Yaskawa Electric America Understanding & Applying Camming Techniques with
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Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 1
Yaskawa Electric America
Understanding & Applying Camming Techniques
with
MP2000iec / MotionWorks IEC
iec
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 2
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
Webinar Highlights
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 3
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
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 4
Sla
ve
Po
sit
ion
3.00
0Time
Ma
ste
r P
os
itio
n
360
0
Core Concept• Electronic Camming controls the
positional relationship of two axes
Camming Overview
3603.00
0
Repeat
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 5
That’s 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.)
Camming OverviewS
lav
e P
os
itio
n
3.00
0Time
Ma
ste
r P
os
itio
n
360
0
3603.00
0
Repeat
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 6
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
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 7
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
On the Surface….
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 8
Camming Block Diagram
Camming Overview
Below the Surface….
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 9
Function Block Breakdown• 4 functional topics
Camming Overview
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 10
Cam Data Management
Common Theme: CamTableID
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 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.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 12
Cam Data Management
Mechatrolink Update Rate
Application Task Rate
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 13
Computer Disk
Cam Memory
Controller File System
Cam Data Management
External Source: Cam Tool or Excel
Other methods for sending files will be addressed
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 14
Data Structure
Cam Data Management
Watch window is a great place to verify the correct data has
been applied
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 15
Code Example
Cam Data Management
All Cam DataTypes included in New Project Template
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 16
Cam Engagement
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 17
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.
Cam Engagement
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 18
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.
Cam Engagement
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 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.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 20
Starting the process
Cam Engagement
0 0 0 0 0
0
360
720
1080
1440
360 360 360 360
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 21
On-The-Fly Adjustments
Identical function blocks, except for
one input
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 22
Master
Slave
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
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 23
On-The-Fly Adjustments
90 degree shift
180
deg
ree
du
rati
on
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 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!
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 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.
Master
Slave
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 26
On-The-Fly Adjustments
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 27
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!
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 28
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.
On-The-Fly Adjustments
Start
Finish
Built into the firmware
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 29
On-The-Fly Adjustments
Smooth Motion
Adjustments
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 30
On-The-Fly Adjustments
Y_AdjustMode#MasterDistance
n/a
n/a
n/a
360
0
90
180
270
Master Position
Y_CamShift.Execute
180 Degrees
LREAL#180.0
LREAL#72.0
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
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 31
On-The-Fly Adjustments
Y_AdjustMode#Duration
n/a
LREAL#72.0
n/a
n/a
Y_CamShift.Execute
360
0
90
180
270
Master Position
LREAL#2.5
?
2.5 Seconds
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.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 32
On-The-Fly Adjustments
Y_AdjustMode#WithinRange
LREAL#72.0
n/a
n/a
Y_CamShift.Execute
360
0
90
180
270
Master Position
AdjustMode – Type 3• 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
LREAL#180.0
LREAL#270.0180 to 270 degreesWaiting…
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 33
Axis Parameters
Crucial to establishing the proper operation by coding interlocks and other logical functions.
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 34
Block Diagram
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 35
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
Use parameter 1541, CamTableIDEngaged in cases like this to verify the currently operating profile
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 36
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
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 37
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
Capabilities & Performance
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 38
Application Discussions
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 39
Rotary Placer – The Placer Cycle
Application Discussion
Pick PositionPick On
Pick DecisionWindow
Place Angle
Adjust Region
0 deg
90 deg
Product Flow
Pick Threshold
0 deg
Product Sensor
DistToLatch
ProductPitch(MasterCycle)
ProductPitch(MasterCycle)
MaxShift
MaxShiftThreshold
[A]
[A] 1:1 Match Point
(PickPosition -PickOn) [%]
mCamShiftRemaining
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 40
Rotary Placer – The Product Buffer
Application Discussion
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 41
Rotary Placer – The Cam Shift• Uses #WithinRange adjust mode
Application Discussion
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 42
Linear Flying Shear• Out & Back slave• Synchronized to product by
registration mark
Application Discussion
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 43
Application Discussion
Linear Flying ShearFlat part of the speed graph is the area where the master & slave are synchronized.
Out
Back
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 44
Application Discussion
Assembly Machine• Rotary Table• Assembly Stations
ST 2
Indexer Table
ST 1
ST 3
ST 8
6 feet 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
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 45
Application Discussion
Y_CamIn Y_ReleaseCamTableCamFile download
to RAMY_CamFileSelect
PC Cam Selector
Cam SwitchLogic
Y_Cam
In.E
xecu
te
CamSta
te=3
PC Activity MP2300Siec Activity
Set Next Use Cam Info
OPC or Modbus
Check forNext Use Cam Flag
CamFlag
ID C
hang
ed
Circular usage of cam tables controlled by Array of CamSequenceStruct
For Needle location
(Stitch #)
CamSequenceStruct
To know current cam being used
Next Cam Selector Logic
MC_ReadActualPosition
Understanding and Applying Camming Techniques with the MP2000iec and MotionWorks IEC 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