Yaskawa Electric America Understanding & Applying Camming Techniques with

1. iec Yaskawa Electric America Understanding & Applying Camming Techniques with MP2000iec / 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

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 360 360 3.00 3.00 Slave Position Master Position 0 0 0 Time Repeat • Core Concept • Electronic Camming controls the positional relationship of two axes

5. Camming Overview 360 360 3.00 3.00 Slave Position Master Position 0 0 0 Time Repeat • 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.)

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

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 Common Theme: CamTableID

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. Watch window is a great place to verify the correct data has been applied 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 Identical function blocks, except for one input

22. On-The-Fly Adjustments Master Slave • 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 Master • 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 • 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!

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 Master Position 360 270 180 90 0 180 Degrees Y_CamShift.Execute • 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 LREAL#72.0 Y_AdjustMode#MasterDistance LREAL#180.0 n/a n/a n/a

31. On-The-Fly Adjustments Master Position 360 270 180 ? 90 0 2.5 Seconds Y_CamShift.Execute Good method if adjustment value known before engaging the slave. Set Duration to zero for instantaneous correction. • 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. LREAL#72.0 Y_AdjustMode#Duration n/a LREAL#2.5 n/a n/a

32. On-The-Fly Adjustments Master Position 360 270 180 90 0 LREAL#180.0 LREAL#270.0 Waiting… 180 to 270 degrees Y_CamShift.Execute • 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#72.0 Y_AdjustMode#WithinRange 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 Product Flow 0 deg [A] Pick Decision Window Pick Position Pick On Pick Threshold MaxShiftThreshold 90 deg [A] 1:1 Match Point Adjust Region Product Sensor MaxShift (PickPosition - PickOn) [%] Place Angle 0 deg ProductPitch (MasterCycle) ProductPitch (MasterCycle) DistToLatch • 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 CamState=3 CamFlagID Changed Y_CamIn.Execute Cam Switch Logic Y_CamIn Y_ReleaseCamTable Y_CamFileSelect PC Cam Selector CamFile download to RAM 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