Welcome to Yaskawa Electric America’s Training Café Express Today’s Topic is Advanced Camming Made Easy With Cam Toolbox iec Audience: Channel Partners, Reps, Customers and Associates Hosts: Kevin Hull and Doug Meyer Date: March 19, 2010. 10am-12Noon CDT

Housekeeping Items 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. Please Mute Yourself when not contributing to the discussion. (Press *6* to mute and unmute your phone) Don’t be shy, we welcome comments and questions. You can also type questions into the “CHAT” window. Please send to Host, Presenter and Panelists if you choose this option. The presenter will try to stop between sections to answer any questions that build up in the Chat window. Questions not answered during the Café can be e-mailed to training@yaskawa.com or can be entered into the survey sent to you at the end of the class.

Agenda Part 1 – Sales Agenda (10:00am – 10:45am CDT) Toolbox Overview Yaskawa Camming Implementation PLCopen Execution in Motion Engine Cam Toolbox functions CamToolbox Focus CamGenerator Profile calculation and update on the controller CamBlend Enhanced engage / disengage functionality Suitable Applications Competitive Comparison Q&A

Agenda Part 2 – Technical Agenda (10:45am – 12 Noon CDT) Example Application Rotary Knife (flying cut-to-length) CamTool Refresher Old school way to enter data Review of IEC61131-3 Datatype Structures Why they are useful and powerful How they are implemented CamGenerator New school Profile calculation on the controller CamBlend Enhanced engage / disengage functionality

Automation Hierarchy “The Machine” Mechanical linkages & actuators MotionWorks IEC Project Motion Engine (firmware) Software Machine Controller Servo Amplifiers Machine Control Network Sensors & solenoids “The Machine” Mechanical linkages & actuators Servo Motors Hardware (BOM)

Implementation Time A clear machine-building trend has been to replace mechanical machine control elements with electronic elements – replace Hardware with Software. This has shifted the time required to implement each element and consequently shifted the focus for enhancing productivity and efficiency. Mechanism-centric Electronic-centric Controls Mechanics Block of Time Controls Mechanics

Automation Hierarchy “The Machine” Mechanical linkages & actuators MotionWorks IEC Project PLCopen Function Blocks Toolboxes Customized User functions Machine Controller Servo Amplifiers Machine Control Network Sensors & solenoids “The Machine” Mechanical linkages & actuators Servo Motors Motion Engine (firmware)

Application Toolbox Kickoff Announcing Yaskawa’s Application Toolboxes This webinar serves as the official kickoff to promote the Application Toolboxes as a sales tool. Almost two years in the making Supporting documentation created Web page updated MP2000iec product page Link to “Application Code Toolboxes”

Express & Pro Versions New Manual No login required! New Web Page

Inserting User Libraries Basic Steps… Download from www.yaskawa.com Extract in MotionWorks IEC Open Your Project Insert User Libraries Your Project User library functions Firmware library functions

Why Yaskawa created toolboxes Toolbox Summary Why Yaskawa created toolboxes While PLCopen function blocks provide a basic to moderate level of built-in functionality, nearly all applications still require an extra level of programming and integration for robust and reliable operation. Our goal is to provide the highest level of support for the MP2000iec controller products, so we created additional functions that provide the machine builder or integrator with a range of commonly required code sequences to further reduce development time.

What's included? What’s the benefit? Toolbox Summary 5 toolboxes 12 datatypes 41 functions providing enhanced functionality And the list keeps growing What’s the benefit? Reduced development time anywhere from one hour to one week per function used.

What’s the cost? Toolbox Summary They’re FREE We offer these tools at no charge to help our channel partners, integrators, and customers become more successful.

What’s the future for Toolboxes? Toolbox Summary What’s the future for Toolboxes? We will continue to add more functionality. We encourage users to submit their own time saving functions to be included in the application toolboxes. Please email to motioninfo@yaskawa.com We envision an IEC code sharing community were users can share ideas with other.

Camming Implementation Yaskawa’s Approach to Camming PLCopen standardization Global Compatibility Yaskawa Expertise Execution in Motion Engine High Speed and Deterministic Value-added functions Enhanced Performance and Ease of Use

PLCopen, Cam Selection (ID number) Application Task Rate Mechatrolink Update Rate

PLCopen, Engage/Disengage Simple PLCopen blocks to engage/disengage cams Simple references to which axis is master and which is follower Uses Cam TableID number as a reference to the data table Engage/Disengage types At Position Immediate Linked / End of Profile Periodic (repeating) or Non-periodic

PLCopen, Adjust Simple PLCopen blocks to adjust running cams References to which axis is master and which is follower Identical blocks except for 1 input – Shift, Offset, or Scale Adjust Modes Over master distance Over time duration Within a master position window

Execution in Motion Engine Mechatrolink Update Rate Cam Block Diagram Execution in Motion Engine Application Task Rate Mechatrolink Update Rate

Cam Toolbox Functions 8 main functions CamGenerator allows user to redefine and calculate cam points on-the-fly CamBlend seamlessly links 3 cams together to smoothly start and stop cams with running masters CamSlave_FeedToLength makes cammed corrections for registration marks SlaveIndex_Lookup provides a tool for e-stop recovery More detailed information in Toolbox User Manual

CamGenerator Function Features Calculates all cam points on specified curve, given the segment endpoints and curve type Features Eliminates need for CamTool 4 supported curve types in v002 Linear Simple Harmonic Tangent Matching Tangent Blending Operates within application program

CamGenerator Step1 – Name the cam (i.e. “RunningCam”), as datatype CamSegmentStruct Step2 – Define the Segments. Easiest to do in ST

CamGenerator Step3 – Feed the cam data into the CamGenerator FB Step4 – Feed the generated cam table into the Select FB to load the table in the motion engine and return the ID number Done! Ready to Engage

CamBlend Function Features Blends RampIn, Running, and RampOut cam profiles together Features Best used for 1-way cam applications such as Rotary Knife where the master does not necessarily start from 0 speed Combines three CamGenerators, Y_CamStructSelects, and Y_Cam_In functions internally with appropriate interlocks to ease the programming task

A typical application for a 1-way cam CamBlend Application A typical application for a 1-way cam Rotary Knife Could be a 1:1 speed relationship, but only if the product length is exactly the same as the circumference of the knife. (doubtful) 180º 0º 345º 15º 10” Circumference 8” Product

CamBlend – Rotary Knife cut Knife goes faster at TDC when product shorter than knife circumference

Competitive Information

Competitive Information

Competitive Information

Recommended Sales Approach Camming is not unique. Differences are more subtle. Yaskawa created the Cam Toolbox to be more competitive and to help implement Yaskawa’s performance advantages on customer’s machines more easily. Ask the question “Can competitor do this?” If no, then use the opportunity to educate. If yes, then show how we do this effectively and easily. Look for ways we can do what they need with pre-written tools. (CamGenerator, CamSlave_FeedToLength) Leverage the Toolbox Manual Leverage the eLMs and eLVs found in Training section

Questions and Discussion Sales Overview Q & A Questions and Discussion The Technical Session will begin at 10:45am CDT.

Motion Control Division Yaskawa Electric America, Inc. Advanced Camming Made Easy with Cam Toolbox using CamGenerator & CamBlend Technical Details and Implementation Hello, I’m ?????????????????? I work in the ????????????? At Yaskawa…… Hand out business cards, make quick map of who’s sitting where. Motion Control Division Yaskawa Electric America, Inc.

Topics Part 2 Typical Application CamTool Refresher Structure Refresher CamGenerator On-The-Fly Cam Changes Cam Blending Modular Approach to Coding

First, lets consider a typical application Focus Application First, lets consider a typical application Flying Shear Could be a 1:1 speed relationship, but only if the product length is exactly the same as the circumference of the knife. (doubtful) 180º 0º 345º 15º 10” Circumference 8” Product

Requirements Focus Application Start and stop knife while the web is moving Calculate a smooth path for knife rotation Provide for variable part length

Focus Application Flying Shear (Running) Speed Matching Region 180º 0º 15º 345º Speed Matching Region

CamTool software refresher Set Style Set Parameter Resulting CDD or CSV file Data Transfer to MP2000iec

CamTool Data Entry 1 2 3

CamTool Process Enter Axis Details Enter Cam Data Save As CSV Download File Y_CamFile Select No Changes Or Start Over

CamTool Limitation No easy solution for applications that require changing the motion profile based on part length or recipe information. Must go back to CamTool, change the data, and then transfer a new CSV file to the controller using the web server or HTTP file transfer.

Structure Review Before describing a better solution, first a very quick review of structured data types. A structure is a complex data type consisting of simpler data types, or other sub structures Helps to organize data More flexible Easier programming when complex data involved.

Example Structure Review Personal Details BirthDate SSN FirstName LastName City State Zip Email

Benefit: Structure Review Step #1 Benefit: Easier to add data for any number of “people.” Easier to write flexible, powerful code. Step #2 Step #3 Step #4 Step #5

CamGenerator Function Block Block Functionality Inputs and Outputs Demonstration Step #1a Step #1b Step #1c Step #2 Step #3

Entering the Cam Data CamTool… MotionWorks IEC… Fixed Variables Step #4

CamGenerator Supported Curves as of March 2010 Cam Toolbox v002 In Development For v003

Use two cam tables On-The-Fly Changes One will be actively running the motion One will be “on deck” to take new changes Write Table 1 Write Table 2

Suitable Applications Applications that synchronize axes with a variable product size … Rotary Knife Linear Flying Shear Thermo Formers Press Feed Insertion Machines And Many More…

CamBlend Function Block Contains three Y_CamIn blocks, a Y_CamOut block and the supporting logic to switch tables based on the BlendData supplied. Block Functionality Inputs and Outputs Demonstration This function makes it possible to ramp a slave axis up to synchronization speed by managing three tables and switching between them on the fly.

Focus Application Flying Shear (Running) Knife is stopped at TDC 180º Flying Shear (Running) Knife is stopped at TDC Normal cam profile will cause infinite acceleration when starting process. 15º 345º 0º

CamBlend – Rotary Knife Master Position cut cut cut cut cut Slave Speed Profile #3 Profile #3 Active Profile Profile #2 Profile #2 Profile #1 Profile #1

CamBlend – Rotary Knife cut cut cut cut cut cut Knife goes faster at TDC when product shorter than knife circumference

CamBlend – Rotary Knife cut Speed match for one cycle

Rotary Knife Setup 180º 0º SyncAngle EngagePos KnifeA KnifeB PartA PartB SyncZone RampIn SwitchOverPos RampIn SwitchOverPos

Modular Code Concept

Five separate Toolboxes available on www.yaskawa.com Review Five separate Toolboxes available on www.yaskawa.com Built-in cam features can be enhanced further with the addition of Toolbox functions such as CamGenerator and CamBlend Modular code concept allows rapid implementation in a variety of applications Pyramid effect, build function upon function

Thanks!