drive module current value 1) Clutch status Number of pulses in this area is transmitted. Clutch status device (OFF) Operation cycle There is no transmission value when 1) is 0.
7. TRANSMISSION MODULE (h) When the "mode setting device" value changes from other than "3" to "4", the clutch status turns OFF independently of whether the clutch ON/OFF command device is ON or OFF. (i) If the "clutch ON address setting device" or "clutch OFF address setting device" data is changed during one-shot clutch processing execution, the new data is made valid when the clutch ON/OFF command device turns from OFF to ON next time.
7. TRANSMISSION MODULE (n) If the moving direction set to the specified before-clutch ON travel value or specified after-clutch ON travel value does not match that of the virtual axis or virtual axis within-one revolution current value, note that the clutch will turn ON/OFF even if the condition is not satisfied when the data found by subtracting the travel value from the specified travel value comes out of the range -2147483648 to 2147483647 (PLS) and changes from + to - or from to +.
7. TRANSMISSION MODULE (5) External input mode (a) In this mode the clutch is turned ON and OFF in accordance with the clutch ON/OFF command bit device and the external input (TRA signal: synchronous encoder start signal). Since the input pulses from the synchronous encoder are counted in response to the leading edge of the external input signal, the clutch in this mode gives high-speed response and high accuracy.
7. TRANSMISSION MODULE (d) The current value of the input shaft (virtual axis) only changes when the clutch is in the ON status. END END processing Sequence program operation END 0 0 END 0 V Input pulse from synchronous encoder ON Clutch ON/OFF command device OFF Clutch status device OFF External input (TRA signal) OFF ON ON ON Min. 3.5 ms required Max. 7.
7. TRANSMISSION MODULE (g) If the clutch connected to an encoder is used in the external input mode, all other clutches connected to the same encoder number must be set to the external input mode. However, it is permissible to use a combination of direct clutches and smoothing clutches. Example 1 Synchronous encoder connected to a drive shaft If an external input mode clutch is used, set all clutches connected to the synchronous encoder to the external input mode.
7. TRANSMISSION MODULE Example 3 Same synchronous encoder connected to a drive shaft and auxiliary input shaft Set all the connected clutches to the external input mode. (See examples 1 and 2 ) Synchronous encoder Set to external input mode Synchronous encoder No.
7. TRANSMISSION MODULE 7.2.2 Parameters The clutch parameters are presented in Table 7.2 and each item in this table is explained in (1) through (6) below. For the method for setting clutch parameters, refer to the SW2SRX-GSV22PE/SW0IX-CAMPE Operating Manual. Table 7.2 Parameter List No.
7. TRANSMISSION MODULE (2) Mode setting device (set only when using ON/OFF mode, address mode, address mode 2 and one-shot mode in conjunction; 1 word) (a) This is the device used to switch between the ON/OFF mode and the address mode. The settings of the mode setting device are as follows: • 0 : ON/OFF mode • 1 : Address mode • 2 : Address mode 2 • 3,4 : One-shot mode If a value other than 0 or 4 is set, this is regarded as an error and the previously set mode remains in effect.
7. TRANSMISSION MODULE (4) Clutch ON/OFF address setting device (can only be set when the ON/OFF mode and address mode are used in conjunction; 2 words for each mode) (a) This device serves to set the address at which the clutch is switched ON and address at which the clutch is switched OFF in the address mode.
7. TRANSMISSION MODULE 7.3 Speed Change Gear This section describes the operation of the speed change gear and the parameters required to use it. 7.3.1 Operation This section describes the operation of the speed-change gear. (1) The speed change gear transmits a speed which is the input shaft speed multiplied by a speed change gear ratio set in the speed change gear ratio setting device, to the output shaft.
7. TRANSMISSION MODULE 7.3.2 Parameter list The speed change gear parameters are presented in Table 7.3 and each item in this table is explained in (1) through (3) below. For the method for setting speed change gear parameters, refer to the SW2SRX-GSV22PE/SW0IX-CAMPE Operating Manual. Table 7.3 Speed Change Gear Parameter List No.
7. TRANSMISSION MODULE (2) Speed change gear ratio setting device (a) This is the setting for the device that sets the speed change gear ratio of the speed change gear. (b) The following devices can be used as speed change gear ratio setting devices. Data register (Note) D800 to D3069 D3080 to D8191 Link register W0 to W1FFF (Note) : D800 to D1559 are devices dedicated to the virtual servo motor axes, synchronous encoder axes and output module "cams" in the virtual mode.
7. TRANSMISSION MODULE 7.4 Differential Gear The differential gear is used for the following purposes; • For shifting the output module phase or carrying out alignment of the operation start position • For carrying out independent operation separated from the virtual main shaft 7.4.1 Operation (1) When the input shaft clutch is engaged The differential gear subtracts the auxiliary input shaft travel distance from the input shaft travel distance and transmits this to the output axis.
7. TRANSMISSION MODULE (3) When the differential gear is used to connect to the virtual main shaft This is used for operation in which the main shaft is switched or when the same drive module is used as auxiliary input to control all blocks. Virtual servomotor/ synchronous encoder Input shaft Differential gear Output shaft Virtual main shaft Auxiliary input shaft Drive module Set different drive modules for the virtual main shaft side and auxiliary input shaft side.
8. OUTPUT MODULES 8. OUTPUT MODULES Determine which of the following categories the mechanism actually controlled by the output module falls under and set the parameters in accordance with that mechanism. • Rollers.................... Section 8.1 • Ball screws............. Section 8.2 • Rotary tables.......... Section 8.3 • Cams ..................... Section 8.4 (1) Output module types (a) Roller This is set when the final output (axis) is used to carry out speed control.
8. OUTPUT MODULES (2) Device range and device data fetch of the output module parameters Such things as the device range and setting method are indicated below for the output module parameters and items that are set indirectly using devices. (a) Device range The number of device words and device range utilized when an item is set indirectly are indicated below.
8. OUTPUT MODULES (b) Device data fetch When the data of a device that has been set indirectly is switched from the REAL to VIRTUAL mode, first acquire everything as default values and thereafter carry out fetch control during virtual mode operation for the corresponding module. Shown in the table below are the fetch timing of each device and the refresh cycle of the set device.
8. OUTPUT MODULES 8.1 Rollers The operation of rollers and the parameter settings required to use rollers are explained here. 8.1.1 Roller operation This section describes the operation of the roller. (1) Operation (a) The roller speed is controlled to a speed which is the speed of the drive module multiplied by the gear ratio/speed change gear ratio of the transmission module. Drive module speed [Roller speed] = (PLS/s) × [gear ratio] × speed change gear ratio (Units: PLS) Drive module Gear...
8. OUTPUT MODULES 8.1.2 Parameter list The parameters for rollers are presented in Table 8.1, and each of the items in the table is explained in (1) to (6) below. For details on setting roller parameters, refer to the SW2SRX-GSV22PE/SW0IXCAMPE Operating Manual. Table 8.1 Parameter List No. Setting 1 Output shaft number 2 Unit setting 3 Roller diameter (L) Default Value Setting Range 0 1 to 32 mm mm inch 0 0.1 to 214748364.7 µm 0.00001 to 21474.
8. OUTPUT MODULES (3) Permissible droop pulse value (a) This is the setting for the permissible number of droop pulses at the deviation counter. (b) The deviation counter value is continually monitored, and if it becomes larger than the permissible droop pulse value, the error detection signal (M2407+20n) comes ON. However, since operation of the roller shaft continues, the user must execute the appropriate error processing.
8. OUTPUT MODULES 8.2 Ball Screws The operation of ball screws and the parameter settings required to use ball screws are explained here. 8.2.1 Ball screw operation This section describes the operation of the ball screw. (1) Operation A ball screw outputs a travel value which is the product of the drive module travel value and the gear ratio of the transmission module. [Ball screw travel value] = [transmission module travel value (PLS)] × [gear ratio] (Units: PLS) Drive module Gear...
8. OUTPUT MODULES 8.2.2 Parameter list The parameters for ball screws are presented in Table 8.2, and each of the items in the table is explained in (1) to (8) below. For details on setting ball screw parameters, refer to the SW2SRX-GSV22PE/ SW0IX-CAMPE Operating Manual. Table 8.2 Parameter List No. Setting Default Value Setting Range 0 1 to 32 1 Output shaft number 2 Unit setting mm mm inch 3 Ball screw pith (P) 0 0.1 to 214748364.7 µm 0.00001 to 21474.
8. OUTPUT MODULES (3) Permissible droop pulse value (a) This is the setting for the permissible number of droop pulses at the deviation counter. (b) The deviation counter value is continually monitored, and if it becomes larger than the permissible droop pulse value, the error detection signal (M2407+20n) comes ON. (c) When the motor connected has feedback pulses of 131072 PLS, set the value which is found by dividing the actual permissible droop pulse value by 100.
8. OUTPUT MODULES (7) Torque limit value setting device (1 word) (a) This sets the device which stores the setting for the torque limit value for the ball screw shaft. Once the device has been set, torque control is executed in accordance with the setting stored in this device. In the virtual mode, the torque limit setting is always valid. If no device setting is made, the torque limit is set at 300%. (b) The following devices can be set as the torque limit setting device.
8. OUTPUT MODULES 8.3 Rotary Tables The operation of rotary tables and the parameter settings required to use rotary tables are explained here. 8.3.1 Rotary table operation This section describes the operation of the rotary table. (1) Operation (a) A rotary table outputs a travel value which is the product of the drive module travel value and the gear ratio of the transmission module.
8. OUTPUT MODULES 8.3.2 Parameter list The parameters for rotary tables are presented in Table 8.3, and each of the items in the table is explained in (1) to (9) below. For details on setting rotary table parameters, refer to the SW2SRX-GSV22PE/ SW0IX-CAMPE Operating Manual. Table 8.3 Parameter List No.
8. OUTPUT MODULES (4) Speed limit value (VL) (a) This is the setting for the maximum speed of the rotary table shaft. (b) Set the speed limit value within the range prescribed by the following formula: 1≤ VL × 10 × ND 5 60 × 360 × 10 5 ≤ 1000000 [PLS/s] (c) If the speed of the rotary table shaft exceeds the speed limit value, the error detection signal (M2407+20n) comes ON. However, the rotary table shaft speed is not clamped.
8. OUTPUT MODULES (8) Virtual axis current value in one revolution storage device (main shaft side) (2 words) This parameter is set if an address mode clutch has been set at the rotary table main shaft side.
8. OUTPUT MODULES (f) An example of the operation of an address mode clutch is shown below. Operation Example Designate clutch ON/OFF at this current value (current value in one virtual axis revolution) 1 axis Number of PULSES per revolution: 20000 PLS 1 axis Virtual servomotor current value (synchronous encoder) Current value in one virtual axis revolution Set the clutch status clutch ON address=0 clutch OFF address=10000 0 0 10000 20000 0 10000 0 359.
8. OUTPUT MODULES (9) Virtual axis current value in one revolution storage device (auxiliary input shaft side) (2 words) This parameter is set if an address mode clutch has been set at the rotary table auxiliary input shaft side.
8. OUTPUT MODULES (f) An example of the operation of an address mode clutch is shown below. Operation Example Designate clutch ON/OFF at this current value (current value in one virtual axis revolution) 1 axis Number of PULSES per revolution: 20000 PLS 1 axis Virtual servomotor current value (synchronous encoder) Current value in one virtual axis revolution Set the clutch status clutch ON address=0 clutch OFF address=10000 0 0 10000 0 20000 10000 0 359.
8. OUTPUT MODULES 8.4 Cams (1) For axes at which the output module is set as a cam, the same action as a cam is achieved by using a ball screw model as shown in the example below. Cam Shaft System of output Module Mechanical Cam Equivalent action Cam Upper dead point Pulse generator Servo motor Reduction gear Moving part Lower dead point Upper dead point Stroke Stroke MR- -B A61P A273UHCPU A278LX (2) The following two types of data have to be set in order to use a cam.
8. OUTPUT MODULES 8.4.1 Cam operation The operation of cams is described below. (1) Procedure for switching from the REAL mode to the VIRTUAL mode On switching from the REAL mode to the VIRTUAL mode, perform device setting in accordance with the following procedure using the sequence program. (a) Set a cam number and stroke in the "cam No. setting device" and "stroke setting device" set for each axis in the cam shaft parameters.
8. OUTPUT MODULES (4) Switching the stroke and cam No. during operation (a) It is possible to change the cam stroke and effective cam number during cam operation by using the sequence program. (b) The stroke and cam No. are changed by means of the address set in the "stroke, cam No. change point" setting made when creating the cam data. When the "stroke, cam No. change point" is passed, the stroke/cam No. is changed on the basis of the value in the stroke setting device and cam No.
8. OUTPUT MODULES 2) Processing in the event of a cam No./stroke error • If the error occurs on attempting to switch from the REAL mode to the VIRTUAL mode, the VIRTUAL mode is not established. • If the error occurs on reaching the set "stroke, cam No. change point" (during cam operation), operation continues without switching to the set stroke/cam No. Reset the error detection signal and the minor error code register with the error reset command (M3207+20n).
8. OUTPUT MODULES (6) Changing control The cam shaft present value in one revolution can be changed to any required value to change cam control during operation in the VIRTUAL mode. The current value change is executed using the CHGA instruction. See Section 10.1. [Example sequence program] CHGA C1 K1234 Change request Current value in one revolution to be changed Cam No.
8. OUTPUT MODULES 8.4.2 Settings when creating cam data The settings made when creating cam data at a peripheral device are described below. Table 8.4 Table of Settings when Creating Cam Data No. Setting Default Value Setting Range 1 Cam No. See (1) 2 Resolution 256 256,512,1024,2048 3 Stroke, cam No. change point 0 0 to (resolution −1) 4 Control mode 5 Cam data table Two-way cam mode 0 •Two-way cam mode •Feed cam mode 0 to 32767 (1) Cam No.
8. OUTPUT MODULES (4) Control mode (a) This is the setting for the two-way cam mode or feed cam mode. 1) Two-way cam mode ........A two-way operation is repeated between the stroke lower limit position (lower dead point) and the range set for the stroke. Stroke Stroke lower limit position (lower dead point) Operation example Cam pattern 32767 Output value (address) Stroke 0 0 1 cycle (1 cam shaft revolution) Stroke lower limit Resolution−1 Stroke Stroke lower limit t V t 2) Feed cam mode ..........
8. OUTPUT MODULES (5) Cam data table (a) The cam data table is generated by setting the stroke ratio (when the stroke is divided into 32767 divisions) at every point in the set resolution. 32767 Cam curve Stroke Stroke ratio Lower dead point (0) 0 1 cycle (b) The cam data table is automatically generated at the peripheral device when the cam curve is created. The cam curves that can be used with the servo system CPU are indicated in Section 8.4.4.
8. OUTPUT MODULES 8.4.3 Parameter list The cam parameters are presented in Table 8.5 and item numbers 2 to 13 in the table are described in (1) through (12) below. For details on how to set the cam parameters refer to the Operating Manual for the relevant motion controller. Table 8.5 Parameter List No. 1 Setting Output shaft number Default Value Setting Range 0 1 to 32 2 Number of pulses per cam shaft revolution 0 2147483647 PLS 3 Used cam No. 4 Cam No.
8. OUTPUT MODULES (3) Cam No. setting device (1 word) (a) This is the setting for the device that sets, in the sequence program, the cam No. that is to be used for control. (b) The following devices can be used as the cam No. setting device. Data register (Note) D800 to D3069 D3080 to D8191 Link register W0 to W1FFF (Note): D800 to D1559 are devices dedicated to the virtual servo motor axes, synchronous encoder axes and output module "cams" in the virtual mode.
8. OUTPUT MODULES (c) Set the stroke within the range indicated below.
8. OUTPUT MODULES (9) Comment (a) A comment is created for purposes such as describing the application of the cam shaft. If a comment is created, it can be displayed when monitoring at a peripheral device. (b) Comments up to 32 characters long can be created. (10) Stroke lower limit value storage device (a) This is the setting for the device that stores the cam stroke lower limit value. The device stores the current stroke lower limit value.
8. OUTPUT MODULES (b) The following devices can be used as the current value in one virtual axis revolution storage device. Data register (Note-1) D800 to D3068 (Note-2) D3080 to D8190 (Note-2) W0 to W1FFE Link register (Note-1) : D800 to D1559 are devices dedicated to the virtual servo motor axes, synchronous encoder axes and output module "cams" in the virtual mode. The areas of the unused virtual servo motor, synchronous encoder and cam axes are available for the user.
8. OUTPUT MODULES (f) An example of the operation of an address mode clutch is shown below.
8. OUTPUT MODULES (12) Virtual axis current value in one revolution storage device (auxiliary input shaft side) (2 words) This parameter is set if an address mode clutch has been set at the cam auxiliary input shaft side. Drive module Virtual axis curennt value in one revolution Address mode clutch Cam Drive module (a) By setting the device to store the virtual axis current value in one revolution for the auxiliary input shaft of the cam, the current value in one revolution of the virtual axis is stored.
8. OUTPUT MODULES (f) An example of the operation of an address mode clutch is shown below.
8. OUTPUT MODULES 8.4.4 Cam curve list Cam curves which can be used in the VIRTUAL mode are discussed below. (1) Cam curve characteristics The cam curve characteristics are compared in Table 8.6 below. Table 8.6 Cam Curve Characteristics Comparison Table Class Cam Curve Acceleration Name Constant - Discontinuous curves speed Uniform (A••V)m 1.00 (V••V)m (S••V)m Remarks 1.00 1.00 ±8.00 4.00 1.09 5th 1.88 ±5.77 ±6.69 3.52 1.19 Cycloid 2.00 ±6.28 ±8.16 4.00 1.26 2.00 ±4.89 ±8.09 4.
8. OUTPUT MODULES (a) Cam data format The following is the format of cam data stored in the block No. 10 to No. 18 of the extended file register area. R0 to Registration code R6 R7 Block No. 10 R8 to R71 R72 Cam data size Cam data address table First block to Block No. 11 R8191 R0 to R8191 Cam data Cam data area Limit output data Limit output data area R0 to R327 R328 to See Section 8.4.6. R631 R632 to Block No.
8. OUTPUT MODULES R1848 to Registration code R1854 R1855 Block No. 15 R1856 to R1919 R1920 to R8191 R0 to R8191 R0 Cam data size Cam data address table Third block Cam data Cam data area to R2175 R2176 Block No. 16 to Registration code R2182 R2183 Block No. 17 R2184 to R2248 R2249 to R8191 R0 to R8191 R0 Cam data size Cam data address table Fourth block Cam data to Block No.
8. OUTPUT MODULES (b) Registration code This code is used to judge whether cam data is stored or not. 1) First block As the registration code, store the following data into R0 to R6. R0 R1 R2 R3 R4 R5 R6 00FFH 11EEH 22DDH 33CCH 44BBH 55AAH 6699H Registration code 2) Second block As the registration code, store the following data into R1520 to R1526.
8. OUTPUT MODULES (c) Cam data size Set the full byte length of the file registers where the cam data are stored. Make setting after converting the file registers from R0 to the file register No. of the last data into bytes. (One file register = 2 bytes) Example When the cam data whose resolution is 256 are stored, the cam data size is as follows.
8. OUTPUT MODULES (d) Cam data address table Set the first address from where the cam data (max. 4 blocks) are stored. Make setting after converting the first address of each cam No. into the number of bytes starting from R0. Set "0" as the first address of the unregistered cam No. 1) First block R8 R9 R10 First address of cam No. 1 First address of cam No. 2 First address of cam No. 3 R70 R71 First address of cam No. 63 First address of cam No.
8. OUTPUT MODULES (e) Cam data • Set the cam data (max. 4 blocks). The order of storing the cam data need not be in the order of the cam Nos. • Set each cam data as the stroke ratio (integer) of 0 to 7FFFH (32767). Also, the cam data requires "0" and "7FFFH (32767)" points. In the beginning of the cam data, store the control mode, cam No., resolution, and stroke/cam No. change position. (Refer to Section 8.4.2) 1) First block b15 b8 b7 b0 Control mode Cam No. Set 1 to 64 (1 to 40H).
8. OUTPUT MODULES 8.4.6 Limit switch outputs in current value mode & real current value in 1 cam revolution mode There are 2 types of limit switch outputs: • Limit switch outputs in real current value mode. • Limit switch outputs in real current value in 1 cam revolution mode. (1) Limit switch outputs in real current value mode. Limit switch outputs occur in accordance with the cam's real current value (stroke).
8. OUTPUT MODULES (b) For feed cam Limit switch output example Cam pattern 0 Limit switch output setting 0 1 cycle (1 cam shaft revolution) Operation example Output value (address) t (2) Limit switch outputs in 1 cam shaft revolution current value Limit switch outputs occur in accordance with the current value within 1 cam shaft revolution (0 to Nc−1).
8. OUTPUT MODULES (a) For two-way cam Different limit switch output patterns can be used for the feed and return strokes.
8. OUTPUT MODULES 8.4.7 Limit switch output data in current value within 1 cam revolution mode Limit switch output data can be created by the user at IBM PC which have been started up with the SW2SRX-GSV22PE software. For details regarding the limit switch output data creation procedure, refer to the SW2SRX-GSV22PE/SW0IX-CAMPE Operating Manual. (1) Limit switch output data storage area (a) The limit switch output data of the axis set to the cam axis within-onerevolution current value mode (see Section 8.4.
8. OUTPUT MODULES (c) The limit switch output data of the file register area are imported when the real mode is switched to the virtual mode. If the limit switch output data are normal, the limit switch output of the axis set to the cam axis within-one-revolution current value mode is controlled on the basis of those data. (b) Executing "write of servo setting data to PC" from the peripheral device writes the limit switch output data of the cam axis within-one-revolution current value mode to block No.
8. OUTPUT MODULES 8.4.8 Batch-changing the cam data/limit switch output data The cam data/limit switch output data stored in block No. 10 to No. 18 of the memory cassette's extended file register area are imported by the PCPU of the A273UHCPU/A173UHCPU (-S1) at power-on or reset to exercise control. Using the sequence program, the cam data/limit switch output data imported by the PCPU can be batch-changed. Change the cam data/limit switch output data in the following procedure.
8. OUTPUT MODULES (1) Write of cam data/limit switch output data to block No. 10 to No. 18 of extended file register area Cam data can be written using: • Sequence program • Peripheral device • Personal computer (a) Write using sequence program Using the transfer or exchange instruction for the cam data/limit switch output data stored in another extended file register, rewrite the cam data/limit switch output data in block No. 10 to No. 18 of the extended file register area.
8. OUTPUT MODULES (c) Write using personal computer Write the cam data/limit switch output data stored in a personal computer or like to block No. 10 to No. 18 of the extended file register area via computer link. A273UHCPU Memory cassette Write Write Computer link unit Personal computer Read Read Extended file register area block No. 10 to No. 18 Read the limit switch output data in block No.
8. OUTPUT MODULES (2) Cam data/limit switch output data batch-change program The following is the sequence program used to write the cam data/limit switch output data stored in block No. 10 to No. 18 of the extended file register area to the PCPU.
8. OUTPUT MODULES (3) Instructions (a) In the test mode using the peripheral device, a cam data/limit switch output data batch-change request is invalid. CAUTION As an interlock, provide test mode judgment (M9075) in the cam data/limit switch output data batchchange request program. (b) While the cam data/limit switch output data are being imported to the PCPU (while M2056 is ON), the real mode cannot be switched to the virtual mode.
8. OUTPUT MODULES 8.5 Common Devices (Input/Output, Internal Relays, Data Registers) The I/Os, internal relays and data registers used in the output modules are explained here. 8.5.1 Internal relays (M) (1) Internal relay (M) list (a) Status of each axis Axis No.
8. OUTPUT MODULES (b) Command signals for each axis Axis No.
8. OUTPUT MODULES (2) Internal relay (M) details (a) In-position signal (M2402+20n) 1) The in-position signal is a signal that comes ON when the number of droop pulses at the deviation counter falls below the in-position range set in the servo parameters. In-position range setting Number of drop PULSES t ON In-position OFF 2) An in-position check is performed at the following times.
8. OUTPUT MODULES (d) Servo error detection signal (M2408+20n) 1) This signal switches ON when an error (excluding causes of warning errors and emergency stops) is detected at the servo amplifier, and it is used to determine if a servo error has occurred. When an error is detected at the servo amplifier, the corresponding error code is be stored at the servo error code storage area.
8. OUTPUT MODULES (g) FLS signal (M2411+20n) 1) The FLS signal is controlled according to the ON/OFF status of upper limit switch inputs (FLS) to the A278LX or A172SENC from an external source. • Upper limit switch input OFF ......... FLS signal ON • Upper limit switch input ON........... FLS signal OFF 2) The upper limit switch (FLS) status at FLS signal ON/OFF is shown below.
8. OUTPUT MODULES (j) DOG signal (M2414+20n) 1) The DOG signal is controlled according to the ON/OFF status proximity dog inputs to the A278LX, A172SENC from an external source. 2) Regardless whether "N/O input" or "N/C input" is designated in the system settings, the DOG signal turns ON when the proximity dog signal is ON, and the proximity dog signal turns OFF. 3) If "N/O input" is designated in the system settings, the proximity dog input turns ON when the proximity dog signal turns ON.
8. OUTPUT MODULES (o) Error reset command (M3207+20n) The error reset command is used to clear the minor error codes and major error codes of axes for which errors have been detected (M2407+20n: ON) and to reset the error detected signal (M2407+20n).
8. OUTPUT MODULES Stroke amount Stroke lower limit 0 Feed current value when M3214+20n is ON (bottom dead center) 1 cycle Nc−1 Current value within 1 cam shaft revolution = 0 • After the system is started and cam's bottom dead center alignment is completed, YnE must be switched ON the first time REAL to VIRTUAL mode switching occurs. Once the bottom dead center setting has been designated, it is not necessary to switch M3214+20n ON when subsequent REAL to VIRTUAL mode switching occurs.
8. OUTPUT MODULES (r) Servo OFF command (M3215+20n) The servo OFF command is used to switch the servo OFF (free run status). • M3215+20n: OFF .......... Servo ON • M3215+20n: ON............ Servo OFF (free run status) This command is inoperative during positioning, and should therefore be executed after positioning is completed. When the servo OFF command occurs in the VIRTUAL mode, the clutch will be disengaged before the servo OFF command is executed.
8. OUTPUT MODULES 8.5.2 Data registers (D) (1) Data register (D) list (a) Monitor devices of each axis Axis No.
8. OUTPUT MODULES (b) Control change registers Axis No.
8. OUTPUT MODULES (c) Cam shaft monitor device Axis Device Number No.
8. OUTPUT MODULES (d) Feed current value/Roller peripheral velocity register (D0+20n, D1+20n) ....................................................................... Data sent from PCPU to SCPU 1) The target address which is output to the servo amplifier is stored at this register. The target address is based on the command address calculated from the mechanical system program settings. 2) A stroke range check occurs at this feed current value data. 3) Roller peripheral velocity is stored.
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART 9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART This section discusses the procedure for switching between the REAL and VIRTUAL modes, and the data items which are checked when such switching occurs. (1) Switching between the REAL & VIRTUAL modes Switching between the REAL & VIRTUAL modes is executed by switching the M2043 signal (REAL/VIRTUAL switching request flag) ON and OFF. • For REAL mode ..........
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART Table 9.
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART (2) Output module check (a) The items shown in Table 9.2 below are checked to determine the output module status. If an error is found, switching to the VIRTUAL mode will not occur, and the corresponding system cannot be started. When an error exists, switch back to the REAL mode and correct the error cause, then switch to the VIRTUAL mode again.
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART (3) Synchronous encoder axis check (a) The items shown in Table 9.3 below are checked to determine the synchronous encoder status. If an error is found, switching to the VIRTUAL mode will not occur. Error causes can only be corrected by switching back to the REAL mode.
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART 9.2 Switching from the VIRTUAL to REAL Mode VIRTUAL to REAL mode switching can be conducted by the user or by the OS. • By user ......... Switch M2043 OFF • By OS........... Switching occurs automatically when a servo error is detected. 9.2.1 VIRTUAL to REAL mode switching by user (1) When a VIRTUAL to REAL mode switching request (M2043 ON→OFF) occurs, the item shown in Table 9.4 is checked. If normal, switching to the REAL mode will occur.
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART 9.3 Precautions When Switching between REAL and VIRTUAL Modes The precautions when switching between the REAL and VIRTUAL modes are described below. (1) The SVST and CHGA/CHGV instructions are inoperative during REAL/VIRTUAL mode switching processing (indicated by asterisks * in the timing chart below). If one of these instructions is attempted at such a time, an error will occur at the START point.
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART (2) During TEST mode operation, M2043 ON/OFF (REAL/VIRTUAL mode switching request) switching from a peripheral device is ignored. During TEST mode operation, REAL/VIRTUAL mode switching can be executed from a peripheral device. M2044 will switch ON/OFF in accordance with the REAL/VIRTUAL mode status. REMARK When REAL/VIRTUAL mode switching is executed from a peripheral device, the data which is checked is identical to that checked at M2043 OFF→ON and ON→OFF.
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART 9.4 STOP & RESTART The basic method for stopping the system (output module) during VIRTUAL mode operation is to stop the main shaft. If an auxiliary input shaft is being used, that shaft should also be stopped. (1) Virtual Axis STOP The procedures for stopping and restarting the virtual shaft, and the stop processing details are discussed below. A virtual servo motor axis can be stopped by the 3 types of stop processing shown below.
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART Affected Virtual Axis No.
9. REAL & VIRTUAL MODE SWITCHING AND STOP/RESTART Error Set Output Module Operation • Deceleration to stop based on smoothing time constant. • Deceleration to stop based on smoothing time constant. Operation Continuation ENABLED (!)/ DISABLED (×) ! • Resume operation by switching the stop command OFF (not necessary when ON) and executing a START. ! • Resume operation by switching the stop command OFF (not necessary when ON) and executing a START.
10. AUXILIARY/APPLIED FUNCTIONS 10. AUXILIARY / APPLIED FUNCTIONS 10.1 Current Value Change / Speed Change Virtual servo motor current value changes, speed changes, and synchronous encoder current value changes are explained here. Current value changes are carried out using the CHGA instruction while speed changes are performed using the CHGV instruction. For details regarding the CHGA and CHGV instructions, refer to the Motion Controller (SV13/22 REAL Mode) Programming Manual (type A273UH/A173UH). 10.1.
10. AUXILIARY / APPLIED FUNCTIONS (3) Synchronous encoder current value change program Encoder No. setting Command M2044 Current value setting M2101 CHGA E1 K2 (a) The change in the current value and speed are set using the devices described below. • Indirect setting.............Data register (D) Link register (W) Double word File register (R) • Direct setting ...............Decimal constant (K) (b) The encoder No. setting range is described below.
10. AUXILIARY / APPLIED FUNCTIONS 10.2 Improved Current Value Management By adding the functions described below, current value management when using an absolute encoder has been improved. (1) Added functions (a) An encoder data validity check is now possible during operation. • It is checked whether the amount of change at the encoder in 3.5ms intervals corresponds to rotation within 180° at the motor shaft. (If abnormal, an error is displayed.
10. AUXILIARY / APPLIED FUNCTIONS (3) Restrictions due to servo amplifier The following restrictions apply depending on the combination of servo amplifier and positioning software package used when using positioning OS version V or later.
11. ERROR CODES STORED AT THE PCPU 11. ERROR CODES STORED AT THE PCPU Errors detected at the PCPU include servo program setting errors, positioning errors, and control mode switching errors. (1) Servo program setting errors Servo program setting errors consist of errors in the positioning data designated at the servo program. A check occurs for these errors each time a servo program is started.
11. ERROR CODES STORED AT THE PCPU (b) When an error occurs, the error detection signal for the axis in question will switch ON, and the corresponding error code will be recorded in the minor error code, major error code, or servo error code storage register.
11. ERROR CODES STORED AT THE PCPU (3) REAL/VIRTUAL mode switching errors A check for REAL/VIRTUAL mode switching errors occurs when the REAL/VIRTUAL mode switching request flag (M2043) switches from OFF to ON, and from ON to OFF. (See Sections 9.1 and 9.2 for the check content.) If an error is found, the following occur: • REAL/VIRTUAL mode switching will not occur, and the current mode will be maintained. • The REAL/VIRTUAL mode switching error detection flag (M2045) switches ON.
11. ERROR CODES STORED AT THE PCPU 11.1 Related Systems & Error Processing The following 2 types of related systems exist in the VIRTUAL mode. (1) System consisting of a drive module and output module. (2) Multiple systems using the same drive module. The following occurs when an error is detected at an output module. (1) If an error is detected at any output module, a drive module START will be impossible, and that system will be disabled.
11. ERROR CODES STORED AT THE PCPU 11.2 Servo Program Setting Errors The error codes, error descriptions, and corrective actions for servo program setting errors are shown in Table 11.1 below. The "n" in the asterisked error codes in Table 11.1 indicates the axis number (1 to 32). Table 11.1 Servo Program Setting Error List Error Codes Stored at D9190 1 Error Name Parameter block No.
11. ERROR CODES STORED AT THE PCPU Table 11.
11. ERROR CODES STORED AT THE PCPU Table 11.1 Servo Program Setting Error List (Continued) Error Codes Stored at D9190 902 903 904 Error Name The instruction code at the designated START is disabled. servo program cannot be decoded due to an instruction code error. A VIRTUAL mode program was started START is disabled. when in the REAL mode. START error A REAL mode program was started when in the VIRTUAL mode.
11. ERROR CODES STORED AT THE PCPU 11.3 Drive Module Errors Table 11.
11. ERROR CODES STORED AT THE PCPU Table 11.
11. ERROR CODES STORED AT THE PCPU Table 11.2 Drive Module Error List (100 to 1199) (Continued) Error Class Error Code Positioning Fixed pitch Feed Speed Virtual Servo Axis Control Item Man- SyncSpeConual hroned stant JOG Pulse ous Swit- SpeGene Encching ed -rator oder ! 215 ! 220 ! 225 300 Position Follow-Up ! ! ! ! ! ! ! ! Error Cause • The address of the speed switching point exceeds the END point address.
11. ERROR CODES STORED AT THE PCPU 11.4 Servo Errors Servo errors are classified into servo amplifier errors and servo power supply module errors. You can set to each system what processing will be performed at servo error detection. (Only servo errors detected by the ADU (when the A273UHCPU is used)) Set the processing and system in the system settings of the peripheral device.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) Error Code Amplifier Type A Error Cause Name P-N non-wiring 2010 M A Low voltage Internal memory alarm • P-N of the servo power supply module are not wired to P-N of the ADU. • The power supply voltage is less than 160 VAC. (320VAC or less for 400VAC series servo) • A momentary power, interruption of 15ms or longer has occurred.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type Error Cause Name A 2020 Encoder error 2 M 2021 M Converter RD off (400VAC series servo only) 2024 M Output ground fault A Absolute position erase 2025 M 2026 2030 A M Description When Error Checked Battery alarm Module mismatch Excessive regeneration • The servo-on (SON) signal turned ON when the ready signal (RD) of the converter is OFF. 1.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type Error Cause Name Description • The servo motor connected is not as set. • The U, V, and W phases of the ADU output resulted in a short circuit or ground fault. A 2032 Overcurrent When Error Checked M Overvoltage • Correct the servo motor wiring. • Damage to the ADU's transistor module. • ADU fault. • Change the ADU. • Coupling fault of servo motor and encoder.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type Error Cause Name Description When Error Checked Error Processing Corrective Action • The command speed is too high. • Reconsider the command speed. M • Servo system CPU fault. • There is excessive variation in the position commands from the servo system CPU; commanded speed is too high. • Noise has entered the commands from the servo system CPU.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type A Error Cause Name Overload Description When Error Checked Error Processing • The rated current of the servo motor is exceeded. • Reduce the load. • Hunting due to parameter setting mistake. • An overload current of about 200% has been continuously supplied to the servo amplifier and servomotor. • Load inertia or friction is too large. • Reconsider the servo parameters.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type Error Cause Name A 2052 Excessive error Description When Error Checked Error Processing • The deviation counter value exceeded the specified value. • Inertia is too large to make enough acceleration. • Reconsider the servo parameters. • Encoder or cable fault. • The droop pulses of the deviation counter exceeded the error excessive alarm level set in the servo parameters.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type Error Cause Name Description When Error Checked Error Processing • The parameter that was set is unauthorized.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type Error Cause Name When Error Checked Description Error Processing • The servo parameter value is outside the setting range. (Any unauthorized parameter is ignored and the value before setting is retained.
11. ERROR CODES STORED AT THE PCPU Table 11.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type Error Cause Name Description • The parameter that was set is unauthorized.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type Error Cause Name Description • The parameter setting is wrong. • The parameter data was corrupted.
11. ERROR CODES STORED AT THE PCPU Table 11.3 Servo Amplifier Error List (2000 to 2799) (Continued) Error Code Amplifier Type Error Cause Name Description • The parameter setting is wrong. • The parameter data was corrupted.
11. ERROR CODES STORED AT THE PCPU (2) Servo power supply module errors (2800 to 2999) The servo power supply module errors are detected by the servo amplifier and assigned error codes 2800 to 2999. When any of the servo errors occurs, the servo error detection signal (M2408+20n) turns ON. Eliminate the error cause and turn ON the servo error reset (M3208+20n) to reset the servo error, and make a restart.
11. ERROR CODES STORED AT THE PCPU 11.5 Output Module Errors (1) Output module errors at REAL→VIRTUAL mode switching (4000 to 5990) Table 11.
11. ERROR CODES STORED AT THE PCPU Table 11.5 Output Module Error List (4000 to 5990) (Continued) Error Class Minor Errors Error Code Output Drive Modu- Module le Output Module Roller Ball Screw Rotary Table Cam Error Cause Processing Corrective Action 5260 526! " 5270 527! " 5280 528! " " " " 5290 529! " " " " 5300 530! " " " " 5310 531! " " " " 5320 532! " " " " 5330 533! " " " " • Stroke setting device is out of range.
11. ERROR CODES STORED AT THE PCPU (2) "No-clutch/clutch ON/clutch status ON" output module errors (6000 to 6990) Table 11.
11. ERROR CODES STORED AT THE PCPU (3) Output module errors when clutch OFF and clutch OFF command issued (6500 to 6990) Table 11.6 Output Module Error List (6500 to 6990) (Continued) Error Class Error Code Output Drive Modu- Module le 6500 6510 Minor Errors 6520 6530 6540 650! Output Module Roller " Ball Screw " Rotary Table " Cam " " 651! " 652! " 653! " " " 654! Error Cause Processing • A servo OFF status existed when a clutch ON command occurred. Clutch remains OFF.
11. ERROR CODES STORED AT THE PCPU (5) Output module errors at VIRTUAL servo mode axis START (10000 to 10990) Table 11.8 Output Module Error List (10000 to 10990) (Continued) Error Class Error Code Output Drive Modu- Module le Output Module Roller Ball Screw Rotary Table Error Cause Cam • The zeroing return request (M2409 + 20n) is ON. Major Errors 10000 1000! 10010 1001! 10020 1002! 10030 1003! " " " " " " " " " " " " " " " Processing START disabled at related systems.
11. ERROR CODES STORED AT THE PCPU (7) Errors when using an absolute position system (12000 to 12990) Table 11.
11. ERROR CODES STORED AT THE PCPU 11.6 Errors At REAL ↔ VIRTUAL Mode Switching Table 11.12 REAL↔VIRTUAL Mode Switching Error Code List Error Codes Stored at D9193 Decimal Hexadecimal Display Display 1 0001 256 0100 512 0200 513* 0201 514* 0202 515* 0203 516* 0204 519* 0207 Error Description Corrective Action • M2043 OFF → ON switching occurred when all axes were not stopped. • M2043 ON → OFF switching occurred when all axes were not stopped.
11. ERROR CODES STORED AT THE PCPU Table 11.12 REAL↔VIRTUAL Mode Switching Error Code List (Continued) Error Codes Stored at D9193 Decimal Hexadecimal Display Display − 4094 F002 − 4095 F001 − 4096 F000 Error Description Corrective Action • During VIRTUAL mode operation, the PLC • Switch M2000 ON. READY signal (M2000) switched OFF, and • Designate the servo system CPU "RUN" the system returned to the REAL mode. status. • The servo system CPU stopped during VIRTUAL mode operation.
APPENDICES APPENDICES APPENDIX 1 Cam Curves The cam acceleration curve formulas used in the VIRTUAL mode are shown below. (1) Acceleration curve formula •A : Dimensionless acceleration • Am : Dimensionless maximum acceleration •T : Dimensionless time • Ta, Tb, Tc : T borderlines when section divisions are used (a) Discontinuous curve 1) Constant-speed curve A = C0 2) Uniform acceleration curve Section I (0 ≤ T ≤ 0.5) A = 4 + C0 Section II (0.
APPENDICES 4) Distorted sine curve 1 Ta = 8 1 Am = 2Ta π + 2 − 8Ta π 2 Section I (0≤T≤Ta) πT + C0 A = Amsin 2Ta Section II (Ta
APPENDICES (c) Both-side stationary asymmetrical curve 1 )Trapecloid curve 1 Ta = 8 2 − 6Ta +πTa Tb = 2+π 2 − 2Ta +3πTa Tc = 2+π 1 Am = (− 3 2 + 4 π + 4 π 2 2 ) T a + (1 + 2 π ) TaTb + 1 2 2 T b+( 2 π − 4 ) (1 − π Tc) 4 ) (1 − π Tc) 2 2 Section I (0≤T≤Ta) πT + C0 A = Amsin 2Ta Section II (Ta
APPENDICES Section II (1−Tc
APPENDICES APPENDIX 2 Processing Time List Shown below are each processing time signal and command when position control is carried out in relation to the servo system CPU. (1) Motion operation cycle (ms) CPU A273UHCPU A173UHCPU(-S1) Number of set axes 1 to 8 9 to 18 19 to 32 1 to 12 Operation cycle 3.5ms 7.1ms 14.2ms 3.5ms 13 to 24 25 to 32 7.1ms 14.
APPENDICES (5) Each axis status Axis Device Number No.
APPENDICES (6) Command signals of each axis Axis Device Number No.
APPENDICES (7) Virtual servo motor axis status Axis Device Number No.
APPENDICES (8) Virtual servo motor axis command signals Axis Device Number No.
APPENDICES (9) Synchronous encoder axis status Axis No.
APPENDICES (11) Common devices (! ! Valid) Device Number M2000 M2001 M2002 M2003 M2004 M2005 M2006 M2007 M2008 M2009 M2010 M2011 M2012 M2013 M2014 M2015 M2016 M2017 M2018 M2019 M2020 M2021 M2022 M2023 M2024 M2025 M2026 M2027 M2028 M2029 M2030 M2031 M2032 M2033 M2034 M2035 M2036 M2037 M2038 M2039 M2040 M2041 M2042 M2043 M2044 M2045 M2046 M2047 M2048 M2049 M2050 M2051 M2052 M2053 M2054 M2055 M2056 M2057 M2058 M2059 M2060 M2061 M2062 M2063 M2064 M2065 M2066 M2067 M2068 M2069 M2070 M2071 M2072 M2073 M2074 M207
APPENDICES (! ! Valid) Device Number Signal Direction Refresh Cycle Preset number of axes (Note-1) 1 to 8 9 to 18 19 to 32 1 to 12 13 to 24 25 to 32 Real Virtual ! ! SCPU←PCPU END (Note-2) — — — — × ! SCPU←PCPU END (Note-2) Unusable (15 points) — — — — Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Axis 7 Axis 8 Axis 9 Axis 10 Axis 11 Axis 12 Axis 13 Axis 14 Axis 15 Axis 16 Axis 17 Axis 18 Axis 19 Axis 20 Axis 21 Axis 22 Axis 23 Axis 24 Axis 25 Axis 26 Axis 27 Axis 28 Axis 29 Axis 30 ! !
APPENDICES (! ! Valid) Device Number M2158 M2159 M2160 M2161 M2162 M2163 M2164 M2165 M2166 M2167 M2168 M2169 M2170 M2171 M2172 M2173 M2174 M2175 M2176 M2177 M2178 M2179 M2180 M2181 M2182 M2183 M2184 M2185 M2186 M2187 M2188 M2189 M2190 M2191 M2192 M2193 M2194 M2195 M2196 M2197 M2198 M2199 M2200 M2201 M2202 M2203 M2204 M2205 M2206 M2207 M2208 M2209 M2210 M2211 M2212 M2213 M2214 M2215 M2216 M2217 M2218 M2219 M2220 M2221 M2222 M2223 M2224 M2225 M2226 M2227 M2228 M2229 M2230 M2231 M2232 M2233 M2234 M2235 M2236 M
APPENDICES (! ! Valid) Device Number M2240 M2241 M2242 M2243 M2244 M2245 M2246 M2247 M2248 M2249 M2250 M2251 M2252 M2253 M2254 M2255 M2256 M2257 M2258 M2259 M2260 M2261 M2262 M2263 M2264 M2265 M2266 M2267 M2268 M2269 M2270 M2271 M2272 M2273 M2274 M2275 M2276 M2277 M2278 M2279 M2280 M2281 M2282 M2283 M2284 M2285 M2286 M2287 M2288 M2289 M2290 M2291 M2292 M2293 M2294 M2295 M2296 M2297 M2298 M2299 M2300 M2301 M2302 M2303 M2304 M2305 M2306 M2307 M2308 M2309 M2310 M2311 M2312 M2313 M2314 M2315 M2316 M2317 M2318 M
APPENDICES (12) Monitor devices of each axis Axis Device Number No.
APPENDICES (13) Control change registers Axis No.
APPENDICES (14) Virtual servo motor axis monitor devices Axis Device Number No.
APPENDICES (15) Virtual servo motor axis main shaft differential gear present value Axis Device Number No.
APPENDICES (16) Synchronous encoder axis monitor devices Axis No.
APPENDICES (18) Cam axis monitor devices Axis Device Number No.
APPENDICES (19) Common devices (! ! Valid) Device Number D704 D705 D706 D707 D708 D709 D710 D711 D712 D713 D714 D715 D716 D717 D718 D719 D720 D721 D722 D723 D724 D725 D726 D727 D728 D729 D730 D731 D732 D733 D734 D735 D736 D737 D738 D739 D740 D741 D742 D743 D744 D745 D746 D747 D748 D749 D750 D751 D752 D753 D754 D755 D756 D757 D758 D759 D760 D761 D762 D763 D764 D765 D766 D767 D768 D769 D770 D771 D772 D773 D774 D775 D776 D777 D778 D779 D770 D781 D782 D783 D784 D785 D786 D787 D788 D789 D790 D791 D792 D793 D794
APPENDICES (20) Special Relays Device No.
APPENDICES APPENDIX 3 Setting Range of Indirect Setting Devices Appendix 3.1 Servo program All settings by servo programs (positioning address, commanded speed, M-code, etc.) can be designated indirectly by PLC devices, excluding the axis numbers. (1) Device ranges The number of device words and device range in indirect designation are shown below.
APPENDICES POINT ⋅ Be sure to designate even-numbered devices for 2-word designation items. Be sure to use the DMOV(P) instruction when setting data in these devices by sequence programs. (2) Device data fetch Data for indirectly designated devices is fetched by the PCPU at the start of the servo program. For this reason, set data in the devices before starting the servo program, and never change the devices unless servo program start is complete.
APPENDICES Appendix 3.2 Mechanical system program The device range and setting method for items indirectly set by devices in the parameters of each module of the mechanical system program are given here. (1) Device ranges The number of device words and device ranges when settings are made indirectly are given in the table below.
APPENDICES (2) Device data fetch When the data of a device that has been set indirectly is switched from the REAL to VIRTUAL mode, first acquire everything as default values and thereafter carry out fetch control during virtual mode operation for the corresponding module. Shown in the table below are the fetch timing of each device and the refresh cycle of the set device.
APPENDICES APPENDIX 4 Magnitude Comparison and Four Fundamental Operations of 32-Bit Monitor Data When a machine value, real current value or deviation counter value is used to perform magnitude comparison or four fundamental operations, the value must be transferred to another device memory once and the device memory of the transfer destination be used to perform processing as described below.
APPENDICES (2) Four fundamental operations example To divide the real current value by the set value Execution command DMOVP S D / D1 D1 D2 D3 1) S, D1, D2 and D3 indicate the following.
HEAD OFFICE:MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100 TELEX: J24532 CABLE MELCO TOKYO NAGOYA WORKS : 1-14 , YADA-MINAMI 5 , HIGASHI-KU , NAGOYA , JAPAN IB (NA) 0300029-A (0106) MEE Printed in Japan Specifications subject to change without notice.
