Robo Cylinder Automation Examples Manual (Part 1)

Transcription

1 Robo Cylinder Automation Examples Manual (Part 1) Intelligent Actuator, Inc.

2 This publication was written to assist you in better understanding this part of your IA system. If you require further assistance, please contact IA Technical Support. For Central and East Coast Time Zones, please call our Itasca, IL office at or FAX For Mountain and Pacific Time Zones, please call our Torrance, CA office at or FAX ; Monday thru Friday from 8:30AM to 5:00PM. Intelligent Actuator, Inc. U.S. Headquarters 2690 W. 237th St Torrance, CA / FAX Central Region Office 1261 Hamilton Parkway Itasca, IL / FAX Eastern Region Office 7 South Main St. Suite F Marlboro, J / FAX Publication o: IAI-077 Aug 2002 Intelligent Actuator, Inc. All rights reserved. o portion of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Intelligent Actuator, Inc. Disclaimer The information and technical data contained herein are subject to change without notice. Intelligent Actuator, Inc. assumes no responsibility for any errors or omissions regarding the accuracy of the information contained in this publication. 2

3 Table of Contents Application Example 1 (Sorting items flowing on the cable track) 4~11 Outline, the differences and benefits 4 Movement flow (entire illustration) 5 System diagram 6 Control specifications, signal terminal diagram of the I/O 7 The Robo Cylinder setting 8 Movement flow chart (for reference) 9 PLC ladder diagram (for reference) 10 Application Example 2 (Liquid inserting work to multiple various shaped containers) 12~19 Outline, the differences and benefits 12 Movement flow (entire illustration) 13 System diagram 14 Control specifications, signal terminal diagram of the I/O 15 The Robo Cylinder setting 16 Movement flow chart (for reference) 17 PLC ladder diagram (for reference) 18 Application Example 3 (Drum roll device for wire material) 20~27 Outline, the differences and benefits 20 Movement flow (entire illustration) 21 System diagram 22 Control specifications, signal terminal diagram of the I/O 23 The Robo Cylinder setting 24 Movement flow chart (for reference) 25 PLC ladder diagram (for reference) 26 Application Example 4 (Stacking wrapped boxes flowing on a cable track) 28~35 Outline, the differences and benefits 28 Movement flow (entire illustration) 29 System diagram 30 Control specifications, signal terminal diagram of the I/O 31 The Robo Cylinder setting 32 Movement flow chart (for reference) 33 PLC ladder diagram (for reference) 34 Application Example 5 (Press-fit a lid onto a plastic container) 36~43 Outline, the differences and benefits 36 Movement flow (entire illustration) 37 System diagram 38 Control specifications, signal terminal diagram of the I/O 39 The Robo Cylinder setting 40 Movement flow chart (for reference) 41 PLC ladder diagram (for reference) 42 3

4 Application Example 1: Device Function: To sort items traveling on a conveyor Movement: Line diverter Speed Acceleration Setting Function: Characteristics: The Robo Cylinder allows the speed allows the speed and acceleration to be set for each position with a numeric value. Speed is set in 1mm/sec increments (minimum input is 1mm/sec), and the acceleration is set in 0.01G increments (minimum input acceleration is 0.01G). By adjusting the velocity and acceleration on the fly, movement of the item is possible without causing damage from the impact. Existing specifications: An air cylinder is used to push items traveling on a conveyor onto a different line. Existing problems: The air cylinder causes damage when the rod tip plate impacts the item at high speed. Therefore, cycle time cannot be reduced because speed is restricted. Machine Changes: Line diverter was modified from air cylinder to the Robo Cylinder. Appropriate Robo Cylinder: RCS-SA5 Slider High Speed Type 400 stroke (Model type: RCS-SA5I-20-H-400) RCS-SA5 Slider High Speed Type Specifications Range Speed Payload Stroke Maximum 800mm/sec (Minimum setting of 1mm/sec) Horizontal: Maximum 4kg Vertical: Maximum 1kg Stroke 50~500mm (50mm increments) Benefits: 1) By decreasing the acceleration during start to 0.05G and setting speed to 800mm/sec, not only is damage to the item from impact avoided, but also the item is quickly transferred to a separate conveyor reducing cycle time. 4

5 Movement Flow: 1) Boxes are traveling across the conveyor. 2) The bar code scanner reads the bar code of the box and determines whether or not sorting is needed. 3) When sorting is needed, the box reaches the set position, and the slider moves forward sliding the box onto the opposite conveyor. 4 ) In case sorting is not needed, continues passing. 1 RCSSA RCSRB RCSSA RCSRB RCSRB

6 System Diagram Bar Code Reader Work 1 Work 1 Work 2 Work 1 Conveyor Drive Motor Slider Passing Detection Sensor M Operation Panel RCS Actuator Electrical Panel Emergency Stop Circuit PLC RCS Controller I/O Power Unit Power Power < General Operation Flow Chart > Operation System start via operation panel Work recognition due to power code reader 2 1 Passing Passing detection RCS start movement RCS movement End 6

7 Control Specifications: 1) Under normal circumstances, Servo O Signal and Hold Signal are turned O. 2) When Robo Cylinder receives Operation Ready Signal from the Conveyor Control Sequence, move to Position0*. 3) Once the Sorting Signal is received from the Conveyor Control Sequence, move to position 1*. 4) When the Conveyor Control Sequence receives the Movement Complete Signal from the Robo Cylinder, return the Robo Cylinder back to Position 0*. 5) Then, repeat steps, 3 and 4. 6) If the Positioning Complete Signal does not turn O within 2 seconds after the Robo Cylinder Start Signal turns O, the alarm will turn O. 7) In case the Alarm Signal from the Alarm Signal turns OFF, the alarm LED will turn O. * Position 0 and 1 refer to o. 0 and 1 of the position data which is located within the controller. For further details, please refer to the section, PC Display Screen, located on the next page. ote: 1. The Hold Signal (normally O) stops the Robo Cylinder s movement due to the hold of the conveyor. To stop the actuator, turn OFF the Hold Signal. To continue movement in progress, turn the Hold Signal back O. To cancel the movement in progress, turn the Hold Signal back O. To cancel the movement in progress, toggle the Reset Signal O before turning back O the Hold Signal. 2. The Operation Ready Signal and Sorting Signal from the Conveyor Control Signal will turn OFF once the RCS control sequence recognizes these Signals. 3. If the RCS is in alarm or emergency stop, the Conveyor Controller will not give a System Ready or Move Signal to any device on the controller. 4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel. 5. This control is specifically for the Robo Cylinder controller. I/O Signal PLC RCS Controller Conveyor Control Sequence RCS Control Sequence Operation Preparation Sorting Signal Alarm Reset Alarm 1 (Over time) Alarm 2 (RCS Alarm) RD STR ALRST AL1 AL2 PC1 *ilk RES SO PM1 PFi ZFi *ALM C *EMG Start Command Position 1 Hold Reset Servo O Complete Position 1 Positioning Complete Homing Complete Alarm Moving Emergency Stop 7

8 Robo Cylinder Setting: The operation for the Robo Cylinder is extremely simple. To move, all Robo Cylinder requires is to teach a position to an assigned number. There are two method to teach positions: 1. umeric input (coordinate value) 2. Input the coordinate value of the desired position by manually moving the slider or by machine operation (JOG function). Use either the PC Software or Teach Pendant to input the position data into the controller. The PC Software and Teach Pendant share the same content for teaching the basic columns (refer to the PC Display Screen diagram shown at the bottom of the page). Positioning between two points (in case of direct numeric input (coordinate value): Set Position 0 at the motor side end (coordinate value 0) and Position 1 at the non-motor end (coordinate value 400), and execute a movement reciprocating between the two points. 1. Input the value 0 into the Position for o Speed, the column next to Position of the PC display screen, will be the speed to move to Position 0, so input your desired speed. Here, we input 800mm/sec. In the Speed Column, next to the Position Column in the PC display screen, input the desired speed at which to move to Position 0. For this case, enter 800mm/sec. 3. Input the value 400 into the Speed Column for Position o Input the value 800 into the Speed column for Position o.1. The above steps s position data input. The other columns are required for other functions. Input is not necessary for this application. Below is the Point Edit Screen located within the controller. Position Data 8

9 Movement Flow Chart (for reference) [Slide Flow Chart] Pusher Servo O Signal O ormally O. Operation prepares homing Hold Signal O Operation Ready Signal O Move to Position 0 Wait for Operation Ready Signal from Conveyor Control Sequence. (Homing) Set Position 0, and turn Start Signal O. In the initial command after power UP, execute home. Stand by Position 0 positioning Stand by position Sorting movement Sorting Signal O Move to Position 1 Position 1 positioning Wait for Sorting Signal from Conveyor Control Sequence. Set position 1 and turn O Start Signal. [Alarm Detection Flow Chart] Alarm detection Start Signal O Operation end Positioning Complete Signal O Move to position 0 Time set Position 0 positioning Alarm Signal Time up End RCS Controller Abnormal detection reset Over time Alarm reset Wait for Alarm Reset Signal from dispenser control sequence. Over time reset RCS Controller Abnormal detection error End 9

10 PLC Diagram Reference The following is a basic circuit to control the Robo Cylinder. Therefore, it does not connect with the circuit that controls the entire machine. In addition, this circuit was not designed for a particular PLC manufacturer and instead, describes a Robo Cylinder controller circuit from a general circuit. When designing your circuit, please remember the aforementioned. SO Servo O *ilk Hold PFi Timer 1 Complete Position Strobe Signal PM1 Timer 1 0.1sec R01 Complete Position 0 PM1 Timer 1 R02 Complete Position 1 RD R04 R03 Homing Start Pulse R03 RD R04 Homing Start Pulse Support R04 R03 PFi ZFi R06 Position 0 Positioning Start Support R02 C R06 Position 0 Start Confirm R06 R06 R01 R08 Position 0 Positioning Complete STR R09 R08 Position 1 Positioning Start Pulse R08 STR R09 Positioning 1 Positioning Start Pulse Support R09 R01 R08 R11 Position 1 Positioning Start Support C R11 Position 1 Start Confirm R11 R11 R02 Positioning 1 Positioning Complete R14 R13 Position 0 Set R13 R13 R14 Position 1 Set R14 R14 PC1 Command Position 1 Timer 2 0.1sec Start Wait Timer 2 Start Signal R15 Position 0 Positioning Over Time Detection Support R15 R16 Position 1 Positioning Over Time Detection Support R16 R15 R16 Timer 3 2sec Positioning Over Time 10

11 Reference Timer 3 AL1 ALRST AL1 Alarm 1 (Overtime) *ALM AL2 ALRST AL2 Alarm 2 (RCS Alarm) 11

12 Application Example 2: Device Function: To insert liquid into multiple types of containers that requires Movement: speed change Liquid Dispensing Speed Change Function: Characteristics: In the midst of moving to a desired position (assumed as P1), the Robo Cylinder allows the user to send a signal to change to another position (assumed as P2). The Robo Cylinder cancels the move to P1 and then continues onto P2 from the point where the signal was received. Using the above function with P1 speed set to 100, P2 speed to 200, and designated position set the same for the both points, speed will increase from 100 to 2000 without stopping. Existing Specifications: When a major distance is set between the dispensing nozzle and the surface of the liquid in the container, the liquid will bubble. In order to prevent the bubbles, the dispensing nozzle must rise at the same rate as the liquid in the container. The rate of the liquid rising increases when the cross section of the container becomes smaller. Existing Problems: Cam component adjustment is required for the dispensing nozzle to match the speed changes of the rising liquid in the container slowing down cycle time. Content Changes: By using the Robo Cylinder Rod Type, the speed setting for the nozzle is easily executed even with multiple types of containers. Applicable Robo Cylinder: RCS-RA 55 High Speed Rod Slim Type with 250 stroke (model type: RCS-RA55I-60-G-H-250-B) RCS-RA55 Rod Slim High Speed Type Specifications Range Speed Payload Stroke Maximum 800mm/sec (Minimum speed possible 1mm/sec) Horizontal: Maximum 12kg (*in case with guide) Vertical: Maximum 2kg 50~300mm (50mm increments) Benefits: 1. Speed can be adjusted in 1mm/sec increments making efficient speed adjustment. 2. ozzle speed is easier to set when no adjustment of hardware is required. 12

13 Movement Flow 1. When the container flows on the conveyor and stops underneath the insert nozzle, the rod lowers to the liquid insert start point. 2. The rod (dispensing nozzle) rises at the same constant speed as the liquid in the container. 3. The speed of the rod (dispensing nozzle) will increase at the position where the container s cross-section becomes smaller. 4. After dispensing the liquid, the rod (dispensing nozzle) will move up to the stand-by position

14 System Diagram RCS Actuator Dispenser Conveyor Driver Motor Passing Detection Sensor M Electrical Control Box Emergency Stop Circuit I/O PLC Power Operation Panel RCS Controller Power Unit Power [General Operation Flow Chart] Operation System start via operation panel ozzle lowering Work detection sensor O Dispenser O liquid insert start RCS start ozzle rises (high speed) Conveyor stop RCS start ozzle rises ozzle rising Stop detection RCS start ozzle lowers ozzle rises (low speed) Timer O Time Up Dispenser OFF liquid insert end Conveyor start End 14

15 Control Specifications: 1) Under normal circumstances, Servo O Signal and Hold Signal are turned O. 2) When Robo Cylinder receives Operation Ready Signal from the Conveyor Control Sequence move to Position 0* (stand-by position). 3) Move to Position 1* (liquid dispense start position) when the container is positioned by the conveyor underneath the nozzle signaling the insert start command from the dispenser control sequence. 4) From the Positioning Signal of Position 1, the dispenser control sequence starts the liquid flow as the Robo Cylinder moves to Position 2*. 5) Upon move start to Position 2*, after 3 seconds (at the position where the cross section of the container becomes smaller), change the move position to Position 3*. 6) Upon completing the move to Position 3*, move to Position 0. 7) Repeat above steps, 3) ~ 6). 8) The alarm will turn O if the Robo Cylinder takes over 5 seconds to return from Position 3* to Position 0. 9) When the Alarm Output (normally O) turns OFF, the alarm LED will turn O. * Position 0 through 3 refer to o. 0 through 3 of the position data located within the controller. For further details, please refer to the section, PC Display Screen, located on the next page. ote: 1. The Hold SIgnal (normally O) stops the Robo Cylinder s movement due to a clog in the liquid dispenser. To stop the actuator, turn OFF the Hold Signal. To continue movement in progress, turn the Hold Signal back O. To cancel the movement in progress, turn the Reset Signal O before turning back O the Hold Signal. 2. The Operation Ready Signal and Insert ozzle Start Signal from the Dispenser Control Sequence turn OFF after confirming the RCS RCS Controller recognized the Signals. 3. If the RCS is in alarm or emergency stop, the Dispenser Controller will not give a System Ready or Move Signal to any device on the controller. 4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel. 5. This program is specifically for the Robo Cylinder Controller. I/O Signal Terminal Diagram PLC RCS Controller Dispenser Control Sequence RCS Control Sequence Operation Ready Insert start Alarm reset Alarm 1 (Overtime) Alarm 2 (RCS alarm) RD STR ALRST AL1 AL2 PC1 PC2 *ilk RES SO PM1 PM2 PFi ZFi *ALM C *EMG Start Command Position 1 Command Position 2 Hold Reset Servo On Complete Position 1 Complete Position 2 Positioning Complete Homing Complete Alarm Moving Emergency Stop 15

16 Robo Cylinder Setting: To change the speed without stopping during movement, send a separate position command. For instance, Position A is set to 300mm/sec, a move command is sent to Position B, which is ahead of Position A. Position B is set to 500mm/sec. Speed will increase from 300 to 500. Speed Changes: When the speed is a direct numeric input, teach the position coordinate value by using the JOG function. Position 0 is the stand-by station. Position 1 is the liquid dispensing start point. Position 2 is the passing point. Position 3 is the liquid dispensing end point. 1. After selecting o. 0, use the JOG (forward backward) button to adjust the suitable position for the stand-by point. Once the position is determined, push the Teach Point button to incorporate the current coordinate value into o. 0 Position. 2. Directly input 500 into the Speed of o Similar to step 1 after selecting o. 1, move the actuator with the JOG function and teach the Liquid Dispensing Start Point. 4. Directly input 500 into Speed of o Apply the above step 1 to the Position of o Directly input 300 into the Speed of o Apply the above step 1 to the Position of o Directly input 500 into the Speed of o. 3. From the above steps, position data input is d. PC Display Screen: Below is the Point Edit Screen which located within the controller. Jog Button Teach Point Button Position Data 16

17 Movement Flow Chart (for reference) [Liquid Dispensing Position Control] Liquid insert position control Servo Signal O Hold Signal O ormally O. Operation Ready Homing Operation Ready Signal O Wait for Operation Ready Signal from dispenser control sequence. Move to Position 0 (Homing) Stand-by Insert the reset Sets Position 0, and turn O Start Signal. Execute homing for the initial command after power UP. [Alarm detection flow chart] Position 0 positioning Stand-by position Alarm detection Insert Movement Insert ozzle command Move to Position 0 Position 1 Portioning Complete Move to Position 1 Moving time timer Time up Wait for insert ozzle command from dispenser control sequence. Set position o and turn O the Start Signal. The dispenser control sequence turns O due to the positioning and begins insert. Set Portion 2 and turn O the Start Signal. Move at the speed assigned in Position 2. Alarm Signal RCS Controller Abnormal detection Insert Start command Insert Timer set Time up Overtime Move to Position 3 Set Position 3 and turn O the Start Signal. Position 3 Positioning Complete Move at the speed assigned in Position 3. Alarm reset Overtime reset Insert nozzle RCS Controller Abnormal detection reset Operation End End Move to Position 0 Position 0 positioning End 17

18 PLC Ladder Diagram The following is a basic circuit to control the Robo Cylinder. Therefore, it does not connect with the Reference PFi PM1 PM1 PM1 PM1 RD R06 circuit that controls the entire machine. In addition, this circuit was not designed for a particular PLC manufacturer and instead, describes a Robo Cylinder controller circuit from a general circuit. When designing your circuit, please remember the aforementioned. PM2 PM2 PM2 PM2 R06 Timer 1 Timer 1 Timer 1 Timer 1 RD SO * ilk Timer 1 0.1sec R01 R02 R03 R04 R06 Servo O Hold Complete Position Strobe Signal Complete Position 0 Complete Position 1 Complete Position 2 Complete Position 3 Homing start pulse Homing start pulse support R04 PFi R19 ZFi R08 Position 0 positioning start support R08 C R09 R08 Position 0 start confirm R08 R09 R01 R09 Position 0 positioning STR R11 R11 STR R11 Position 1 positioning start pulse Position 1 positioning start pulse support R01 R13 Position 1 positioning start support R13 C R14 R13 Position 1 start confirm R13 R14 R02 R15 R14 Position 1 positioning R02 R15 R14 R16 R15 Position 2 positioning start support R15 R16 C R17 R16 Position 2 start confirm R16 Timer 2 R17 R18 Timer 2 3sec R17 Position 3 start wait Position 3 start support R17 R18 C R19 R18 Position start confirm R18 R19 R04 R19 Position 3 positioning 18

19 Reference R20 R15 R17 R21 R22 R23 R20 Position o set R21 R15 R17 R20 R22 R23 R21 Position 1 set R15 R22 R17 R20 R21 R23 R22 Position 2 set R17 R23 R15 R20 R21 R22 R23 Position 3 set R21 R23 PC1 Command position 1 R22 R23 PC2 Command position 2 Timer 2 0.1sec Star wait R15 R17 Timer 2 OK R24 R09 R25 R24 Start signal Overtime detection support R24 R25 R15 R09 R25 Start confirm R24 Timer 3 AL1 ALRST Timer 3 5sec AL1 Insert movement overtime Alarm 1 (Overtime) *ALM AL2 ALRST AL2 Alarm 2 (RCS alarm) 19

20 Application Example 3: Device Function: Movement: Multiple Positions (Pitch) Function: Wire feeder to roll on drum Position the wire material that is being drum rolled Characteristics: The incremental move function of the Robo Cylinder is a relative movement. The numeric value in the position data* is incremented from the current position. The procedure for the incremental movement is the same as a normal movement. By assigning the position data* number and toggle the start signal input, the Robo Cylinder moves to the coordinate value. However, with the increment setting, the actuator increment [+] or [-] for only the amount in the position data. Existing Specifications: * Position data is the position data that is input into the controller. For details, please refer to the PC Display Screen located on Page 21 of this manual. Existing Problems: In cases where accuracy is not required, the current synchronized machine increased cost and production time; therefore, an easier and more affordable device is needed. Machine Changes: Mount the wire on the Robo Cylinder Slider Type and move only in the needed area. Appropriate Robo Cylinder: RCS-SA5 Slider High Speed Type 300 stroke (model type: RCS-SA51-20-H-300) Benefits: RCS-SA5 Slider High Speed Type Specifications Range Speed Payload Stroke Maximum 800mm/sec (minimum setting of 1mm/sec) Horizontal: Maximum 4kg (*in case with guide) Vertical: Maximum 1kg 50~300mm (50mm increments) 1. Utilizing the Robo Cylinder s pitch function, the price of rolling machine was reduced. 2. Programming of the machine became less complicated because the only a signal to the controller is required. 3. Machine change to different size of drums or wire thickness is now smoother. Only the increment amount needs to be changed in the Robo Cylinder controller. 20

21 Movement Flow 1. By toggling the operation ready switch, the slider will move to the start position. 2. By toggling the start switch, the drum begins rolling the wire and the actuator constantly increments 10mm. 3. When the wire reaches the edge of the drum, the actuator increments at the same rate in the opposite direction. 4. Once the wire is ly wound, the Robo Cylinder stops

22 System Diagram RCS Actuator M Drum driver motor [+] [-] EC Drum rolling detection encoder Electric Panel Emergency stop circuit I/O PLC Power Operation panel RCS Controller Power unit Power [General Operation Flow Chart] Operation System start via operation panel Rolling angle search RCS start Move to start position Start position move RCS start [+] pitch transfer [+] pitch transfer count count up [-] pitch transfer count up Drum rolling start RCS start [-] pitch transfer Drum rolling counter up RCS start Move to stand-by position End 22

23 Control Specifications: 1) Under normal circumstances, Servo O Signal and Hold Signal are turned O. 2) When the Robo Cylinder controller receives Operation Ready Signal from the Drum Rolling Controller, move to position 0*. 3) When Robo Cylinder controller receives start position command from the Drum Rolling Controller, move to Position 1. 4) The incremental Signal from the Drum Rolling Controller pulses 1 time per roll at the same rotating angle. 5. When the first row of wire is on then roll, from the control sequence, the reverse pitch transfer command outputs. 6. Repeat steps 4) and 5) for the amount set into the Control Sequence. After receiving Roll Complete Signal, move to Position 0 and wait for new drum. 7. The time out alarm will turn O if the increment move does not in 1 second or if the move to Position 0* does not within 5 seconds after roll signal.g 8. The alarm LED indicator will turn O when the Alarm Signal (normally O) is turned OFF from the Robo Cylinder. * Positions 0~3 refer to the o.0~3 of the position data located within the controller. (For details, please refer to the section, PC Display Screen located on the next page of this manual. ote: 1. The Hold Signal (normally O) will turn OFF when the drum stops. In order to continue with the move simply turn the Hold Signal O again. To cancel the move in progress, toggle the Reset Signal before turning O the Hold Signal. 2. The start position transfer command, Rolling Complete Signal and the Operation Ready Signal from the Drum Rolling Controller turn OFF when either the Increment Pulse Signal or RCS control recognizes the signal. 3. If the RCS is in alarm or emergency stop, the Drum Roll Controller will not give a System Ready or Move Signal to any device on the controller. 4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel. 5. The Drum Roll Controller checks for the Operation Ready Signal and the Start Move Signal. The RCS Controller does not perform the check. 6. This program is specifically for the Robo Cylinder Controller. I/O Signal Terminal Diagram PLC RCS Controller Drum Rolling Controller RCS Controller Prepare operation Start location move + Incremental transfer - Incremental transfer (Reverse direction) Rolling Alarm reset Alarm 1 (Overtime) Alarm 2 (RCS alarm) RD STR PPiT MPiT ED ALRST AL1 AL2 PC1 PC2 *ilk RES SO PM1 PM2 PFi ZFi *ALM C *EMG Start Command Position 1 Command Position 2 Hold Reset Servo O Complete Position 1 Complete Position 2 Positioning Complete Homing Alarm Moving Emergency stop 23

24 Robo Cylinder Setting: The Incremental move function of the Robo Cylinder is a relative movement. The numeric value in the position data* is incremented from the current position. The procedure for the incremental movement is the same as a normal movement. By assigning the position data* number and toggle the start signal input, the Robo Cylinder moves to the coordinate value. However, with the increment setting, the actuator increments [+] or [-] for only the amount in the position data. Incremental Move Method (with direct numeric input of move amount): Position 0 is the stand-by point. Position 1 is the start point (coordinate value 0). Position 2 is the increment amount in the positive direction (move amount 10). Position 3 is the incremental amount in the negative direction (move amount -10). 1) Input 0 into the position of o. 0. 2) Input 500 into the speed of o.0. 3) Input 100 into the position of o.1 4) Input 400 into the speed of o.1. 5) Input 10 into the position of o.2. 6) Input 300 into the speed of o.2. 7) Input 1 into the incremental assign of o.2. 8) Input 1 into the incremental assign of o.3. 9) Input -10 into the position of o.3. 10) Input 300 into the speed of o.3. The above steps position data input. When in normal positioning mode (move distance from home), the incremental column value is 0, and to increment move (distance from current position), the incremental column value is 1. In the above scenario, if you select to move to Position 1, the actuator move 100mm away from home, or if you select Position 2, the actuator moves 10mm in the positive [+] direction from the current position (Position 3 move 10mm in the negative [-] direction). PC Display Screen: * To input a negative numeric value to a position, first input 1 into the incremental assign. The following screen shows the Point Data Edit Screen seen through the PC software. Position Data 24

25 Movement Flow (For reference) [Rolling Drum Incremental Flow Chart] Rolling drum incremental flow Servo O Signal O [Alarm Detection Flow Chart] Operation prepares Homing Stand-by Hold Signal O Operation Ready Signal O Move to Position 0 Position 0 Positioning Complete Start position move command ormally O. Wait for start position move command from rolling drum controller. (Homing) Set Position 0 and turn O the Start Signal. Execute homing for the first command upon homing. Stand-by position Wait for start position move command from rolling drum controller. Alarm detection [+] Incmrental command Positioning signal O [-] Incremental command Timer set Move to Position 1 Set Position 1 snf turn O the Start Signal. Alarm Signal Time-up Position 1 Positioning The rolling drum controller starts the drum rotation from this signal. RCS controller abnormal detection Over-time [+] incremental move command Alarm reset Rolling movement Move to Position 2 Position 2 Positioning Incremental Signal from controller executes incremental move in [+] direction. Overtime reset RCS Controller abnormal detection reset End [-] Incremental move command Move to Position 3 Incremental Signal from controller executes incremental move in [-] direction. Operation End Position 3 Positioning Move to Position 0 Rolling Position 0 Positioning End 25

26 PLC Ladder Diagram Reference The following is a basic circuit to control the Robo Cylinder. Therefore, it does not connect with the circuit that controls the entire machine. In addition, this circuit was not designed for a particular PLC manufacturer and instead, describes a Robo Cylinder controller circuit from a general standpoint. When desigining your circuit, please remember the aforementioned. SO Servo O *ilk Hold PFi Timer 1 Complete Position Strobe Signal PM1 PM2 Timer 1 0.1sec R01 Complete Position 0 PM1 PM2 Timer 1 R02 Complete Position 1 PM1 PM2 Timer 1 R03 Complete Position 2 PM1 PM2 Timer 1 R04 Complete Position 3 RD R06 Homing start pulse RD R06 Homing start pulse support R06 PFi ZFi R08 Position 0 positioning start support R25 R04 C R09 R08 Position 0 start confirm R08 R08 R01 R09 Position 0 positioning R09 STR R11 Position 1 positioning start pulse STR R11 Position 1 positioning start pulse support R11 R01 R13 Position 1 positioning start support C R14 R13 Position 1 start confirm R13 R13 R02 R17 R14 Position 1 positioning R14 PPiT R16 R15 Position 2 positioning start support R15 PPiT R16 Position 2 positioning start pulse support R16 R02 R14 R15 R18 R17 Position 2 positioning start support R03 R19 R17 R17 C R19 R18 Position 2 start confirm R18 R18 R03 R17 R22 R19 Position 2 positioning R19 MPiT R21 R20 Position 3 positioning start pulse 26

27 Reference R20 R21 MPiT R21 Position 3 positioning start pulse support R03 R04 R19 R24 R20 R23 R22 Position 3 positioning start support R22 R22 R23 C R24 R23 Position 3 start confirm R23 R24 R04 R22 R24 Position 3 positioning ED R26 R25 Position 0 positioning start pulse R25 R26 ED R26 Position 0 positioning start pulse support R27 R17 R22 R28 R29 R30 R27 Position 0 set R28 R17 R22 R27 R29 R30 R28 Position 1 set R17 R29 R22 R27 R28 R30 R29 Position 2 set R22 R30 R17 R27 R28 R29 R30 Position 3 set R28 R30 PC1 Command position 1 R29 R30 PC2 Command position 2 Timer 2 0.1sec Start wait R17 R22 Timer 2 Start Signal R17 R31 R19 R31 Position 2 increment overtime detection support R22 R32 R24 R32 Position 3 increment overtime detection support R31 R32 Timer 3 1sec Pitch transfer overtime ED R33 R09 R33 Complete positioning overtime detection support R33 Timer 4 Complete position positioning overtime Timer 3 5sec AL1 Alarm 1 (overtime) Timer 4 AL1 ALRST *ALM AL2 ALRST AL2 Alarm 2 (RCS alarm) 27

28 Application Example 4: Device Function: Movement: Stacking boxes traveling on a conveyor Move down at a constant increment stacking a constant number of boxes Multiple Positions (Increment) Function: Characteristics: The Incremental move function of the Robo Cylinder is a relative movement. The numeric value in the position data* is incremented from the current position. The procedure for the incremental movement is the same as a normal movement. By assigning the position data* number and toggle the start signal input, the Robo Cylinder moves to the coordinate value. However, with the increment setting the actuator increments [+] or [-] for only the amount in the position data. Existing Specifications: The robot receives the box traveling on the conveyor and stacks them up until the set amount is reached then transfers the stacked boxes to the next machine. Existing Problems: Increasing the line is not possible to decrease the cycle time. Machine Changes: Use the increment function of the Robo Cylinder and lower the items in a constant amount in the middle of the conveyor. Then stack the items one after another until the set amount is reached and send them to the next station. Appropriate Robo Cylinder: RCS-RA55 Low Speed Rod Type 300 stroke (model number: RCS-RA55I-100-G-L-300B) RCS-RA55 Low Speed Rod Type Specifications Range Speed Payload Stroke Maximum 200mm/sec (minimum setting is 1mm/sec) Horizontal: Maximum 60kg (*in case with guide) Vertical: Maximum 18kg 50~300mm (50mm increments) Benefits: 1. Cycle time dramatically reduced. 2. The increment amount is adjustable to allow for multiple box sizes. 3. In comparison to an articulate robot system, cost is reduced. 28

29 Movement Flow 1. The boxed item travels on the conveyor. 2. After the box hits Stopper 1, the Robo Cylinder lowers the thickness of one box. 3. The next box traveling on the conveyor stacks on top of the previous box. Once the box hits Stopper 1, the actuator lowers the thickness of one box again. 4. Repeat above moves until the assigned number of boxes has been stacked. Then Stopper 2 rises and Stopper 1 lowers. The Robo Cylinder rises after the stoppers are done moving. 5. Once the Robo Cylinder rises parallel with the conveyor, the stacked boxes transfer to the next packaging machine Stopper Stopper 2 29

30 System Diagram Packaging Machine Part Detection Sensor Separate Packaging Machine Part Part Part Stopper 1 Stopper 2 RCS Actuator Conveyor Drive Motor M Electrical Control Box Emergency Stop Circuit I/O PLC Power Operation Panel RCS Controller Power Unit Power [General Operation Flow Chart] Operation System start via operation panel Stopper 1 rises Part detection O Stopper 2 rises Stopper 1 lowers Stopper 2 lowers Part count RCS rising Part counter count UP RCS start RCS rises RCS start 1 increment lowers via increment function Part detection OFF 1 incremental End 30

31 Control Specifications: 1) Under normal circumstances, Servo O Signal and Hold Signal are turned O. 2) After receiving Operation Ready Signal from the Packaging Controller, move to Position 0*. 3) Upon Position 0*, move, move the Robo Cylinder to Position 1 (stand-by position). 4) After Positioning Complete Signal of Position 1, the Packaging Controller raises Stopper 1 and lowers Stopper 2. 5) When the part hits the stopper on the conveyor, the Packaging Controller counts the part. 6) ext, move to Position 2* after receiving Lower Command (increment=height of box). 7) Repeat steps, 5 and 6 until the value on the counter matches the preset amount. 8) Once the counter matches the preset amount, the Packaging Controller raises Stopper 2 and lowers Stopper 1. 9) Then, when given the Rise Command, the Robo Cylinder moves to Position 1 (stand-by position). 10) When the Robo Cylinder s the move to Position 1, the rollers on the conveyor rotate sending the part to the next packaging machine, 11) After the Part Detection Sensor turns OFF, Stopper 1 rises up, and Stopper 2 lowers. 12) Repeat steps 5 through ) If the Increment movement does not within 2 seconds, the alarm output will turn OFF. 14) The alarm LED indicator will turn O if the Alarm Output is turned OFF by the Robo Cylinder. * Positions 0~2 refer to o. 0~2 in the position data stored in the controller. (For details, please refer to the section, PC Display Screen which is located on the next page of this manual.) ote: 1. To stop the Robo Cylinder in the event of a part clog, turn OFF the Hold Signal (normally O). turn OFF the Hold Signal (normally O). To continue the move in progress, run the Hold Signal O. To cancel the move in progress, toggle the Reset Signal O before turning O the Hold Signal. 2. The Operation Ready Signal, Rise command, and Lower command from the Packaging Controller turn OFF when the Pulse Signal or RCS controller recognizes the signals. 3. If the RCS is in alarm or emergency stop, the Conveyor Controller will not give a System Ready or Move Signal to any device on the controller. 4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel. 5. This control is specifically for the Robo Cylinder. I/O Signal Terminal Diagram PLC RCS Controller Packaging Control Sequence RCS Control Sequence Operation Ready Lower Command Riser Command Alarm Reset Alarm 1 (Overtime) Alarm 2 (RCS Alarm) RD DW UP ALRST AL1 AL2 PC1 PC2 *ilk RES SO PM1 PM2 PFi ZFi *ALM C *EMG Start Command Position 1 Command Position 2 Hold Reset Servo O Complete Position 1 Complete Position 2 Positioning Complete Homing Complete Alarm Moving Emergency Stop 31

32 Robo Cylinder Setting: Increment Function (Direct numeric input of coordinate value): When a layer of box is 50 and is stacked up in 5 layers: Position 0 is home (coordinate value of 0). Position 1 is the stand-by position (coordinate value of 300). Position 2 is the increment amount in the negative direction (move amount -50). 1) Input 0 into the position of o. 0. 2) Input 100 into the speed of o.0. 3) Input 300 into the position of o.1. 4) Input 200 into the speed of o.1. 5) Input 1 into incremental column of o.2. 6) Input -50 into the position of o.2. 7) Input 100 into the speed of Position o.2. Position data is now. For normal positioning (coordinate value from home), the Incremental Flag column is 0. The value 1 in the Incremental Flag is for Increment Function. When Position 1 is selected, the rod moves 300mm away from home. If Position 2 is selected, the rod will move 50mm back from the current location. PC Display Screen To input a negative numeric value into the position, first input 1 into the incremental column. The following screen is the Point Data Edit Screen located within the controller. Position Data 32

33 Movement Flow Chart (For reference) [Work Stacking Flow Chart] Work stacking Servo Signal O Hold Signal O ormally O. Operation prepares Homing Operation Ready Signal O Move to Position 1 Wait for the Operation Ready Signal from the packaging controller. (Home) Set Position 0 and toggle the Start Signal. If first command after power UP, execute home. Position 0 homing Ready position Stand-by Move to Position 1 Position 1 positioning Lowering command Set Position 1 and toggle the Start Signal. Stand-by position Wait for Lower Signal from packaging controller. [Alarm Detection Flow Chart] Alarm detection Lower command Pitch transfer Increment Position 2 amount Positioning 2 positioning Set Position 2 and toggle Start Signal (increment). Position 2 positioning Timer set Rise command Alarm Signal Time Up Operation end RCS Controller Abnormal detection Overtime Move to Position 1 Alarm Signal Wait for the Alarm Reset Signal from the packaging controller. Position 1 move End Overtime reset RCS Controller Abnormal detection reset End 33

34 PLC Ladder Diagram Reference The following is a basic circuit to control the Robo Cylinder. Therefore, it does not connect with the circuit that controls the entire machine. In addition, this circuit was not designed for a particular PLC manufacturer and, instead, describes a Robo Cylinder controller circuit from a general standpoint. When desigining your circuit, please remember the aforementhioned. SO Servo O *ilk Hold PFi Timer 1 Complete Position Strobe Signal PM1 PM2 Timer 1 0.1sec R01 Complete Position 0 PM1 PM2 Timer 1 R02 Complete Position 1 PM1 PM2 Timer 1 R03 Complete Position 2 RD R04 Homing start pulse R04 RD Homing start pulse support R04 PFi ZFi R06 Position 0 positioning start support R06 R06 C R08 Position 0 start confirm R01 R09 R08 Position 0 positioning R08 UP R09 Position 1 start pulse R09 UP Position 1 start pulse support R08 R01 R11 Position 1 positioning start support R09 R03 R11 R11 C R13 Position 1 start confirm R02 R14 R13 Position 1 positioning R13 DW R15 R14 Position 2 start pulse R14 DW R15 Position 2 start pulse support R15 R02 R14 R17 R16 Position 2 positioning start support R03 R16 R16 C R18 R17 Position 2 start confirm R17 R17 R03 R16 R18 Position 2 positioning R18 34

35 Reference R06 R19 R11 R16 R20 R21 R19 Position 0 set R11 R20 R06 R16 R19 R21 R20 Position 1 set R16 R21 R06 R11 R19 R20 R21 Position 2 set R20 R21 R06 R11 PC1 PC2 Timer 2 0.1sec Command Position 1 Command Position 2 Start wait R16 Timer 2 R16 R22 R18 R22 Start Signal Increment overtime detection support R22 Timer 3 AL1 ALRST Timer 3 2sec AL1 Increment overtime Alarm 1 (overtime) *ALM AL2 ALRST AL2 Alarm 2 (RCS Alarm) 35

36 Application Example 5: Device Function: Movement: Push Function: Press-fit a lid onto a plastic container Press-fit a lid onto a plastic container Characteristics: Although the Robo Cylinder is an electrical cylinder with an AC servo motor, pushing can be maintained similar to an air cylinder. Existing Specifications: The push functions ideal for press-fit and clamp applications because push power percentage can be controlled. Existing Problems: The supplied air pressure to the air cylinder fluctuates. When the air pressure is raised to increase the speed of the rod, too much power is supplied causing damage to the product. Modification Suggestion: Used an air cylinder to press-fit a lid. Appropriate Robo Cylinder: RCP-RSA Rod High Speed Type 100 stroke (model type: RCP-RSAI-H-100-B) RCP-RSA Rod High Speed Type Specifications Range Speed Payload Stroke Benefits: 1. Adjustable push power reduces part damage. Maximum 458mm/sec (1mm/sec minimum input speed) (ote: In case the stroke is 300mm, the maximum speed is 350mm/sec. Horizontal: Maximum 25kg Vertical: Maximum 4.5kg 50~300mm (50mm increments) 2. Cycle time is reduced by moving faster until right before the push point. 36

37 Movement Flow 1. A box with its lid placed by the previous station flows on the conveyor. 2. When the Part Detection Sensor sees the part, the Robo Cylinder lowers and presses the lid into position. 3. Once the press-fit is, the box moves to the next station, and the Robo Cylinder rises to stand-by position

38 System Diagram RCP Actuator Part Detection Sensor M Conveyor Drive Motor Electrical Control Panel Emergency Stop Circuit I/O PLC Power Operation Panel RCP Controller Power Unit Power [Rough Operation Flow Chart] Operation RCP actuator rise System start via operation panel Push Part Detection Sensor O RCP start Actuator riser Conveyor stops Rise Stop detection Conveyor start End 38

39 Control Specifications: 1) Under normal circumstances, Hold Signal is turned O. 2) Move to Position 0* upon receiving Operation Ready Signal from the Conveyor Controller. 3) When the part on the conveyor reaches the point right underneath the Robo Cylinder, the Conveyor Controller stops the conveyor and send the Press-fit command to lower the Robo Cylinder to Position 1. 4) After receiving the Positioning Complete Signal from Position 1, the Robo Cylinder returns to Position 1. 5) Repeat steps, 3 through 4. 6) If the Increment move does not within 2 seconds, the Alarm will turn OFF. 14) The Alarm LED Indicator will turn O when the Alarm Signal Output is turned OFF from the Robo Cylinder. * Positions 0 and 1 refer to the o.0 and 1 of the position data located within the controller. (For details, please refer to the section, PC Display Screen located on the next page of this manual. ote: 1. The Hold Signal (normally O) stops the Robo Cylinder s movement due to the hold of the conveyor. To stop the actuator, turn OFF the Hold Signal. To continue movement in progress, turn the Hold Signal back O. To cancel the movement in progress, toggle the Reset Signal O before turning back O the Hold Signal. 2. The Operation Ready Signal and Press-Fit Move Signal from the Conveyor Controller will turn OFF once the RCP controller recognizes these Signals. 3. If the RCS is in alarm or emergency stop, the Conveyor Controller will not give a System Ready or Move Signal to any device on the controller. 4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel. 5. This program is specifically for the Robo Cylinder Controller. I/O Signal Terminal Diagram PLC RCP Controller Cable Control Sequence RCP Control Sequence Operation Ready Press-Fit Alarm reset Alarm 1 (Overtime) Alarm 2 (RCP Alarm) RD PUSH ALRST AL1 AL2 PC1 *ilk PM1 PFi ZFi *ALM *EMG Start Command Position 1 Hold Complete Position 1 Positioning Complete Homing Complete Alarm Emergency Stop 39

40 Robo Cylinder Setting: Pitch Method (In case of direct numeric input (coordinate value): Position 0 is home (coordinate value of 0). Position 1 is push start position (coordinate value of 300). Push power of Position 1 is set as 20% (approximately 2kgf). 1) Input 0 into the position of o. 0. 2) Input 458 into the speed of o.0. 3) Input 50 into the position of o.1 4) Input 458 into the speed of Position 1. 5) Input 20 into the push of o.1. 6) Input 30 into the positioning width of o.1. Position data input is d. If numeric data is input into the Push Percentage Column and a Positioning width is specified, the actuator will move to the specified location at the designated speed and begin to push at a fixed lower speed to the specified distance at the push percentage. With the above specifications, the Robo Cylinder moves 50mm away from home at 458mm/sec, and from there, the Robo Cylinder pushes at a slow fixed speed within the 30mm range. Once it hits the part, the Push function turns O the Positioning Complete Signal and continues pushing until reaching 2kgf. PC Display Screen: The below screen is the Point Data Edit Screen that is located within the controller. Position Data 40

41 Movement Flow Chart (Reference) [Press-Fit (Push] Flow Chart] Press-Fit (Push) Hold O ormally O. Operation prepares Homing Operation Ready Signal O Wait for Operation Ready Signal from the Conveyor. Stand-by Move to Position 0 Position 0 positioning Press-fit command (Homing) Stand-by position Wait for the Press- Fit Move Signal from the Conveyor Controller. Set Position 0 and toggle O the Start Signal. If first command after power UP, execute home. [Alarm Detection Flow Chart] Alarm detection Push movement Move to Position 1 Position 1 Positioning Set Position 1 and toggle O the Start Signal (push movement). Press-fit command Operation end Move to Position 0 Position 1 positioning Position 0 positioning Position 0 positiong Timer set End Alarm Signal Timer up RCP Controller Abnormal detection Overtime Alarm reset Wait for the Alarm Reset Signal from the Conveyor Controller. Overtime reset RCP Controller Abnormal detection reset End 41

42 PLC Ladder Diagram Reference The following is a basic circuit to control the Robo Cylinder. Therefore, it does not connect with the circuit that controls the enire machine. In addition, this circuit was not designed for a particular PLC manufacturer and, instead, describes a Robo Cylinder controller circuit from a general standpoint. When desigining your circuit, please remember the aforementioned. *ilk Hold PFi Timer 1 Complete Position Strobe Signal PM1 Timer 1 0.1sec R01 Complete Position 0 PM1 Timer 1 R02 Complete Position 1 RD R04 R03 Homing Start Pulse R03 RD R04 Homing Start Pulse Support R04 R03 PFi ZFi R06 Position 0 Positioning Start Support R02 PFi R06 Position 0 Start Confirm R06 R06 R01 Position 0 Positioning Complete PUSH R09 R08 Position 1 Push Start Pulse R08 PUSH R09 Position 1 Push Start R09 R01 R08 R11 Position 1 push start support PFi R11 Position 1 start confirm R11 R11 R02 Position 1 positioning R14 R13 Position 0 set R13 R13 R14 Position 1 set R14 R14 PC1 Command position 1 Timer 2 0.1sec Start wait Timer 2 Start Signal R15 Push overtime detection support 1 R15 R15 R16 Push overtime detection support 2 R16 R16 Timer 3 2sec Push overtime 42

43 Reference Timer 3 AL1 ALRST AL1 Alarm 1 (Overtime) *ALM AL2 ALRST AL2 Alarm 2 (RCP Alarm) 43

44 Intelligent Actuator, Inc W. 237th St. Torrance, CA (310) / (310) Fax