MP2200

1
Yaskawa Electric America Understanding Applying
Camming Techniques with MP2000iec / MotionWorks
IEC
2
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
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

5
Camming Overview

• Thats It!
• Everything else relates back to the core concept.
• Positional relationship of two axes.
• Master can be a servo, external encoder, or time
  (virtual master.)

6
Camming Overview

• (OK we lied) Theres more
• Master / Slave lookup table is the core with
  these surrounding topics
• We will focus on these six supporting features

7
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
Camming Overview

• Function Block Breakdown
• 4 functional topics

10
Cam Data Management
11
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
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
Cam Data Management

• Data Structure

15
Cam Data Management

• Code Example

All Cam DataTypes included in New Project Template
16
Cam Engagement
17
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
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
Cam Engagement

• Engage Modes
• AtPosition is better if the master is already
  moving.
• Immediate is 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
0
360
360
360
360
0
0
0
0
0
21
On-The-Fly Adjustments
22
On-The-Fly Adjustments

• Shifting
• Master Side Adjustment
• Useful when a registration mark detects products
  on the master axis
• Slave pattern is unchanged

Shifting is a controlled slippage of the red cam
lobe on the black shaft
23
On-The-Fly Adjustments
90 degree shift
180 degree duration
24
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!
25
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.

26
On-The-Fly Adjustments
27
On-The-Fly Adjustments

• AdjustMode
• Weve 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!
28
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
29
On-The-Fly Adjustments
Smooth Motion Adjustments
30
On-The-Fly Adjustments

• AdjustMode Type 1
• Y_AdjustModeMasterDistance
• 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

LREAL72.0
Y_AdjustModeMasterDistance
LREAL180.0
n/a
n/a
n/a
31
On-The-Fly Adjustments
Good method if adjustment value known before
engaging the slave. Set Duration to zero for
instantaneous correction.

• AdjustMode Type 2
• Y_AdjustModeDuration
• 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.

LREAL72.0
Y_AdjustModeDuration
n/a
LREAL2.5
n/a
n/a
32
On-The-Fly Adjustments

• AdjustMode Type 3
• Y_AdjustModeWithinRange
• 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

LREAL72.0
Y_AdjustModeWithinRange
n/a
n/a
33
Axis Parameters

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

34
Block Diagram
35
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.

36
Capabilities Performance

• 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.

37
Capabilities Performance

• 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

38
Application Discussions
39
Application Discussion

• Rotary Placer The Placer Cycle

mCamShiftRemaining
40
Application Discussion

• Rotary Placer The Product Buffer

41
Application Discussion

• Rotary Placer The Cam Shift
• Uses WithinRange adjust mode

42
Application Discussion

• Linear Flying Shear
• Out Back slave
• Synchronized to product by registration mark

43
Application Discussion
Flat part of the speed graph is the area where
the master slave are synchronized.

• Linear Flying Shear

Out
Back
44
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
45
Application Discussion
PC Activity
MP2300Siec Activity
OPC or Modbus
CamState3
CamFlagID Changed
Y_CamIn.Execute
Y_CamIn
Y_ReleaseCamTable
Cam Switch Logic
CamFile download to RAM
Y_CamFileSelect
PC Cam Selector
Set Next Use Cam Info
Check for Next Use Cam Flag
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
46

• 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