Tm446 Acopos Smart Process Technology

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ACOPOS Smart Process TechnologyTM446



2 TM446 ACOPOS Smart Process Technologyy

Introduction

R equirements

Training modules: TM410 - The Basics of ASiM TM445

- ACOPOS ACP10 Sof twar e

Sof twar e: AS 2.5 or later / ACP10 sof twar e 1.100 or later

Har dware: None



Introduction

Table of contents

1. I NTR ODUCT IO N 41.1 O b jective 5

2. GENERAL 6

3. CO NCEPT 8

3.1 SPT f unctions 8

3.2 Im plementation 11

3.3 Parameter update of SPT f unctions 14

3.4 Pr ocessing 15

3.5 Diagnostics 16

4. FU NCTIO N OVER VIEW 18

4.1 Var ia bles 18

4.2 Constants 18

4.3 Available f unctions 19

4.4 S pecial f unctions 28

5. EXER CISES 30

6. SUMMARY 31

7. APPE NDIX 32

7.1 Solutions 32

ACOPOS Smart Process Technology TM446 3



Introduction

1. INTR ODUCTION

Application scenar ios in which a minimum r eaction time is r equir ed are

becoming mo re and mor e common (e.g. print mark contr ol). Howe ver,

highly com plex calculations (e.g. off set com pensation) still have to bemad e to prevent a loss of accuracy at high s peeds.

This is exactly why B&R integr ated Smart Process Technology (SPT)

f unctions in the dr ives.

SPT f unctions run dir ectly on the ACOPOS processor. This gives the user

dir ect access to the f unctionalities of the ACOPOS at sof twar e level.

In addition to pure SPT networks, SPT f unctions can also access other

ACOPOS inf or mation and f unctionalities. This opens up endless

possi bilities for oper ating the ACOPOS without the overhead on the PLC or the network delay aff ecting the r eaction time.

Fig. 1: Pr inter with print mark corr ection

I/O plug-in cards for the ACOPOS su pplement the SPT f unctions. They are

dir ectly accessed using the SPT f unctions, which makes it possi ble to

contr ol e.g. dr um sequencers at high speed and with high pr ecision.

Thanks to a wide range of f unctions, SPT allows the user to im plement

even highly com plex f unctionalities with minimum cycle times.

4 TM446 ACOPOS Smart Process Technology



Introduction

1.1 Ob jective

You will r eceive an over view of how and when SPT f unctions are used.

You will learn how to use SPT f unctions on the ACOPOS and how they areconf igur ed in Automation Studio.

You will be able to move f ast-r eacting parts of the a pplication on the

ACOPOS to create a high- per f or mance a pplication.

Fig. 2: O b jectives




General

2. GENERAL

Smart Process Technology can be viewed as a sort of separate

pr ogr amming language. SPT f unctions are pr ef a br icated, separate f unction

units on the ACOPOS that can be used freely by the user.

SPT f unctions are " pr ogr ammed" in parameter ta bles using Par IDs because

they run at a very deep level to spare unnecessary over head.

The f unctions are also inter -connected with the help of Par IDs by using e.g.

the out put Par ID of a f unction as value for the input of another SPTf unction.

These inter -connections can make it poss i ble to create extr emely power f ul

networ k s.

Fig. 3: Exam ple of a com plex SPT networ k




General

These networks are availa ble in Automation Studio as parameter lists,

however it is recommended to first sketch the SPT connections on paper

bef or e star ting with pr ogr amming. This hel ps to maintain a clear and

or ganized over view, which also mak es diagnostics and f unction testing

much easier.

The schematic diagr ams in this document were created in Micr osof t™

Visio™ .

Fig. 4: VISIO dr awings for SPT network

The parameter ta ble can be created once the network has been designed

on paper. If necessary, an SPT network can also be distr i buted in multiple

ta bles. However, this should only be done when multiple SPT networks,

inde pendent from each other, ar e running on one axis.

Note:

Inf or mation about parameter ta bles can be found in the online help files

under Automation Sof tware: Automation Studio: Motion

Components: NC data ob jects: ACOPOS parameter table




Concept

3. CONCEPT

3.1 SPT f unctions

In this manual the AR ITH f unction is used for ex plaining the functionality of the SPT f unctions.

It is basically used for executing the four basic ar ithmetical oper ations.

3.1.1 In puts/out puts

SPT f unctions contain a number of in puts in accordance to the f unction, a

se par ate me mory area and a r es pective number of outputs. Inter nal data

cannot be accessed. The in puts and outputs are a pp lied as Par IDs.

Fig. 5: Diagr am AR ITH : In puts/out puts

Fig. 6: AR ITH in puts/out puts




Concept

There are essentially two types of in puts and outputs when using SPT

f unctions. The Par ID is def ined either with an actual value or with a pointer .

Pointer means that a target or source Par ID is s pecif ied instead of a

numer ical value.

Fig. 7: Diagr am AR ITH: Pointer

Fig. 8: AR ITH pointer

Note:

The f ollowing aspects indicate a pointer in the parameter ta ble:

"Par ameter ID of …" in the descr i ption

" _ PAR ID" at the end of the Par ID def inition

Note:

A detailed descr i ption of the in puts and outputs of an SPT f unction can

be found in the online help files under :

Automation Sof tware: Automation Studio: NC Sof tware: ACP10:

ACOPOS drive functions: F unct i on name: Parameter IDs




Concept

3.1.2 Instances

Every SPT f unction r equir es its own memory area on the ACOPOS.

This memory is limited and that’s why each f unction type has a maximum

of eight instances (instance 0 – 7).

Which instance is used by which f unction is deter mined by the number

attached to the Par ID as "+X".

Fig. 9: Exam ple of instances

3.1.3 Connections

The in puts and outputs of the SPT f unctions can be linked with any Par ID

with the corr es ponding attr i butes (RD, WR, R D/WR ).

Linking means that a Par ID of a f unction can be attached as a value to the

Par ID of another f unction.

In addition to com bine SPT f unctions with each other, they can also becom bined with "exter nal" Par IDs. An "exter nal" Par ID is a Par ID that is

present on the ACOPOS but not part of an SPT f unction.

Fig. 10: FB-FB and "exter nal" link




Concept

3.2 Implementation

3.2.1 Cr eating an instance

An instance has to be created in a parameter ta ble bef or e in order to use a

f unction. Cr eating means that the ACOPOS reserves memo ry for exactly

this SPT f unction instance dur ing startup and places it in cyclic pr ocessing.

The SPT f unctions are "cr eated" using FU NCT IO N _ BLOCK _CR EATE (Par ID

777). Any Par ID of the f unction to be created can be s pecif ied as value for

this Par ID.

Fig. 11: Parameter table with SPT Cr eate




Concept

3.2.2 Order of execution

An im por tant aspect of SPT f unctions is the pr ocessing sequence. Failure

to pr oper ly follow this order can r esult in errors, which of ten take a long

time of intensive sear ching to uncover. The order of execution isdeter mined by the instancing sequence and always goes from top to

bottom.

Fig. 12: Order of execution

The SPT f unctions should be created in the order equal to the dir ection of

data flow in the schematic diagr am.

Fig. 13: Dir ection of data f low




Concept

3.2.3 Conf igur ing SPT f unctions

After being instanced, the f unctions must still be conf igur ed and

connected. A new group is created for adding an SPT f unction to the

parameter ta ble.

The desir ed f unction and instance can now be selected from the drop-

down list in the dialog box.

Fig. 14: Selecting the f unction block Fig. 15: Selecting the instance

After com pleting the dialog box, a new su b-f older, with the name of the

SPT f unction, is added to the parameter ta ble.

Fig. 16: SPT - parameter gr ou p

The f unction inter f ace, contained in this group, can then be filled with

values or pointer s.

All parameters can be initialized right in the parameter ta ble. Howe ver, it is

also possi ble to write these values dur ing r untime (Par ID (cyclic) Read,Par ID (cyclic) Wr ite).

Note:

When using the wizard to add an SPT f unction, all f unction in puts and

f unction output pointer s are added to the gr ou p.

Howe ver, the output Par IDs of an SPT f unction are not automatically

contained in the parameter gr ou p.




Concept

3.3 Parameter update of SPT f unctions

As mentioned ear lier, SPT networks run on the ACOPOS processor,

inde pendent of the main CPU. In most cases, it is necessary for SPT

f unctions to be u pdated from the a pplication.

Print mark contr ol pr ovides an exam ple for this:

The position values are read by the CPU and the corr ection value is

calculated. The com pensation distance is then tr ansf err ed to the ACOPOS,

which a pplies the corr ection. The print mark detection process can also be

ena bled/disa bled and the number of non-detected print marks can be r ead.

Communication pr of ile:

Position value: Read cyclically by the CPU

Num ber of errors: Read by the CPU

Com pensation distance: Written cyclically by the CPU

Ena ble in put: Set by the CPU

Fig. 17: Parameter update diagr am

Note:

Further inf or mation about parameter updates can be found in the online

help f iles under Automation Sof tware: Automation Studio: NC

Sof tware: ACP10: ACOPOS drive functions: F unct i on name




Concept

3.4 Process ing

3.4.1 Cyclic pr ocessing

The pr ocessing cycle of the SPT f unctions corresponds to the position

contr oller cycle and set value generator cycle. This means that each

instanced SPT f unction is called every 400 µs. Only a limited number of

SPT f unctions can be used on the ACOPOS because the processor must

also process all other drive f unctions on the ACOPOS in this time per iod .

The number of poss i ble Par IDs cannot be deter mined in advance.

ACOPOS outputs the f ollowing error messag e if the processor is

over loaded:

Maximum cycle time exceeded - CPU load too high

3.4.2 Order of execution for oper ating system f unctions

In addition to the SPT f unctions, the processor also carr ies out other drive

f unctions. K nowing the order of execution can be im por tant for

a pp lications in order to avoid unnecessary dead times.

The ACOPOS processes the drive f unctions in this order:

Data acquisition

Network communication

SPT

Cam profile automat

Set value generator

Vir tual axis




Concept

3.5 Diagnostics

Diagnostics for sof twar e wr itten in SPT has some consider a ble diff er ences

f r om sof twar e wr itten with other pr ogr amm ing languages.

Diagnostics are pr inci pally handled using NC Trace, mainly for time-cr itical

Par IDs. Par ID Read can also be used for slow changing values.

Fig. 18: Diagnostics Tr ace

Caution:

If the ACOPOS processor is alr eady under consider a ble load, Trace may

no longer be able to record all 10 possi ble Par IDs for each axis because

every additional Par ID incr eases the process or load.




Concept


In addition to the NC Trace, the network comm and Trace can also be

hel pf ul. It can be used to check the individual parameters tr ansf err ed from

the PLC to the ACOPOS f or each block .

Fig. 19: Network command tr ace

This method is very usef ul f or :

check ing WHICH Par IDs were wr itten WHE N

check ing the order of execution if, for exam ple, multiple

par ameter ta bles are being used

check ing initialization values



Function Overview

4. FUNCTION OVER VIEW

4.1 Variables

In addition to the SPT f unctions, ACOPOS also pr ovides the user with"f r ee

"

memor y s pace that can be used as data sink. There are three diff er ent data

types I NT(I2), DI NT(I4) and REAL(R4). Just like f unctions, user var ia bles

must be created first and there are eight instances.

Each instance consists of four var ia bles with the same data type (var ia ble

num ber ).

Just one data type has to be created with FU NCT IO N _ BLOCK _CR EATE

(Par ID 777 ) so that the same instance can be used with all data ty pes.

These var ia bles can be called using the f ollowing Par IDs:

VAR _ I2 _ x+y

VAR _ I4 _ x+y

VAR _ R 4 _ x+y

x…Variable number (0-3)

y…Instance (0-7)

Fig. 20: Available var iables after cr eating an instance

4.2 Constants

To cut back on the number of user var ia bles, there are two pr edef ined

constants from the DI NT data type that can be read, but not wr itten.

CO NST_ I4 _ZER O (0) (Par ID 292 )

CO NST_ I4 _ O NE (1) (Par ID 310 )




Function Overview


4.3 Available f unctions

SPT curr ently contains 18 diff er ent f unctions. 16 of these f unctions can be

used with any drive. The two r emaining f unctions can only be used in

com bination with s pecial har dwar e.

This is an over view with descr i ptions for the individual SPT f unctions:

Function name Description

AR ITH Ar ithmetic oper ations

LOGIC Logic oper ations

CMP Com par ator

EVWR Event contr olled parameter wr iting

MUX Multi plexer, switch

CAMCO N Cam contr ol

VAR ITH Vector Ar ithmetic

DELAY Dead time element

BIT Bit oper ations

IPL Inter polator

MI NMAX Minimum Maximum

FIFO Fir st-In, First-Out memor y

PID PID tr ansf er f unction

LATCH Event-contr olled saving

CURVE Curve f unction

MPGE N Motion Profile Gener ator

DIO Digital IO inter f ace

AIO Analog IO inter f ace



Function Overview

4.3.1 AR ITH

This SPT f unction uses an ar ithmetic f unction to link two input values.

Ar ithmetic oper ation is set as mode.

Fig. 21: AR ITH

4.3.2 LOGIC

This SPT f unction is used to logically link up to four input values. Logical

oper ation is set as mode.

Fig. 22: LOGIC

4.3.3 CMP

The SPT f unction, CMP, creates a comp arator which can be conf igur ed.

Com par ison oper ation is set as mode.

Fig. 23: CMP

Example: Basics, Part 1

Design and create an SPT network that produces a sum of two var ia bles.

A flag should be set for check ing when this sum is greater than 25 and

an Ena ble input is active.




Function Overview


4.3.4 EVWR

This SPT f unction make s it possi ble to write a value from one Par ID to

another Par ID. This happens when the value of the Event input is equal to

the s pecif ied level, either edge-contr olled or level-contr olled.

Fig. 24: EVWR

4.3.5 MUX

The SPT f unction, MUX, selects one of n in puts and connects it through to

the out put. The selection is contr olled via a "selector in put". The method of

switching can be set using the mode.

Fig. 25: MUX



Function Overview

4.3.6 CAMCO N

The SPT f unction, CAMCON, switches an output de pending on the position

of a master axis. The on and off positions can be set with each cam. The

entire cam switching sequence for an output is called a track. The start procedure and method of oper ation f or cam contr ol are def ined using one

mode.

Fig. 26: CAMCO N

Example: Basics, Part 2

A inter val of 10,000 should be produced from the dr ive's set position.

A value should be wr itten to a new user var ia ble if the flag is set:

The value depends on the inter val position:

0 – 5,000 Value of AR ITH

5,000 – 10,000 100

Use the test window to check the f unctioniality




Function Overview

4.3.7 VAR ITH

This SPT f unction uses an ar ithmetic f unction to link two input vectors. The

input and output values consist of an array of n similar elements. The

ar ithmetic oper ation of these vectors is set as mode. De pending on theoper ation, the r esult is pr ovided as out put vector or as scalar in the first

element.

Fig. 27: VAR ITH

4.3.8 DELAY

The DELAY f unction f orwar ds a value with a s pecif ied delay (dead time).

Fig. 28: DE LAY




Function Overview

4.3.9 BIT

This SPT f unction uses n input values and n inter nal operands to execute

diff er ent bit mani pulations. The bit oper ation is s pecif ied by the mode.

Fig. 29: BIT

4.3.10 IPL

The IPL f unction can be used to per f or m an ad justment of diff er ent clock ing

systems. Inter polation uses existing data po ints x(tn) to pr edict additional

values y( t i ).

Exam ple: The 2 ms set value steps from the network are inter po lated and

ad justed to the 400 µs ACOPOS cycle.

This f unction block is mostly used when enter ing set values via the CAN

network and via Power link , if a master cycle of 400 µs cannot be set.

Fig. 30: IPL




Function Overview

4.3.11 MI NMAX

Each cycle, the SPT f unction deter mines the current extreme value of all

inputs. The extreme value is set using the mode: As "Minimum" for the

smallest value or as "Maximum

"for the lar gest value.

Fig. 31: MI NMAX

4.3.12 FIFO

In its basic method of oper ation, the FIFO f unction is similar to a shif t

r egister. The data appears in the same sequence as it was entered. The first

value entered (First In) is also the first value read (First Out). Unlike the shif t

r egister, this procedure can run com pletely asynchronous in a FIFO (i.e. the

output rate is not dependent on the input r ate).

Fig. 32: FIFO

4.3.13 PID

The SPT f unction creates a real PID contr oller which can be conf igur ed (PID

tr ansf er function). This Proportional Integr al Differential contr oller with delay

and anti-windu p is constructed in add itive (parallel) f or m.

Fig. 33: PID




Function Overview

4.3.14 LATCH

The value of a changing input value, is saved (i.e. "latched") when cer tain

trigger events occur. The trigger signal must fulfill cer tain conditions – such

as: r eaching a trigger edge within a cer tain window and with a cer tainsignal width.

In most cases, the input value is a position value, with a corr es ponding

position sensor as trigger event. Ther ef or e, the LATCH f unction can be

used for tr igger positioning, length measurement and for print mark

detection.

Fig. 34: LATCH

Example: Detail 1

Design and create an SPT network that latches the set position with a

delay of 10 ms as soon as the current motor speed exceeds the 60

r ev/min limit

Do not use the Par ID for speed to deter mine the speed. Instead,

deter mine the speed from the set position

(ADV ICE: use the PID f unction)

Use the test window to check the f unctionality




Function Overview

4.3.15 CURVE

The CURVE f unction pr ovides a f unction f(x) between input and output

value.

The f unction is im plemented with cam profile polynomials. Ther ef or e, allexisting mechanisms for cr eating and downloading cam pr of iles can be

used.

Some of the areas of a pp lications for the CURVE f unction are: cr eating

char acter istic curves, cyclic off sets and im plementation of corr ection

f unctions.

Fig. 35: CUR VE

4.3.16 MPGE N

The SPT f unction, MPGEN, creates a movement profile that can be

conf igur ed. This profile corresponds to a com pensation f unction, which

can work as a position link or as a time-contr olled movement.

Fig. 36: MPGE N

Example: Detail 2

Use the MPGEN time-de pendent com pensation profile to smooth a jump

of one half r evolution on the additional slave axis

(AUT_ SL _ADD_AXIS _ VAX1 (Par ID 582)) of a virtual automat.

Use the test window to check the f unctionality




Function Overview

4.4 Special f unctions

These f unctions can only be used if an I/O plug-in card is present in the

drive. The card is detected by the ACOPOS and the r equir ed SPT f unctions

are automatically cr eated. Ther ef or e, this f unction's instances do not haveto be created in the parameter ta ble.

4.4.1 DIO

This SPT f unction is used to operate the dr ive's digital in puts and outputs.

This f unction is availa ble for the f ollowing har dwar e:

8AC130.60-1

8AC131.60-18BAC0124.000 -1

Note:

The f unction can vary de pending on the hardware.

Inf or mation is availa ble in the online help files under :


ACOPOS drive functions: DIO – Digital IO interf ace

4.4.2 AIO

This SPT f unction is used to operate the dr ive's analog in puts and outputs.

This f unction is availa ble for the f ollowing har dwar e:

8AC131.60-1

8AC132.60-1

8BVxxxxxxx xx.xx1

Note:

The f unction can vary de pending on the hardware.

Inf or mation is availa ble in the online help files under :


ACOPOS drive functions: AIO – Analog IO interf ace




Function Overview

Note:

Detailed inf or mation about the individual SPT f unctions and

conf igur ation can be found in the Automation Studio online help filesunder Automation Sof tware: Automation Studio: NC Sof tware:

ACP10: ACOPOS drive functions: F unct i on name




Exercises

5. EXER CISES

Note:

Pr actical exer cises for the individual SPT f unctions can be found in theonline hel p files under :


ACOPOS drive functions: F unct i on name: Example




Summary

6. SUMMARY

Now you know how tocreate the SPT f unctions on the ACOPOS and how

to conf igur e and connect them to a network. The decision of whether to

run the sof twar e r emotely on the ACOPOS or on the PLC, depends on thedesir ed r eaction times and the load on the main CPU.

Fig. 37: Pr inter with print mark corr ection

If the decision is made in favor of SPT, the network is created on pa per.

This hel ps maintain a clear and or ganized over view and allows you to moreeasily check and diagnose the networ k .

In the event that minor errors were made, you can use NC Trace to record

up to ten parameters, thereby minimizing the time needed for finding

err or s.




Appendix

7. APPENDIX

7.1 Solutions

7.1.1 Basics, Part 1 (Section 4.3.3):

Fig. 38: Solution approach for Basics, Part 1

Fig. 39: Solution to Basics, Part 1




Appendix

7.1.2 Basics, Part 2 (Section 4.3.6):

Fig. 40: Solution approach for Basics, Part 2

Fig. 41: Solution to Basics, Part 2




Appendix

7.1.3 Detail 1 (Section 4.3.14 ):

Fig. 42: Solution approach for Detail 1

Fig. 43: Solution to Detail 1




Appendix

7.1.4 Detail 2 (Section 4.3.16 ):

Fig. 44: Solution approach for Detail 2

Fig. 45: Solution to Detail 2


Tm446 Acopos Smart Process Technology

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