Yaskawa Electric America Understanding & Applying Camming Techniques iec Yaskawa Electric America Understanding & Applying Camming Techniques with MP2000iec / MotionWorks IEC TP.MCD.09.056 To make this Café enjoyable for all, please follow these tips on web class etiquette. Please do not put us on hold. Others will hear the hold music. Do not use a speaker phone. Background noise can be heard. Don’t be shy, we welcome comments and questions. (Press *6* to un-mute your phone to speak) Questions not answered during the eCafé can be e-mailed to motioninfo@yaskawa.com or can be entered into the survey at the end of the class.

Six Essential Camming features Webinar Highlights Camming Overview Core Concept Six Essential Camming features Data Management Function Blocks Parameters Engage Modes Adjust Modes Block Diagram Application Discussions Rotary Knife Linear Flying Shear Feed to Length

Mechanical Origin Shaft rotation Linear motion Camming Overview Mechanical Origin Shaft rotation Represents the master Typically a 360 cycle Linear motion Position is dictated by the angular position of the shaft Lots of limitations with mechanical cams

Camming Overview Core Concept Electronic Camming controls the positional relationship of two axes Time Master Position 360 Slave Position 3.00 360 3.00 Repeat

That’s It! Camming Overview Everything else relates back to the core concept. Positional relationship of two axes. Master can be a servo, external encoder, or time (virtual master.) Time Master Position 360 Slave Position 3.00 360 3.00 Repeat

(OK we lied) There’s more Camming Overview (OK we lied) There’s more Master / Slave lookup table is the core with these surrounding topics We will focus on these six supporting features

All functions customized by Yaskawa Camming Overview On the Surface…. 10 Function blocks Firmware Library PLCopen-v_2_2 All functions customized by Yaskawa Based on: PLCopen specification Previous controllers cam technology Decades of synchronized motion experience The cam engine operates at the Mechatrolink update rate. Camming performance not dependant on application scan rate.

Camming Overview Below the Surface…. Camming Block Diagram

Function Block Breakdown Camming Overview Function Block Breakdown 4 functional topics

Common Theme: CamTableID Cam Data Management

Two basic methods for loading cam data Cam Data Management Two basic methods for loading cam data Externally generated Internally generated These functions are only required once per power up. If the same cam is disengaged and re engaged, the CamTableID remains valid until Y_ReleaseCamTable or power is cycled.

Cam Data Management Application Task Rate Mechatrolink Update Rate

External Source: Cam Tool or Excel Controller File System Cam Data Management Computer Disk External Source: Cam Tool or Excel Controller File System Cam Memory Other methods for sending files will be addressed

Data Structure Cam Data Management Watch window is a great place to verify the correct data has been applied Data Structure

All Cam DataTypes included in New Project Template Cam Data Management Code Example All Cam DataTypes included in New Project Template

Cam Engagement

Cam Masters Virtual External Encoder Another Mechatrolink Axis Cam Engagement Cam Masters Virtual External Encoder LIO-01, LIO-02, LIO-06 Quadrature pulses only Another Mechatrolink Axis Programming is identical regardless of master type. AXIS_REF function block input is a logical reference.

Capabilities & Performance Cam Engagement Capabilities & Performance Multiple methods for engaging based on application scenarios. Function block input parameter lets the programmer decide how the slave should engage to the master.

Engage Modes Cam Engagement ‘AtPosition’ is ideal if the master is already moving. ‘Immediate’ is best in situations when the master is stationary, and the slaves cannot wait idle for the master to move a portion of the cycle, such as during E-Stop recovery.

Cam Engagement Starting the process 1440 1080 720 360 360 360 360 360

Cam Engagement Engage Window Details The window allows for detecting the Engage Position while the master is at speed. Determining an optimal value Maximum master speed * Mechatrolink rate * 2 Extremely large window will cause the slave to jump to the corresponding cam table position. Master slave relationship not affected by window size. Extremely small window may cause the slave not to engage. Controller might never see the master in the window. Default window size is 1% of the master cycle, which is appropriate for most applications. Small (normal) window Jump Large (oversized) window

On-The-Fly Adjustments Identical function blocks, except for one input On-The-Fly Adjustments

On-The-Fly Adjustments Shifting Master Side Adjustment Useful when a registration mark detects products on the master axis Slave pattern is unchanged Master Slave Shifting is a controlled slippage of the red cam lobe on the black shaft

On-The-Fly Adjustments 90 degree shift 180 degree duration

On-The-Fly Adjustments Scaling Slave Side Adjustment Simple Multiplier on all data points Slave pattern can be magnified or reduced. No way to do this on a mechanical cam!

On-The-Fly Adjustments Slave Offset Slave Side Adjustment Simple Addition to all data points Slave pattern can will be the same, but repositioned over a different range. Master Slave

On-The-Fly Adjustments

On-The-Fly Adjustments AdjustMode We’ve described the three types of adjustments, now lets discuss the “When” and “What.” When should the adjustment start? When must the adjustment finish? What is the profile from A to B? Detailed help is available by right clicking on any function block!

On-The-Fly Adjustments Finish AdjustModes Three types Master Distance The adjustment starts immediately and completes when the master has traveled the specified Master Distance. Within Range The adjustment starts when the master first crosses the StartPosition and completes when the master reaches the EndPosition. Time The adjustment starts immediately and completes within the specified Time (in seconds). Same Profile Modified Sine profile sweeps the correction profile from the current to requested adjustment. Built into the firmware Start

On-The-Fly Adjustments Smooth Motion Adjustments

On-The-Fly Adjustments AdjustMode – Type 1 Y_AdjustMode#MasterDistance The adjustment starts immediately and completes when the master has traveled the specified relative Master Distance. Master speed dictates the amount of time required to complete the correction 360 90 180 270 Master Position 180 Degrees LREAL#72.0 Y_AdjustMode#MasterDistance LREAL#180.0 n/a n/a n/a Y_CamShift.Execute

On-The-Fly Adjustments AdjustMode – Type 2 Y_AdjustMode#Duration The adjustment starts immediately and takes place over a time period. This is a non-synchronized correction method. Correction is the same regardless of machine speed. Good method if adjustment value known before engaging the slave. Set Duration to zero for instantaneous correction. 360 90 180 270 Master Position ? 2.5 Seconds LREAL#72.0 Y_AdjustMode#Duration n/a LREAL#2.5 n/a n/a Y_CamShift.Execute

AdjustMode – Type 3 On-The-Fly Adjustments Y_AdjustMode#WithinRange The adjustment starts when the master is within the StartPosition and is scaled to complete when the master reaches the EndPosition. This mode is for applications that must move at synchronized speeds during certain portions of the cycle 360 90 180 270 Master Position 180 to 270 degrees LREAL#72.0 Y_AdjustMode#WithinRange n/a n/a Waiting… LREAL#180.0 LREAL#270.0 Y_CamShift.Execute

Axis Parameters Crucial to establishing the proper operation by coding interlocks and other logical functions.

Block Diagram

Capabilities & Performance Use parameter 1541, CamTableIDEngaged in cases like this to verify the currently operating profile Capabilities & Performance Change cam data on the fly CamTableID can be changed and Y-CamIn can be re-executed during motion. Allows for use of multiple profiles with similar, yet different characteristics. Pick a location where the slave data is the same for a seamless switchover.

Capabilities & Performance OPC Cam data transfer Set the cam data (Y_MS_Cam_Struct) as an OPC variable, and a PC or HMI can send updated cam data to the controller. Execute Y_CamStructSelect or Y_WriteCamTable to load the new cam data.

Capabilities & Performance Hundreds of small cam tables or dozens of large cam tables can be loaded into the controller flash memory. Exact size dependant on other application data stored in flash, such as IEC 61131 source code. HTTP file transfer is another method for cam file download. Useful for PC HMI applications

Application Discussions

Application Discussion Rotary Placer – The Placer Cycle Pick Position Pick On Pick Decision Window Place Angle Adjust Region 0 deg 90 deg Product Flow Pick Threshold Product Sensor DistToLatch ProductPitch (MasterCycle) MaxShift MaxShiftThreshold [A] 1:1 Match Point (PickPosition - PickOn) [%] mCamShiftRemaining

Application Discussion Rotary Placer – The Product Buffer

Application Discussion Rotary Placer – The Cam Shift Uses #WithinRange adjust mode

Linear Flying Shear Out & Back slave Application Discussion Linear Flying Shear Out & Back slave Synchronized to product by registration mark

Application Discussion Flat part of the speed graph is the area where the master & slave are synchronized. Linear Flying Shear Out Back

Application Discussion Assembly Machine Rotary Table Assembly Stations Camming Benefits Station synchronization at any machine speed Use Virtual Master if Rotary table must stop during station operation Variable number of operable stations Table Station 1 Station 2 Station 3 Station 4 Station 5

Application Discussion PC Activity MP2300Siec Activity OPC or Modbus CamFlagID Changed Y_CamIn.Execute CamState=3 PC Cam Selector CamFile download to RAM Set Next Use Cam Info Check for Next Use Cam Flag Y_CamFileSelect Cam Switch Logic Y_CamIn Y_ReleaseCamTable To know current cam being used For Needle location (Stitch #) CamSequenceStruct MC_ReadActualPosition Next Cam Selector Logic Circular usage of cam tables controlled by Array of CamSequenceStruct

Conclusion Camming with the MP2000iec series requires an understanding of these pieces: Other Resources: EM.MCD.09.043 = Manual for Simple Cam from CSV file MC.MCD.09.044 = Example Code for Simple Cam from CSV file