1. Yaskawa Electric America Understanding & Applying Camming Techniques
iec
Yaskawa Electric America
Understanding & Applying Camming Techniques
with
MP2000iec / MotionWorks IEC
TP.MCD
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Questions not answered during the eCafé can be ed to or can be entered into the survey at the end of the class.

2. 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

3. 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

4. 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

5. 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

6. (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

7. 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.

8. Camming Overview
Below the Surface….
Camming Block Diagram

9. Function Block Breakdown
Camming Overview
Function Block Breakdown
4 functional topics

10. Common Theme: CamTableID
Cam Data Management

11. 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.

12. Cam Data Management
Application Task Rate
Mechatrolink Update Rate

13. 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

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

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

16. Cam Engagement

17. 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.

18. 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.

19. 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.

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

21. 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

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

23. 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

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

25. 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!

26. 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

27. On-The-Fly Adjustments

28. 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!

29. 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

30. On-The-Fly Adjustments
Smooth Motion Adjustments

31. 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

32. 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

33. 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

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

35. Block Diagram

36. 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.

37. 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.

38. 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 source code.
HTTP file transfer is another method for cam file download.
Useful for PC HMI applications

39. Application Discussions

40. 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

41. Application Discussion
Rotary Placer – The Product Buffer

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

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

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

45. 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

46. 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

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