APPLICATION Electronic Cam

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1 APPLICATION 5 th Generation of STÖBER Inverters FUNCTIONS DETAILS PARAMETER V 5.5 /2010 EN

2 Table of Contents i Table of Contents 1. Introduction Notes on Safety Software Presentation of notes on safety Function Description Cam Profiles Table Coupling PLCopen Programming MC_MoveAbsolute MC_MoveRelative MC_MoveAdditive MC_MoveVelocity MC_Stop MC_Home MC_Reset MC_CamIn MC_CamOut MC_MoveSuperimposed End of command Interface ID

3 Table of Contents i 4. Additional Functions Cams Jogging (Tipping) Master Slave Coupling External Encoder Main drive Virtual Master with Positioning Capability Application-Specific Solutions Operating indicators Application Examples Flying Saw Synchronizer/Switching Cycle Coupler/Uncoupler Cross Sealing with Welding Bars Printing Mark Offset Used Parameters Parameter Legend Parameter List ID

4 Table of Contents i - This page was purposely left blank - ID

5 Introduction 01 1 Introduction The is a drive-based drive architecture. This application enables you to implement applications such as the flying saw or the rotating knife. SPS Fieldbus POSIDYN SDS 5000 SSI-Motionbus Servo motors Figure 1-1 Drive-based drive architecture with SDS 5000 and MDS 5000 POSIDRIVE MDS 5000 You can interconnect PLCopen blocks to program the final sequence of movement. Movements are implemented such as absolute target specification, relative positioning paths, endless positioning, or synchronous movements. When the MC_Camin block is triggered the "table coupling" between a master and the axis is activated. This "table coupling" is called the electronic cam. An electronic cam establishes a unique relationship between a position of the master drive/master axis and a position of the next/slave axis. Implementation of an electronic cam in a machine differs from the construction of the mechanical cam. The electronic cam offers the following advantages over the mechanical version: No jolting Maximum accelerations ID

6 Introduction 01 No excitation from mechanical vibrations No mechanical changes required for format changes Diagnostic capabilities No wear Hygienic design The cam can be used in many applications, but primarily with packaging machines, printing presses, robots and the wood industry. Electronic cam The cam technology function is a standard part of the device firmware and the POSITool configuration and commissioning software starting with version 5.2. Prior to commissioning the cam, your participation in the training course Free Programming is required See the following manuals for more information: Instructions for installing the FDS 5000 (ID ) or instructions for installing the MDS 5000 (ID ) or instructions for installing the SDS 5000 (ID ). Programming manual (ID ) for a detailed description of the system and the Free Programming option. Block description (ID ) with the description of the blocks required for programming. If you have questions on the use of the devices of the 5th generation of STÖBER inverters and the POSITool software which are not answered in this manual, we will be glad to help. Just call us at To make it easier for you to get started with our software applications we offer courses. Please contact our Training Center at the following address: GmbH + Co. KG Trainings Center Kieselbronner Straße Pforzheim ID

7 Notes on Safety Electronc Cam 01 2 Notes on Safety When in operation, inverters from GmbH + Co. KG may have energized or rotating parts depending on their protection rating. Surfaces may heat up. For these reasons, comply with the following: The safety notes listed in the following sections and points The technical rules and regulations In addition, always read the mounting instructions and the short commissioning instructions. GmbH + Co. KG accepts no liability for damages caused by non-adherence to the instructions or applicable regulations. Subject to technical changes to improve the devices without prior notice. This documentation is purely a product description. It does not represent promised properties in the sense of warranty law. Component part of the product The technical documentation is a component part of a product. Since the technical documentation contains important information, always keep it handy in the vicinity of the device until the machine is disposed of. If the product is sold, disposed of, or rented out, always include the technical documentation with the product. Operation in accordance with its intended use In the sense of DIN EN (previously VDE 0160), the POSIDRIVE FDS 5000 and MDS 5000 and the POSIDYN SDS 5000 model series represent the electrical equipment of power electronics for the control of power flow in high-voltage current systems. They are designed exclusively to power: Servo motors (MDS 5000, SDS 5000) Asynchronous motors (FDS 5000, MDS 5000 and SDS 5000) Operation for purposes other than the intended use include the connection of other electrical loads! Before the manufacturer is allowed to put a machine on the market, he must have a danger analysis prepared as per machine guideline 98/37/EG. This analysis establishes the dangers connected with the use of the machine. The danger analysis is a multi-stage, iterative process. Since this documentation cannot begin to provide sufficient insight into the machine guidelines, please carefully study the latest standards and legal situation yourself. After the drive controller has been installed in machines, it cannot be commissioned until it has been determined that the machine complies with the regulations of EG guideline 98/37/EG. ID

8 Notes on Safety 01 Electronc Cam Ambient conditions Model series POSIDRIVE FDS 5000 and MDS 5000 and POSIDYN SDS 5000 are products of the restricted sales class as described in IEC This product may cause high-frequency interference in residential zones and the user may be asked to take suitable measures. The inverters are not designed for use in public low-voltage networks which power residential areas. High-frequency interference must be expected when the inverters are used in such a network. The inverters are only intended for use in TN networks. The inverters are only designed for use on supply current networks which can delivery at the most a maximum of symmetrical rated short circuit current at 480 Volts as per the following table: Max. symmetrical rated short circuit Device family Size current FDS 5000, MDS 5000, SDS 5000 BG 0 and BG A MDS 5000 BG A SDS 5000 BG A Install the inverter in a switching cabinet in which the permissible maximum surrounding air temperature is not exceeded (see mounting instructions). The following applications are prohibited: Use in potentially explosive areas Use in environments with harmful substances as per EN (e.g., oils, acids, gases, fumes, powders, irradiation) Use with mechanical vibration and impact stresses which exceed the information in the technical data of the mounting instructions Implementation of the following applications is only permitted when STÖBER ANTRIEBSTECHNIK GmbH + Co. KG has been contacted first for permission: Use in non-stationary applications Qualified personnel Since the drive controllers of the model series POSIDRIVE FDS 5000, POSIDRIVE MDS 5000 and POSIDYN SDS 5000 may harbor residual risks, all configuration, transportation, installation and commissioning tasks including operation and disposal may only be performed by trained personnel who are aware of the possible risks. ID

9 Notes on Safety 01 Electronc Cam Personnel must have the qualifications required for the job. The following table lists examples of occupational qualifications for the jobs: Activity Possible occupational qualifications Transportation and storage Worker skilled in storage logistics or comparable training Configuration Graduate engineer (electrotechnology or electrical power technology) Technician (m/f) (electro-technology) Installation and connection Electronics technician (m/f) Commissioning (of a standard Technician (m/f) (electro-technology) application) Master electro technician (m/f) Programming Graduate engineer (electro-technology or electrical power technology) Operation Technician (m/f) (electro-technology) Master electro technician (m/f) Disposal Electronics technician (m/f) In addition, the valid regulations, the legal requirements, the reference books, this technical documentation and, in particular, the safety information contained therein must be carefully: read understood and complied with. Transportation and storage Immediately upon receipt, examine the delivery for any transportation damages. Immediately inform the transportation company of any damages. If damages are found, do not commission the product. If the device is not to be installed immediately, store it in a dry, dust-free room. Please see the mounting instructions for how to commission an inverter after it has been in storage for a year or longer. Installation and connection Installation and connection work are only permitted after the device has been isolated from the power! The accessory installation instructions allow the following actions during the installation of accessories: The housing of the MDS 5000, SDS 5000 and FDS 5000 in the upper slot can be opened. The housing of the MDS 5000 and SDS 5000 in the bottom slot can be opened. Opening the housing in another place or for other purposes is not permitted. ID

10 Notes on Safety Electronc Cam 01 Use only copper lines. For the line cross sections to be used, see table of the NEC standard for 60 o C or 75 o C. Protect the device from falling parts (pieces of wire, leads, metal parts, and so on) during installation or other tasks in the switching cabinet. Parts with conductive properties inside the inverter can cause short circuits or device failure. The motor must have an integrated temperature monitor with basic isolation in acc. with EN or external motor overload protection must be used. The permissible protection class is protective ground. Operation is not permitted unless the protective conductor is connected in accordance with the regulations. Comply with the applicable instructions for installation and commissioning of motor and brakes. Commissioning, operation and service Remove additional coverings before commissioning so that the device cannot overheat. During installation, provide the free spaces specified in the mounting instructions to prevent the inverter from overheating. The housing of the drive controller must be closed before you turn on the supply voltage. When the supply voltage is on, dangerous voltages can be present on the connection terminals and the cables and motor terminals connected to them. Remember that the device is not necessarily de-energized after all indicators have gone off. When network voltage is applied, the following are prohibited: Opening the housing Connecting or disconnecting the connection terminals Installing accessories Proceed as shown below to perform these tasks: 1. Disable the enable (X1). 2. Turn off the supply voltage (power pack and controller power supply as well as any auxiliary voltages for encoder, brake, etc.). 3. Protect the supply voltages from being turned on again. 4. Wait 5 minutes (time the DC link capacitors need to discharge). 5. Determine isolation from the voltage. 6. Short circuit the network input and ground it. 7. Cover the adjacent, voltage-carrying parts. You can then start your work on the drive controller. Repairs may only be performed by GmbH + Co. KG. Send defective devices together with a fault description to: GmbH + Co. KG Abteilung VS-EL Kieselbronner Str Pforzheim GERMANY ID

11 Notes on Safety Electronc Cam 01 Disposal Please comply with the latest national and regional regulations! Dispose of the individual parts separately depending on their nature and currently valid regulations such as, for example: Electronic scrap (PCBs) Plastic Sheet metal Copper Aluminum Residual dangers The connected motor can be damaged with certain settings of drive controllers. Longer operation against an applied motor halting brake Longer operation of self-cooled motors at slow speeds Drives can reach dangerous excess speeds (e.g., setting of high output frequencies for motors and motor settings which are unsuitable for this). Secure the drive accordingly. ID

12 Notes on Safety Electronc Cam Software Using the POSITool software The POSITool software package can be used to select the application and adjust the parameters and signal monitoring of the 5th generation of STÖBER inverters. The functionality is specified by selecting an application and transmitting these data to an inverter. The program is the property of GmbH + Co. KG and is copyrighted. The program is licensed for the user. The software is only provided in machine-readable form. GmbH + Co. KG gives the customer a nonexclusive right to use the program (license) provided it has been legitimately obtained. The customer is authorized to use the program for the above activities and functions and to make copies of the program, including a backup copy for support of this use, and to install same. The conditions of this license apply to each copy. The customer promises to affix the copyright notation to each copy of the program and all other property notations. The customer is not authorized to use, copy, change or pass on/transmit the program for purposes other than those in these regulations. The customer is also not authorized to convert the program (i.e., reverse assembly, reverse compilation) or to compile it in any other way. The customer is also not authorized to issue sublicenses for the program, or to rent or lease it out. Product maintenance The obligation to maintain refers to the two latest program versions created by GmbH + Co. KG and approved for use. GmbH + Co. KG will either correct program errors or will provide the customer with a new program version. This choice will be made by GmbH + Co. KG. If, in individual cases, the error cannot be immediately corrected, STÖBER ANTRIEBS- TECHNIK GmbH + Co. KG will provide an intermediate solution which may require the customer to comply with special operation regulations. A claim to error correction only exists when the reported errors are reproducible or can be indicated with machine-generated outputs. Errors must be reported in a reconstructable form and provide information which is useful to error correction. The obligation to correct errors ceases to exist for such programs which the customer changes or edits in any way unless the customer can prove that such action is not the cause of the reported error. GmbH + Co. KG will keep the respective valid program versions in an especially safe place (fireproof data safe, bank deposit box). ID

13 Notes on Safety Electronc Cam Presentation of notes on safety NOTICE Notice means that property damage may occur if the stated precautionary measures are not taken. CAUTION Caution with warning triangle means that minor injury may occur if the stated precautionary measures are not taken. WARNING Warning means that there may be a serious danger of death if the stated precautionary measures are not taken. DANGER Danger means that serious danger of death exists if the stated precautionary measures are not taken. Information indicates important information about the product or a highlighted portion of the documentation which requires special attention. ID

14 Function Description 03 3 Function Description This chapter explains terms such as the configuration of a cam profile and functions such as the integration of table coupling and the PLCopen blocks. 3.1 Cam Profiles The relationship of the positions is illustrated in a 2-dimensional system of coordinates. The horizontal line shows the position of the master axis while the vertical line shows the position of the slave axis. The master circular length corresponds to the position circumference of the horizontal line. The position circumference of the vertical line corresponds to the slave circular length. A straight line with a slope of 1 corresponds to a 1:1 coupling of master to slave axis. Up to 4 different cam profiles can be stored on the inverter with the Electronic Cam application. You can switch between the cam profiles of congruent cam sections at any time. y = green = red blue Slave scaling 0 Master circular length Figure 3-1 Open (red, green)/closed cam profile (blue) Repeated execution of a cam profile is called cyclic (periodic) processing. Both open and closed cam profiles are possible (Figure 3-1). Behavior for an open and a closed cam profile after a master overflow differs. An open cam profile is when the slave axis is not located at the starting point again after a master circular length. Open cam profiles are used for endless positioning. Closed cam profiles are used for axes with a limited position range. Both endless and limited axis types can be used for the master and slave axis. There are no restrictions on the combination of axis types between master and slave. You specify the kind of slave axis type by selecting the application in the Configuration Assistant. The axis type of the master is set with the parameter G30 master axis type. x ID

15 Function Description 03 The relationship between master and slave can be evaluated absolutely or relatively. The absolute relationship requires master referencing. It can be reconstructed so that only a one-time referencing procedure is necessary. Master referencing is executed via the signal master reference position. The source of the signal is set in parameter G103. When the signal has a positive change in edge the current master position is set to the value entered in the parameter G38 master reference position. Master referencing Information When the master encoder triggers event 37:Encoder, the In Reference bit of the master is deleted regardless of the encoder being used. After power OFF/ON the position is reconstructed correctly even though the bit remains deleted. The In Reference signal of the slave is not affected by this (see chap. 3.3). ID

16 Function Description Table Coupling The coordinates of the cams are stored standardized to 2 30 on the device. Master and slave scaling and master and slave offset are then performed [mm] [ ] 0 0 Figure 3-2 Scaling of a standardized cam Master circular length = 360 The scaling values are transferred by calling the MC_CamIn command. The values for master and slave scaling are specified on the inputs of the block (see Figure 3-3). Figure 3-3 Example of interconnection for MC_CamIn ID

17 Function Description 03 The respective current values are indicated in the following parameters: G854 Master scaling G855 Master offset G856 Slave scaling G857 Slave offset Figure 3-4 illustrates how scaling procedures and offset values work Input SlaveScal* + + Input MstrScal* Input SlavOffs* G80 Masterfilter Master positio G Input MstrOffs* Figure 3-4 Calculation of the scaling and offset values When the MastrAbs input of the MC_CamIn block is active when a rising edge occurs on the Execute input, the master position is evaluated absolutely and is used directly for indexing in the cam table. When the input is inactive, indexing always starts at the beginning of the table. The SlaveAbs input must always be inactive at this time. Remember that this means that, when the cam starts, the value indicated in G862 output table coupling velocity must match the speed in I88. If not, ramping is performed with I11 maximum acceleration to the cam speed. This causes a position difference in the result If the Periodic input is active when there is a rising edge on Execute, the curve is executed cyclically. The prerequisite for this is that the master position must also be cyclic (i.e., the master type must be endless position range). If the input is inactive when there is a rising edge, the cam is executed before the next overflow of the master position via the circular length (or underflow under 0). ID

18 Function Description 03 NOTICE If the cam profile is to be changed during the motion or the scaling is to be modified, always remember to execute this in cam sections which must be congruent in both cam profiles to prevent the axis from jolting. The position cams in the application can be used for this purpose. The master filter is activated by parameter G340. When the master filter is deactivated, the master position is processed unfiltered. Masterfilter Figure 3-5 shows the setup of the master filter. PT n G348 Filtered masterposition Master position G80 2 n PT Modulo 2 Master position Master speed 2 n Master period G341 Masterfilter increment multiplier 1 G342 Masterfilter position low pass Figure 3-5 Setup of the master filter G G344 The standardized cam disk can be linked in in csv format. Any cam profiles can be calculated with this by existing table calculation programs (Excel, OpenOffice, and others) and imported to the POSITool software. Another option is to create cam profiles with the Optimus Motus software. You will find the software on the STÖBER Electronics 5000 CD or on the Internet at You will need a dongle to use this software. This dongle is available from STÖBER Antriebstechnik GmbH & Co. KG under following article no.: Optimus Motus version Article no. Introductory packet Standard packet Filter dead time compensation Masterfilter speed low pass Masterfilter dead time compensation d dt G349 Filtered master-speed Over/And Master speed 1 Will be considered in due course. 2 Only for circular axes ID

19 Function Description 03 After you have installed the software on your PC and connected the dongle, you can call the software from the wizard Master scaling/optimus Motus on the Cams page (see Figure 3-7). For a description of the software, see Online Help (F1 key). Remember that when you use Optimus Motus, you must always import the cam tables via Optimus Motus. Cam profiles exported by POSITool can also be processed. The csv file of an exported cam is shown below: Figure 3-6 View of a CSV file in Excel The first line contains the original source parameters (in Figure 3-6, G64 and G65). These parameters tell you which of the four cam profiles were exported (in our example, cam table 3). These two values can be disregarded when importing a cam profile since each of the four cams can be imported with the Import Assistant. The position coordinates of master and slave axis which do not have to be equidistant are listed starting with the second line. On the master side they must ascend monotonically. In our example point 0 contains the 0 coordinates for master and slave position. The first point x 0 is used for values less than 0 on the cam input. The last point x n is used for values greater than Figure 3-7 shows the page cams of the cam table / master scaling assistant. The first cam profile can be imported and exported on this page. You can access the other cam profiles from the tabs at the bottom. ID

20 Function Description 03 Figure 3-7 Cam table / master scaling assistant Information Cam data can be imported during online operation of POSITool as long as the number of reference points remains the same. If the number of reference points changes cam data can only be imported in offline operation and in configuration mode of POSITool. New cam profiles can only be imported in a configuration. Import in a reverse documentation is not possible. A cam profile can always be exported. ID

21 Function Description PLCopen Programming The application offers the following commands: MC_MoveAbsolute MC_MoveSuperimposed MC_MoveRelative MC_Home MC_MoveAdditve MC_Stop MC_MoveVelocity MC_Reset MC_CamIn MC_CamOut The PLCopen blocks interface with the system via parameters I400 ff. When a PLCopen block is called in the program it uses the parameters starting at I400 ff to communicate with position control within the application and passes on such data as command, target position and speed. The commands change the current state of position control. The following diagram shows the possible states and state changes ID

22 Function Description :Synchronized Motion :Discrete Motion 30 4:Continuous Motion :Stopping :Errorstop :Standstill 8:Homing Figure 3-8 State diagram and presentation of the transitions :Passive ID

23 Function Description 03 Description of the transitions Changeover Triggering 1 : Passive to Standstill MC_AktivierePositionierung when the device is enabled Automatic when I52 = active and when the device is enabled 2: Standstill to Passive MC_DeaktivierePosi MC_Reset Enable off 3: Standstill to Homing MC_Home 4: Homing to Standstill Done 5: Homing to Errorstop Error 1 6: Standstill remains Default With MC_Stop "Standstill" is retained without any other state change 7: Standstill to Errorstop Error 1 8: Errorstop to Standstill MC_Reset when no further quick stop request is queued. Otherwise Errorstop is retained. 9: Stopping to Errorstop Error 1 10: Errorstop remains Default 11: Stopping to Standstill When the profile generator outputs 0 as the reference value speed 12: Standstill to Continuous Motion 13: Standstill to Synchronized Motion MC_MoveVelocity Jog +/- MC_Continue when the command MC_MoveVelocity was aborted with MC_Stop before MC_CamIn 1 Cause of the error condition: Falling edge on a hardware limit switch (except in the Homing state) Quick stop request from the device state machine Motion jobs rejected because of the following reasons: Impermissible direction Target is outside the software limit switches Absolute motion job in unreferenced state Circular axis absolute target position greater than circular length ID

24 Function Description 03 Changeover Triggering 14: Continuous Motion to Error 1 Errorstop 15: Continuous Motion to MC_Stop Stopping Jogging is activated 16: Stopping remains As long as the profile generator outputs a reference value speed other than 0. 17: Discrete Motion to Standstill Done 18: Standstill to Discrete Motion MC_MoveAbsolute MC_MoveRelative MC_MoveAdditive TipStep MC_Continue if MC_MoveAbsolute, MC_MoveRelative or MC_MoveAdditive was aborted by MC_Stop before 19: Homing to Stopping MC_Stop 20: Discrete Motion to Errorstop Error 1 21: Discrete Motion to Stopping MC_Stop Jogging is activated 22: Discrete Motion remains As long as the motion is moving MC_MoveAbsolute MC_MoveRelative MC_MoveAdditive 23: Synchronized Motion to Discrete Motion MC_MoveAbsolute MC_MoveRelative MC_MoveAdditive 24: Discrete Motion to MC_CamIn Synchronized Motion 25: Continuous Motion remains As long as no new command is being executed, no quick stop request is issued and no software limit switch is reached. 1 Cause of the error condition: Falling edge on a hardware limit switch (except in the Homing state) Quick stop request from the device state machine Motion jobs rejected because of the following reasons: Impermissible direction Target is outside the software limit switches Absolute motion job in unreferenced state Circular axis absolute target position greater than circular length ID

25 Function Description 03 Changeover 26: Continuous Motion nach Synchronized Motion 27: Synchronized Motion nach Continuous Motion 28: Discrete Motion nach Continuous Motion 29: Continuous Motion nach Discrete Motion Triggering MC_CamIn MC_MoveVelocity MC_CamOut MC_MoveVelocity MC_MoveAbsolute MC_MoveRelative MC_MoveAdditive 30: Synchronized Motion nach MC_Stop Stopping Jogging is activated 31: Synchronized Motion bleibt As long as no command other than MC_CamIn or MC_MoveSuperimposed is being executed, no quick stop request is issued and no software limit switch is reached. 32: Synchronized Motion nach Error 1 Errorstop 33: Aus allen Zuständen außer MC_Reset Errorstop nach Passive 34: In den Zustand Homing aus MC_Home den Zuständen Continous Motion, Discrete Motion und Synchronized Motion 35: Continuous Motion nach Software limit switches are reached Standstill The commands will now be described. For a description of the block inputs and outputs see block description documentation (ID ). 1 Cause of the error condition: Falling edge on a hardware limit switch (except in the Homing state) Quick stop request from the device state machine Motion jobs rejected because of the following reasons: Impermissible direction Target is outside the software limit switches Absolute motion job in unreferenced state Circular axis absolute target position greater than circular length ID

26 Function Description MC_MoveAbsolute The MC_MoveAbsolute command is triggered via blocks (with time stamp) and (without time stamp). It causes a movement to an absolute position. The drive must be referenced before the command can be triggered (see MC_Homing below). With an endless axis this command only accepts target positions which are less than the circular length I01. Figure 3-9 shows an example of the interconnection of two MC_MoveAbsolute blocks. The time diagram in Figure 3-10 shows two processing procedures. In the first case the block with the target position P00 = 500 mm and the speed P01 = 5000 mm/s is started (BE1) and finished. The Done signal of the first block causes the second motion job with the target position P02 = 800 mm and the speed P04 = 3000 mm/s to be executed. The two separate motion profiles can be clearly seen. In the second case the next process block is already started before the target position of the first process block was reached. This causes the process block data of the second process block (target position, speed and acceleration ramps) to become valid at the rising edge of the signal on BE2. The second motion profile differs from the first case. Figure 3-9 Example of interconnection for MC_MoveAbsolute ID

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