User Manual. Motion Analyzer Software Version 7.00

Transcription

1 User Manual Motion Analyzer Software Version 7.00

2 Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited. Throughout this manual, when necessary, we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence. SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. IMPORTANT Identifies information that is critical for successful application and understanding of the product. Allen-Bradley, Kinetix, MP-Series, ProposalWorks, Rockwell Automation, Rockwell Software, RSLogix, TechConnect, TL-Series, and Ultra are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

3 Summary of Changes This manual contains new and updated information. New and Updated Information This table contains the changes made to this revision. Topic Removed the Activation Wizard section. Added Group/Ungroup and Add Drive Group descriptions to the Home Tab section. 16 Updated Power Data, Shunt, and Energy tab examples for the Power Supply/Accessories - Single-axis Drive Systems section. Added Power Supply/Accessories AC/DC Power Sharing Systems (Kinetix 5500 drives) section. 51 Updated the Output Format Selection dialog boxes in the Export to RSLogix 5000 Wizard section. 65 Added new Explorer View examples and updated the Drives Group Node description. 78 Updated the Solution List dialog box example. 209 Added Preferred Product section. 210 Page N/A 46 Rockwell Automation Publication MOTION-UM004B-EN-P - October

4 Summary of Changes Notes: 4 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

5 Preface About This Publication The versatility of Motion Analyzer software lets users of various application complexities and experience levels use one software package to size their systems. This manual is designed to accommodate basic users, advanced users, and everyone in between. Who Should Use This Manual This manual is intended for engineers directly involved in the selecting, sizing, and optimizing of drives and motors or actuators for a motion control system. Conventions Used in This Manual The following conventions are used throughout this manual: Bulleted lists such as this one provide information, not procedural steps. Numbered lists provide sequential steps or hierarchical information. Hyperlinks are embedded throughout this document so that you can easily navigate to and obtain information that is relevant to your particular application. System Requirements Motion Analyzer software requires the following operating conditions. Attribute Computer hardware requirements Operating systems supported Microsoft Office software supported Pentium IV processor 1 GB RAM minimum 1280x800 screen resolution Windows XP - 32 Bit (SP2) Windows XP - 64 Bit (SP2) Windows Vista - 32 Bit Office 2007 Office MB free space in the installation directory.net Framework 2.0 Windows Vista - 64 Bit Windows 7-32 Bit Windows 7-64 Bit Additional Resources Resource These documents contain additional information concerning related products from Rockwell Automation. Download Motion Analyzer software from: Kinetix Motion Control Selection Guide, publication GMC-SG001 Industrial Automation Wiring and Grounding Guidelines, publication Product Certifications website, Comprehensive motion application sizing tool used for analysis, optimization, selection, and validation of your Kinetix Motion Control system. Overview of Kinetix servo drives, motors, actuators, and motion accessories designed to help make initial decisions for the motion control products best suited for your system requirements. Provides general guidelines for installing a Rockwell Automation industrial system. Provides declarations of conformity, certificates, and other certification details. You can view or download publications at To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Rockwell Automation Publication MOTION-UM004B-EN-P - October

6 Preface Notes: 6 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

7 Chapter 1 Welcome to Motion Analyzer Software Topic Page Before You Begin Sizing 8 Database Updater Program 8 Welcome to Motion Analyzer 13 Menu Bar and Quick Access Toolbar 14 File Tab 15 Home Tab 16 Graphical View 17 Group View 22 Multiple Profile View 26 Power Supply/Accessories View 29 Preferences Tab 62 Export Import Tab 65 Export to RSLogix 5000 Wizard 65 Bill of Materials (BOM) Tab 76 Help Tab 76 Explorer View 78 Rockwell Automation Publication MOTION-UM004B-EN-P - October

8 Chapter 1 Welcome to Motion Analyzer Software 1.1. Before You Begin Sizing After downloading and starting Motion Analyzer software, you ll want to update the Motion Analyzer database with the latest Allen-Bradley products available for motion control applications. This section steps you through that process. TIP Download Motion Analyzer software from Database Updater Program The Motion Analyzer Database Updater program updates your Motion Analyzer software with the latest database available for the version currently installed on your personal computer. 1. To start the Motion Analyzer database updater program, go to Start>All Programs>Rockwell Automation>Motion Analyzer 7.00> Database Updater. TIP To update the software version, download Motion Analyzer software from The Motion Analyzer Database Updater wizard opens. Table 1 - Database Updater Analysis Attribute Installed Motion Analyzer version Installed database version Indicates the version of Motion Analyzer software currently installed. Indicates the database version currently installed. 2. Click Next. 8 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

9 Welcome to Motion Analyzer Software Chapter 1 The program checks for database updates. If the program finds that you already have the current database installed, the following dialog box opens. 3. Click Finish. Rockwell Automation Publication MOTION-UM004B-EN-P - October

10 Chapter 1 Welcome to Motion Analyzer Software 4. If the program finds that a database update is available, a dialog box opens with the following information: Installed software and database versions Available database version Database download file size Summary of new features and products in the new database 5. Click Update. 10 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

11 Welcome to Motion Analyzer Software Chapter 1 6. If the database updater program detects that your current version of Motion Analyzer software is running, a dialog box opens with the following instructions. 7. If the program finds that a new software version is available, a dialog box opens with the following options: Click the link to download the new version of Motion Analyzer software Click Next to skip the download and just update your current database Rockwell Automation Publication MOTION-UM004B-EN-P - October

12 Chapter 1 Welcome to Motion Analyzer Software 8. When the database updater program begins the update, this dialog box opens. 9. When the database updater program completes the update, this dialog box opens. 10. Click Finish. 12 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

13 Welcome to Motion Analyzer Software Chapter Welcome to Motion Analyzer The Welcome to Motion Analyzer dialog box opens when the software application is launched. Two modes of operation are possible. Figure 1 - Welcome to Motion Analyzer Dialog Box Table 2 - Motion Analyzer Modes of Operation Mode Size and Select Just Quote Intuitive workflow to help size, select, and optimize the motion control system. This mode also creates a bill of materials. Creates only a bill of materials so no sizing input is required. Click either of the New option modes to start a new application or click Browse to open a previously configured application. Rockwell Automation Publication MOTION-UM004B-EN-P - October

14 Chapter 1 Welcome to Motion Analyzer Software 1.2. Menu Bar and Quick Access Toolbar Your Motion Analyzer application file opens and the menu bar appears across the top of the dialog box. Above the menu bar is the Quick Access toolbar. Figure 2 - Size and Select Dialog Box Quick Access Toolbar Menu Bar The Quick Access toolbar provides shortcuts to commonly used functions. These functions include New, Open, Save, and Print. Table 3 - Menu Bar Tab s Options Page File Tab Standard File menu options. 15 Home Tab Most commonly used actions across different views in Motion Analyzer software. Preferences Tab Setting /View user preference option. 62 Export Import Tab All data Export Import functionality. 65 Bill of Materials (BOM) Tab Useful shortcuts for navigating through the Bill of Materials view. 76 Help Tab Standard Help menu options Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

15 Welcome to Motion Analyzer Software Chapter File Tab The File tab is similar to the file menu in many computer applications. Figure 3 - File Tab Options Table 4 - File Tab s (refer to Figure 3) Options New Open Save Save As Recent Files Sample Applications Click New to go to the Welcome dialog box in Motion Analyzer software. Click Open to browse folders and open Motion Analyzer applications. Standard Open functionality. Click to save the running Motion Analyzer application. Standard Save functionality. Click to launch a dialog box, browse to the path on your computer, and save the current application to an.mba file. Click for the list of recently opened applications. You can open one of these applications directly from this shortcut. Lets you open Motion Analyzer sample applications present in the Motion Analyzer installation. Print Print Click to print the application data. Print Preview Click to see a preview of printable application data. Help This is similar to the Help Tab on page 76. Exit Click to close the running application. Rockwell Automation Publication MOTION-UM004B-EN-P - October

16 Chapter 1 Welcome to Motion Analyzer Software Home Tab The Home tab contains five sections. Figure 4 - Home Tab Options Table 5 - Home Tab s Option Views (label 1 in Figure 4) Clipboard (label 2 in Figure 4) Edit (label 3 in Figure 4) Add (label 4 in Figure 4) Tools (label 5 in Figure 4) Used to access the different views available in Motion Analyzer software. Graphical View Click to open the Graphical view on page 17. Group View Click to open the Group view on page 22. Multiple Profile View Click to open the Multiple Profile view on page 26. Power Supply/ Accessories View Click to open the Power Supply/Accessories view on page 29. Identify Your Load Axis View Click to open the Axis view on page 82. System Bill of Materials (BOM) View Click to open the BOM view on page 36. Used to access the Cut, Copy, and Paste functions. Click to perform these functions that are common to many software programs. Used to access these editing functions. Each one works on the entity selected in Explorer hierarchy view. Rename Click to rename the selected entity. Delete Click to delete the selected entity from the application. Sort by Power Click to sort the axes in Drives group for Multi Axis Family application by Axis Power. Sort is valid at the Rack, Group, or IPIM level. Allocate Unallocate Group/Ungroup Allocate the axis from Un-allocate Axes Group to Drives Group. Un-allocate the axis from Drives Group to un-allocate Axes Group. Select multiple axes in Explorer view and click Group to create a Power Sharing Drive Group. This feature is available only for families that support AC and DC power sharing (Kinetix 5500 drives). Select Power Sharing Drive Group in the Explorer view and click Ungroup to ungroup the axes of the selected group. Used to access these add functions. Each one works on the entity selected in Explorer hierarchy view. Add IPIM Add a new IPIM module in the selected Drives Group in Explorer hierarchy view. Add Axis Add a new axis in the Drives Group/Unallocated Group or IPIM based on user s current selection in Explorer hierarchy view. Add Drive Group Add a new Drives Group under the Project node in the Explorer hierarchy view. This feature is available only for families that support AC and DC sharing (Kinetix 5500 drives). Motion Analyzer/SolidWorks Integration is used to launch the SolidWorks Integration wizard. 16 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

17 Welcome to Motion Analyzer Software Chapter Graphical View The Graphical view applies to multi-axis drive families and provides graphical representation of the current (Bulletin 2093 and 2094) power rail and Kinetix 6000M integrated drive-motor system configurations. Figure 5 - Graphical View Example Table 6 - Graphical View Options (refer to Figure 5) Options Page Power Rail View Power Interface Module View Displays the graphical representation of the current Bulletin 2093 or 2094 power rail configuration. Displays the graphical representation of the Kinetix 6000M integrated drivemotor system on the Bulletin 2094 power rail Rockwell Automation Publication MOTION-UM004B-EN-P - October

18 Chapter 1 Welcome to Motion Analyzer Software Power Rail View The Power Rail view displays the graphical representation of the current Bulletin 2093 or 2094 power rail configuration. Figure 6 - Power Rail View Example Table 7 - Power Rail View Options Options Product Rack Summary (label 1 in Figure 6) Image view (label 2 in Figure 6) Module Information (label 3 in Figure 6) Additional Module Information (inside red box) Part Number Total No. of Slots Slots Occupied Displays the selected power rail catalog number. Displays the total number of slots available in the selected power rail. Displays the number of slots currently occupied in the selected power rail. Graphical representation of the power rail with the drive modules and empty slots are displayed along with the selected catalog numbers. Power rail configurations like Axis Slot mapping can be configured using options available in this view. Right-click the modules and choose operations to perform from the menu (refer to Figure 7). Selected Slot Module Part Number Slot Number Axis Name View Axis Un- allocate View Product Guide Refers to the type of the module that is currently selected in the power rail. For example, axis module (AM), integrated axis module (IAM), power interface module (IPIM), or empty slot. Catalog number of the selected drive module. Power rail slot number occupied by the selected drive module. Name you assigned to the axis associated with the selected drive module. Click to launch the Axis view of the axis associated with the selected drive module. Un-allocates the axis associated with the selected drive modules. Click to open the Kinetix Motion Control Selection Guide. The page displayed from the selection guide corresponds to the selected drive module. 18 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

19 Welcome to Motion Analyzer Software Chapter 1 Figure 7 - Operations to Perform Example Additionally, you can click, drag, and drop a module to reposition that module on the power rail (refer to Figure 8). Figure 8 - Drag and Drop Modules to Reposition on Power Rail Rockwell Automation Publication MOTION-UM004B-EN-P - October

20 Chapter 1 Welcome to Motion Analyzer Software Power Interface Module View The integrated drive-motor power interface module (IPIM) mounts to the Bulletin 2094 power rail and connects (daisy-chains) with up to sixteen integrated drive-motor (IDM) units. Figure 9 - Power Rail View Example (Kinetix 6000M integrated drive-motor system) Table 8 - Power Rail View Options (Kinetix 6000M integrated drive-motor system) Options IPIM Summary (label 1 in Figure 9) Image view (label 2 in Figure 9) Selected Slot Module (label 3 in Figure 9) Additional Module Information (inside red boxes) Slot Number Number of Associated Axis Number of Additional Axis Allowed Power rail slot number occupied by the selected IPIM module. Displays the number of axes currently associated with the selected IPIM module. Displays the additional number of axis that can be added in this IPIM module. Graphical representation of the Kinetix 6000M integrated drive-motor system are displayed with the selected catalog numbers. Power rail configurations, like the order of IDM axes, can be configured using options available in this view. Right-click an IDM unit and choose operations to perform from the menu (refer to Figure 10). Selected Slot Module Part Number IDM Position Axis Name View Axis Un- allocate View Product Guide Back to Rack Refers to the type of the module that is currently selected in the power rail. For example, integrated drive-motor unit (IDM) or power interface module (IPIM). Catalog number of the selected unit or module. The position of the selected unit or module, assuming the IDM unit closest to the IPIM module is identified as 1. Name you assigned to the axis associated with the selected IDM unit. Click to launch the Axis view of the axis associated with the selected IDM unit. Un-allocates the axis associated with the selected IDM unit. Click to open the Kinetix Motion Control Selection Guide. The page displayed from the selection guide corresponds to the selected IDM unit. Click to switch back to the power rail view. 20 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

21 Welcome to Motion Analyzer Software Chapter 1 Figure 10 - Operations to Perform Example Additionally, you can click, drag, and drop an IDM unit to reposition that unit in the daisy-chain configuration (refer to Figure 11). Figure 11 - Drag and Drop to Reposition IDM Units Rockwell Automation Publication MOTION-UM004B-EN-P - October

22 Chapter 1 Welcome to Motion Analyzer Software Group View The Group view provides a summary of all the axes associated with the drive group. Additionally, the Group view gives a visual representation of the axis mapping in the power rail for multi-axes drive families. Group view varies depending on the Application mode selected. Refer to Figure 12 and Figure 13 for examples of each. Figure 12 - Group View Example (Select and Size mode) Figure 13 - Group View Example (Just Quote mode) 22 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

23 Welcome to Motion Analyzer Software Chapter 1 There are two areas of interest in the Group view, as illustrated in Figure 14. Figure 14 - Group View Example Table 9 - Power Rail View Options Options Page Power Rail Image (label 1 in Figure 14) Axis Summary Image (label 2 in Figure 14) Power rail image based on the current system configuration. This graphic only applies to multi-axis drive families. Displays a summary of the current axis configurations including drive module and motor/actuator catalog numbers Rockwell Automation Publication MOTION-UM004B-EN-P - October

24 Chapter 1 Welcome to Motion Analyzer Software Power Rail Image The power rail image only applies to multi-axis drive families. In this example, the current configuration of Kinetix 6000 servo drives is shown on an eight-axis Bulletin 2094 power rail. Figure 15 - Bulletin 2094 Power Rail Image Table 10 - Power Rail Slot Example (refer to Figure 15) Option IAM Module (slots 1 and 2) AM Modules (slots 3 5) Empty Slots (slots 6 8) Integrated axis module (IAM) is always the first drive module on the power rail. In this case, the IAM module is a double-wide module, so it occupies two slots. Axis modules (AM) are always right of the IAM module. Empty slots are always to the far right on the power rail and must be occupied by slotfiller modules. 24 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

25 Welcome to Motion Analyzer Software Chapter Axis Summary Image The axis summary images apply to all drive families. In this example, the current configuration of Kinetix 6000 servo drives includes the drive/motor combination featured below. Figure 16 - Axis Summary Bar (servo drive) Table 11 - Axis Summary Example Option Title Band (label 1 in Figure 16) Axis Bar (label 2 in Figure 16) Short-cuts to Axis view (label 3 in Figure 16) Axis Solution Status Icon Warning Icon Axis Name Axis Solution Status icon indicates the status of the selected solution. Axis solution status is defined in Solution on page 208. A warning triangle icon indicates a warning with this axis, which requires your attention. Name of the Axis. Displays information about the selected drive/motor axis or IPIM module. Motor (1) Selected motor catalog number. Drive Gearbox RBM Selected drive module catalog number. Selected gearbox catalog number. Selected RBM module catalog number. Icons are a graphical representation of the selected axis components. Click icons to switch to the corresponding data page in the Axis view. (1) Configure Motor BOM is available for the selected motor. Click to launch the Configure Motor dialog box. In this example, the current configuration includes a Kinetix 6000M power interface module (IPIM). Figure 17 - Kinetix 6000M Power Interface Module IPIM module icon along with the catalog number of the selected IPIM module is displayed in this bar. Click + to access the IPIM child nodes (IDM units). Rockwell Automation Publication MOTION-UM004B-EN-P - October

26 Chapter 1 Welcome to Motion Analyzer Software Multiple Profile View The Multiple Profile view permits viewing profiles of multiple axes simultaneously and defining axes synchronization and offsets among the axes. Figure 18 - Multiple Profile View Example Table 12 - Multiple Profile View Options Options Page Top Band (label 1 in Figure 18) Graph View (label 2 in Figure 18) Lets you define the Time Span to which all graphs should be scaled. Additionally, this view lets you select a subset of the available axes to view. Profiles of all axes are displayed in this section with the shorter profiles being repeated to fit the length of the longest profile Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

27 Welcome to Motion Analyzer Software Chapter Top Band This area lets you define the Time Span to which all graphs should be scaled. Additionally, this view lets you select a subset of the available axes to view. Figure 19 - Top Band of Multiple Profile View Table 13 - Top Band Example Option Modify Time Span (label 1 in Figure 19) Show Axis (label 2 in Figure 19) Sort By (label 3 in Figure 19) Time span is the length of x-axis on which all the profiles are plotted. Use this option to zoomin or zoom-out on the time scale. Enter the minimum and maximum value of the time scale of interest and click Apply to re-plot all graphs to this scale. Select All to display all axes. Select Selected (Change) to choose the axis of interest (refer to Figure 20 for typical dialog box). This option lets you sort the axes in the graph area according to the Slot Number or Axis Name. Figure 20 - Selected Axis Example Rockwell Automation Publication MOTION-UM004B-EN-P - October

28 Chapter 1 Welcome to Motion Analyzer Software Graph View The Graph view displays profiles of all axes with the shorter profiles being repeated to fit the length of the longest profile. Figure 21 - Graph View Example Table 14 - Graph View Options (refer to Figure 21) Option Synchronized with Offset The phase relationship between the various axis profiles in a common DC bus system affects the peak bus current requirement. For example, if all axes accelerate simultaneously, the bus current demand is much greater than if each axis accelerates in turn. From the Synchronized with pull-down menu, choose the random or synchronized operation for each axis. Set at least one axis to Random as the reference axis. Set other axes to be synchronized with the reference axis or Random. The safe setting for system sizing is all Random. In this case the worst case current demand for each axis is automatically lined up by adjusting the phase relationship of the axis profiles. If the phase relationship is known and will not change, the Cycle Profiles should be set up in the correct relationship and Synchronized with set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected. If all axis profiles are the same length and start at their correct respective positions, then the offsets will be zero. Otherwise, the offset may be used to align the profiles correctly. 28 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

29 Welcome to Motion Analyzer Software Chapter Power Supply/Accessories View In Axis view, you matched a drive with your motor. However, if there are power components needed for your application, you ll select them in Power Supply/ Accessories view Power Supply/Accessories - Multi-axis Drive Systems If your drive family is Kinetix 2000, Kinetix 6000, or Kinetix 6200/6500, you ll also need to configure the IAM module and select the appropriate power rail. Figure 22 - Power Supply/Accessories Dialog Box Table 15 - Power Supply/Accessories Tabs (refer to Figure 22) Parameters Page Power Data Tab View regeneration and motoring data for each axis. 30 IAM and Shunt Tab Select drive modules and external shunt resistors for multi -axis systems. 31 IAM Control Power Tab Analysis Tab Energy Tab Configure Power Supply BOM Tab Displays total auxiliary input power, input VA, input current, and power distribution across the axes. These are the installation ratings for the IAM module. Analyze the drive module activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters. View Input Current values, System Power values, Shunt Power, and Energy Savings Estimates. Configure the bill of materials (BOM) for the power supply after fully sizing the application Rockwell Automation Publication MOTION-UM004B-EN-P - October

30 Chapter 1 Welcome to Motion Analyzer Software Power Data Tab Use the Power Data tab to view regeneration and motoring data for each axis. Table 16 - Power Data Tab Properties (refer to Figure 22) Parameters Axis Histograms Random/Sync Relationship Offset The axis histograms show a multi-axis representation of axis currents including Peak Motoring, Average Motoring, Peak Regenerating, and Average Regenerating. The phase relationship between the various axis motion profiles in a common DC bus system affects the peak bus-current requirement. For example, if all axes accelerate simultaneously (for example, synchronous operation), the bus current demand is much greater than if each accelerates in turn. The pull-down menu lets you choose Random or Synchronized mode for axes operation. At least one axis should be set to Random as the reference axis. Other axes may be set to Synchronized or Random relative to the reference axis. The safe setting for system sizing is all Random. In this case, the worst case current demand for each axis is automatically lined up by adjusting the phase relationship of the axis motion profiles. If the phase relationship is known and will not change, the Cycle Profiles should be set up in the correct relationship and appropriate synchronized set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected. If all axis motion profiles are the same length and start at their correct respective positions at the default time, then the offsets will be zero. Otherwise, a specified time offset may be used to align the motion profiles correctly. 30 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

31 Welcome to Motion Analyzer Software Chapter IAM and Shunt Tab Click Search to automatically configure the IAM and/or shunt module catalog number. Figure 23 - IAM and Shunt Tab Table 17 - IAM and Shunt Tab Properties Parameters IAM & Shunt Selection (label 1 in Figure 23) Utilizations (label 2 in Figure 23) Component Listings of Kinetix Shunts (label 3 in Figure 23) Click Search to configure the IAM module (Kinetix 2000, Kinetix 6000, and Kinetix 6200/6500 drives) based on the selection made in Axis view, and/or an external shunt module, should an existing internal shunt for a given drive be outside its rating. Where multiple external shunts exist, these can be readily chosen by searching for a shunt. Both the drive module and shunt module have automatic and manual selection options. You can manually select a drive or IAM module and the compatible shunt. The manual selection of only one of the two components is also provided. This means that you can have manual drive and automatic shunt selection or vice versa. The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed. Use the forward or backward arrows to scroll through other drive and shunt options. Click the drive module or shunt module catalog number to view their product specifications. This window is available only for the Kinetix multi-axis drive families after a valid IAM module and shunt solution is found. This window displays the shunt resistance, power, and capacitance values for all the components involved in the IAM and shunt module solution. The components may include converter (IAM), all the inverters (AM), shunt module and shunt resistor. The Shunt Protect limit is also shown in order to reflect the shunt power utilization of the component. Rockwell Automation Publication MOTION-UM004B-EN-P - October

32 Chapter 1 Welcome to Motion Analyzer Software IAM Control Power Tab The IAM Control Power tab displays total auxiliary input power, input VA, input current, and power distribution across the axes. These are the installation ratings for the IAM module. Figure 24 - IAM Control Power Tab Table 18 - IAM Control Power Tab Properties Parameters Auxiliary AC Voltage (label 1 in Figure 24) Power Rail Summary (label 2 in Figure 24) Power Rail Details (label 3 in Figure 24) Auxiliary AC Voltage is a user input value. The value can lie within the IAM Control Voltage Range. Refer to the Kinetix Servo Drives Technical Data, publication GMC-TD003, for servo drive power specifications. This view shows the total auxiliary input power, input VA, and input current in a tabular format. This view contains the slots occupied, slot number, drive module, and continuous output power distribution details in tabular format. The IPIM module is available as line item (axis level item) in this view. 32 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

33 Welcome to Motion Analyzer Software Chapter Analysis Tab Click Analysis to conduct detailed analysis of the drive module activity in terms of bus volts and system current, along with the capability of simulating changes to the system parameters. Figure 25 - Analysis Tab Dialog Box Table 19 - Analysis Tab Properties Parameters Simulation Parameters (refer to Figure 25) Zoom Window (refer to Figure 25) Adjust these parameters to observe how changes to the parameters impact the bus voltage and current. Time From/ Voltage From Time Slice Check these boxes to adjust the X- and Y-axis values for the plot. The Time Slice variable sets the time interval for the Analysis display. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is equal to the longest axis cycle. In the case of a very long length of time, it is suggested that a longer time slice be used for early checks, but a time slice of less 0.1 ms should be used for the final selection. If the time is increased, this error message often appears. This time slice message may also appear as soon as you click Solution on the main taskbar. In this case, clicking Yes or No still takes you to the Solution tab, but if you click No, some pre-calculations are not performed. This time slice message often appears if one of the motion cycles is a cam, which often has very short time segments. In this case, click No to ignore the message. Rockwell Automation Publication MOTION-UM004B-EN-P - October

34 Chapter 1 Welcome to Motion Analyzer Software Energy Tab Click Energy to display the main power supply parameters including Input Current, System Power, Shunt Power and Energy Savings Estimates. 34 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

35 Welcome to Motion Analyzer Software Chapter Configure Power Supply BOM Tab Click the Configure Power Supply BOM tab to complete the bill of materials (BOM) for the Power Supply after fully sizing the application. In this tab, you select options for the power rail, shunt module, filters, circuit breakers, and fuses. Rockwell Automation Publication MOTION-UM004B-EN-P - October

36 Chapter 1 Welcome to Motion Analyzer Software System Bill of Materials (BOM) View Click BOM view to review the entire BOM (bill of materials) for the system and add any additional parts that may be needed. Table 20 - BOM View Tabs Parameters Page Configuration Summary Tab Shows all the axis components in axis order. 37 Software and Accessories Tab Contains the Controllers, Software, and other Accessories to complete your system. Additional Parts Tab Select any additional components. 39 BOM Tab Displays the full bill of materials (BOM) Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

37 Welcome to Motion Analyzer Software Chapter Configuration Summary Tab Click Configuration Summary to display all the axis components and descriptions in axis order. Scroll down to see all the axes. Rockwell Automation Publication MOTION-UM004B-EN-P - October

38 Chapter 1 Welcome to Motion Analyzer Software Software and Accessories Tab Click Software and Accessories to complete your system. To assist in selecting the Sercos cables, click Auto Select to automatically build a set of these cables with the required lengths to link the axes according to their slot configuration. Break-out boards, cables, kits, and various connectors are available to complete cabling from drive to motor. Other components such as connectors, safe-off headers, and line filters for example, are available. 38 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

39 Welcome to Motion Analyzer Software Chapter Additional Parts Tab Click Additional Parts to add any additional components you may need. From the Product Family pull-down menu, choose the Family, Motor Series, and then by component category to reduce the time required to search for motion control components. If you know the catalog number, entering that is the quickest way to find your part. Rockwell Automation Publication MOTION-UM004B-EN-P - October

40 Chapter 1 Welcome to Motion Analyzer Software BOM Tab Click BOM to display the full bill of materials (BOM) in the same section headings as the other tabs. This BOM can be exported to Microsoft Word or Microsoft Excel software by clicking the appropriate button. 40 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

41 Welcome to Motion Analyzer Software Chapter Power Supply/Accessories - Integrated Drive-Motor (IDM) Systems The integrated drive-motor (IDM) power interface module (IPIM) is effectively a power management module for the DC link to a group of individual IDM units, but to the 2094 power rail it looks like an axis module. Each IPIM module can handle up to 16 axes, with certain limitations. Table 21 - IPIM Module Configuration Options Page Power Data Tab View regeneration and motoring data for each IDM unit. 41 IPIM Module Selection Tab Lets you select the IPIM module. 42 Cable Length Tab Control Power Tab Configure IPIM Module BOM Tab Power Data Tab Click the Power Data tab to view regeneration and motoring data for each IDM unit. Figure 26 - Power Data Tab Cable selection for connecting IPIM module-to-idm unit and IDM unit-to-idm unit. Bar graph for control power Summary view Details view Configure the bill of materials (BOM) for the power supply after fully sizing the application Rockwell Automation Publication MOTION-UM004B-EN-P - October

42 Chapter 1 Welcome to Motion Analyzer Software Table 22 - Power Data Tab s Options Label 1 in Figure 26 IDM Axis view (label 2 in Figure 26) Back to Power Rail (label 3 in Figure 26) Name of the power rail and selected IPIM module slot is displayed here. Click the power rail name label switches the view from IPIM view to Power Rail - Power Supply view. Summary of the all IDM units associated with the selected IPIM module along with the Axis Motoring Bus Current and Axis Regenerating Bus Current values of each IDM unit. Click to switch the view from IPIM view to Power Rail - Power Supply view IPIM Module Selection Tab Click the IPIM Module Selection tab to select an IPIM module. Figure 27 - IPIM Selection Tab Table 23 - IPIM Selection Tab s Options Selection mode (label 1 in Figure 27 Utilizations (label 2 in Figure 27) Automatic Manual Current Selection Search IPIM DC Bus Current RMS Limit DC Bus Current Instantaneous Limit Select Automatic for Motion Analyzer software to search for the best IPIM module solution for the selected slot. Select Manual to manually select the IPIM module. Displays the selected IPIM module catalog number. Search button is disabled because only one catalog number is available. Arrows provide the means to scroll forward/backward to smaller/larger IPIM module catalog numbers. Graphical representation of DC bus current rms limit for the selected IPIM module. Graphical representation of DC bus current instantaneous limit for the selected IPIM module. 42 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

43 Welcome to Motion Analyzer Software Chapter Cable Length Tab Click the Cable Length tab to select cables for connecting IPIM module-to-idm unit and IDM unit-to-idm unit. Figure 28 - Cable Length Tab Table 24 - Cable Length Tab s Options IDM Cables (label 1 in Figure 28 IDM System Graphic (label 2 in Figure 28) From the Cable Length pull-down menus, choose the appropriate cable length for connecting IPIM module-to-idm unit and IDM unit-to-unit. The maximum cable lengths in an IDM system are specified as 25 m (82 ft) IDM unit-to-idm unit and 100 m (328 ft) total cable length. Cable For Cable Length Total Length Specifies the modules the cables will join. Specifies the cable length. Specifies the total length of the cables. Graphical representation of IPIM module, associated IDM units and joining cables. Cable length is displayed over the cables. Rockwell Automation Publication MOTION-UM004B-EN-P - October

44 Chapter 1 Welcome to Motion Analyzer Software Control Power Tab Click the Control Power tab for utilization views and to select the number of sensor inputs and outputs. Figure 29 - Control Power Tab Table 25 - Control Power Tab s Options Utilizations (label 1 in Figure 29 Selection for Control Power Usage (label 2 in Figure 29) Detailed View (label 3 in Figure 29) Control Power Total IPIM Summary view This bar graph displays the percentage of power utilized by all IDM units to the maximum power that can be supplied by IPIM module. Displays the sum of power utilized by all the IDM units. Displays the maximum power that can be supplied by the selected IPIM module. From the pull-down menu, choose the quantity of each of I/O Sensor. Summary view displays the control power usage and control voltage for each IDM unit. Click the Details arrow (refer to Figure 30) to display complete information for each IDM unit. This table is hidden by default. Figure 30 - Control Power Tab (details arrow) 44 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

45 Welcome to Motion Analyzer Software Chapter 1 Figure 31 - Control Power Tab (details revealed) Configure IPIM Module BOM Tab Click the Configure IPIM Module BOM tab to select hybrid and network cables, and other IDM system accessory items. Figure 32 - Configure IPIM Module BOM Tab Table 26 - Configure IPIM Module BOM Tab s Options Step 1 (Figure 32) IPIM module IPIM module selected on the IPIM Module tab is displayed here. Step 2 (Figure 32) Hybrid cables Hybrid cable lengths selected on the Cable Lengths tab are displayed here. Step 3 (Figure 32) Network cables Network cables can be routed with the hybrid cables, so network cable lengths should be the same as the hybrid cable. The IPIM-to-IDM1 cable must have a straight connector to the IPIM module. Step 4 (Figure 32) Hybrid coupler The hybrid coupler connects between two hybrid cables, to bypass an IDM unit. Step 5 (Figure 33) Network bulkhead adapter Figure 33 - Configure IPIM Module BOM Tab Use the network bulkhead adapter for securing network cables as they pass through the cabinet. Rockwell Automation Publication MOTION-UM004B-EN-P - October

46 Chapter 1 Welcome to Motion Analyzer Software Power Supply/Accessories - Single-axis Drive Systems If your drive family is single axis, for example, Kinetix 300, Kinetix 350, Kinetix 3, or Ultra 3000, Ultra5000, and Ultra1500, you must configure a shunt or specify no shunt required. Figure 34 - Power Supply/Accessories Dialog Box Table 27 - Power Supply/Accessories Tabs (refer to Figure 34) Parameters Page Power Data Tab View the regeneration and motoring data for each axis. 47 Shunt Tab Select the external shunt resistors for single-axis systems. 47 Analysis Tab Analyze the drive module activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters. Energy Tab View input current values and energy savings estimates for each axis. 49 Configure Power Supply BOM Tab Configure the bill of materials (BOM) for the power supply after fully sizing the application Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

47 Welcome to Motion Analyzer Software Chapter Power Data Tab Use the Power Data tab to view regeneration and motoring data for each axis. Table 28 - Power Data Tab Properties (refer to Figure 34) Parameters Axis Histograms The axis histograms show a multi-axis representation of axis currents including Peak Motoring, Average Motoring, Peak Regenerating, and Average Regenerating Shunt Tab Click Search to automatically configure the shunt module catalog number for each axis. Figure 35 - Shunt Tab Table 29 - Shunt Tab Properties Parameters Shunt selection (refer to Figure 23) Continuous Current utilization bar (refer to Figure 23) Click Search to configure external shunts if an existing internal shunt for a given drive is outside its rating. If you need more than one external shunt, click search to select multiple shunt modules. You can also select a compatible shunt manually. The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed in percentage form. Click the drive module or shunt catalog number to view its product specification. Rockwell Automation Publication MOTION-UM004B-EN-P - October

48 Chapter 1 Welcome to Motion Analyzer Software Analysis Tab Click Analysis to display plots of drive module activity in terms of the DC bus voltage and DC bus current: The red line is the bus voltage trip point. The green line is the DC bus voltage. The grey line is the bus current. Figure 36 - Analysis Tab Dialog Box Table 30 - Analysis Tab Properties Parameters Simulation Parameters (1) (refer to Figure 25) Zoom (refer to Figure 25) Shunt On Shunt Off Trip Resistance Power Capacitance Time From/ Voltage From Time Slice The voltage level where the shunt enables. The voltage level where the shunt turns off. The voltage level where the drive trips on an overvoltage fault by changing the trip volts. The shunt resistance level in ohms. Changing the power value modifies how much energy the shunt resistor can dissipate continuously. Changing the capacitance value changes the DC bus capacitance. Check these boxes to adjust the X- and Y-axis values for the plot. Click Plot to implement these changes. The Time Slice variable sets the time interval for the Analysis tab. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is equal to the longest axis cycle. (1) Click Apply to implement these changes. 48 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

49 Welcome to Motion Analyzer Software Chapter 1 If the time slice variable is increased, this error message often appears. This time slice message may also appear as soon as you click Solution on the main taskbar. In this case, clicking Yes or No still takes you to the Solution tab, but if you click No, some pre-calculations are not performed. This time slice message often appears if one of the motion cycles is a cam, which often has very short time segments. In this case, click No to ignore the message Energy Tab Click the Energy tab to display the main power supply parameters including input current, cost of system energy, and cost of shunt energy. Rockwell Automation Publication MOTION-UM004B-EN-P - October

50 Chapter 1 Welcome to Motion Analyzer Software Configure Power Supply BOM Tab Click the Configure Power Supply BOM tab to complete the bill of materials (BOM) for the Power Supply after fully sizing the application. In this tab, you select options for the shunt module, filters, circuit breakers, and fuses. 50 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

51 Welcome to Motion Analyzer Software Chapter Power Supply/Accessories AC/DC Power Sharing Systems (Kinetix 5500 drives) If your drive family is Kinetix 5500, you must define a valid power sharing configuration and then configure a shunt and capacitor, or specify if no shunt or capacitor are required. Figure 37 - Power Supply/Accessories Table 31 - Power Configuration Options (refer to label 1 in Figure 37) Parameters Power Configuration options (label 1 in Figure 37) Axes sharing AC/DC (label 2 in Figure 37 DC Sharing AC Sharing Only Use this option for shared AC/DC or common bus configuration. The following restrictions are imposed on the number of drives allowed in common bus, or shared AC/DC configuration, based on the converter capacity and/or connectors: Single phase operation is not allowed. The bus master drive or drives with an AC connection should have the same power rating (catalog number). The bus master drive or drives should always have a rating equal to, or greater than, the followers. The number of bus master drives cannot exceed the following rule: Frame 3 = two drives; Frame 2 = four drives; Frame 1 = eight drives. The number of follower drives is driven by the frame of the master drive or drives, and cannot exceed this rule: Frame 1 drive = only four more bus followers can be added; Frame 2 drive = only six more bus followers can be added. Converter power output should be reduced by 30% of the sum of the individual converter power capacities of drives configured for shared AC/DC. The maximum number of drives in a bus power sharing group is eight drives. 3-phase AC input power can be shared among drives with the same power rating. No DC bus connections are allowed in this configuration. AC power sharing allows you to minimize the system components, such as circuit breakers and fuses. The following limitations apply when drives are configured for sharing AC input power: Single-phase operation is not allowed. All drives must be configured for the same converter voltage rating. Drives with the same power rating (catalog number) can be used for this configuration. The maximum number of drives that can be configured for shared AC operation is limited by the amp capacity of the AC input connector. The following rules apply: Frame 1 drives can share AC with up to five drives of the same rating; Frame 2 drives can share AC with up to three drives of the same rating; Frame 3 drives can share AC with up to two drives of the same rating. Select the AC and DC sharing option for each axis individually. Rockwell Automation Publication MOTION-UM004B-EN-P - October

52 Chapter 1 Welcome to Motion Analyzer Software DC Sharing Use the DC Sharing configuration to group axes to share a common DC bus and input AC supply (optional). Table 32 - Power Supply/Accessories Tabs (refer to Figure 37) Parameters Power Data Tab Converter and Shunt Tab Analysis Tab Energy Tab Configure Power Supply BOM Tab View regeneration and motoring data for each axis. Select the shunts and capacitor for your system. Analyze the drive module activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters. View input current values and energy savings estimates for each axis. Configure the bill of materials (BOM) for the power supply after fully sizing the application Power Data Tab Click the Power Data tab to view regeneration and motoring data for each axis. Figure 38 - Power Data Tab Table 33 - Power Data Tab Properties (refer to Figure 38) Parameters Axis histograms Random/Sync relationship Offset The axis histograms show a multi-axis representation of axis currents including peak motoring, average motoring, peak regenerating, and average regenerating. The phase relationship between the various axis motion profiles in a common DC bus system affects the peak bus-current requirement. For example, if all axes accelerate simultaneously (for example, synchronous operation), the bus current demand is much greater than if each accelerates in turn. The pull-down menu lets you choose Random or Synchronized mode for axes operation. At least one axis should be set to random as the reference axis. Other axes may be set to synchronized or random relative to the reference axis. The safe setting for system sizing is all Random mode. In this case, the worst case current demand for each axis is automatically lined up by adjusting the phase relationship of the axis motion profiles. If the phase relationship is known and will not change, the cycle profiles should be set up in the correct relationship and appropriate synchronized set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected. If all axis motion profiles are the same length and start at their correct respective positions at the default time, then the offsets will be zero. Otherwise, a specified time offset may be used to align the motion profiles correctly. 52 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

53 Welcome to Motion Analyzer Software Chapter Converter and Shunt Tab Select shunt and capacitor modules for your system. Figure 39 - Converter and Shunt Tab Table 34 - Converter and Shunt Tab Properties (refer to Figure 39) Parameters Shunt Selection and Component Listing (label 1 in Figure 39) Calculation Utilizations Utilization (label 2 in Figure 39) In this section you select a shunt for each axis, and a capacitor module for the system. Click Calculate Utilizations to analyze the behavior of the bus, and to calculate the drive and shunt utilizations. The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed in this area. Click the drive module catalog number to view the drive specifications. Rockwell Automation Publication MOTION-UM004B-EN-P - October

54 Chapter 1 Welcome to Motion Analyzer Software Analysis Tab Click the Analysis tab to conduct detailed analysis of the drive module activity in terms of bus volts and system current, along with the capability of simulating changes to the system parameters. The analysis activities are described as follows: The red line is the bus voltage trip point. The green line is the DC bus voltage. The grey line is the bus current. Figure 40 - Analysis Tab Table 35 - Analysis Tab Properties (refer to Figure 40) Parameters Simulation Parameters (refer to Figure 40) Adjust these parameters to observe how changes to the parameters impact the bus voltage and current. Zoom window (refer to Figure 40) Time From/ Voltage From Time Slice Check these boxes to adjust the X- and Y-axis values for the plot. The Time Slice variable sets the time interval for the analysis display. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is equal to the longest axis cycle. In the case of a very long length of time, we suggest that a longer time slice be used for early checks, but a time slice of less than 0.1 ms should be used for the final selection. 54 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

55 Welcome to Motion Analyzer Software Chapter 1 If the time is increased, the time slice error message often appears. This time slice message may also appear as soon as you click Solution on the main taskbar. In this case, clicking Yes or No still takes you to the Solution tab, but if you click No, some pre-calculations are not performed. This time slice message often appears if one of the motion cycles is a cam, which often has very short time segments. In this case, click No to ignore the message Energy Tab Click the Energy tab to display the main power supply parameters including Input Current, System Power, Shunt Power, and Energy Savings Estimates. Figure 41 - Energy Tab Rockwell Automation Publication MOTION-UM004B-EN-P - October

56 Chapter 1 Welcome to Motion Analyzer Software Configure Power Supply BOM Tab Click the Configure Power Supply BOM tab to complete the bill of materials (BOM) for the power supply after fully sizing the application. In this tab, you select options for the power rail, shunt module, filters, circuit breakers, and fuses. Figure 42 - Configure Power Supply BOM Tab AC Sharing Only Use the AC Sharing Only configuration to group axes to share input AC supply only, with no DC bus sharing. Figure 43 - Power Configuration Tab for AC Sharing Only Mode 56 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

57 Welcome to Motion Analyzer Software Chapter 1 Table 36 - Power Supply/Accessories (refer to Figure 43) Parameters Power Data Tab Converter and Shunt Tab Analysis Tab Energy Tab Configure Power Supply BOM Tab View regeneration and motoring data for each axis. Select the shunt and capacitor for your system. Analyze the drive module activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters. View input current values and energy savings estimates for each axis. Configure the bill of materials (BOM) for the power supply after fully sizing the application Power Data Tab Use the Power Data tab to view regeneration and motoring data for each axis. Figure 44 - Power Data Tab Table 37 - Power Data Tab Properties (refer to Figure 44) Parameters Axis histograms The axis histograms show a multi-axis representation of axis currents including peak motoring, average motoring, peak regenerating, and average regenerating. Rockwell Automation Publication MOTION-UM004B-EN-P - October

58 Chapter 1 Welcome to Motion Analyzer Software Shunt Tab Select the shunt and capacitor module for your system. Figure 45 - Shunt Tab Table 38 - Shunt Tab Properties (refer to Figure 45) Parameters Shunt selection (refer to Figure 45) Continuous Current utilization bar (refer to Figure 45) Click Search to configure external shunts if an existing internal shunt for a given drive is outside its rating. If you need more than one external shunt, click search to select multiple shunt modules. You can also select a compatible shunt manually. The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed in percentage form. Click the drive module or shunt catalog number to view its product specification. 58 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

59 Welcome to Motion Analyzer Software Chapter Analysis Tab Click the Analysis tab to display plots of drive module activity in terms of the DC bus voltage and DC bus current. The analysis activities are described as follows: The red line is the bus voltage trip point. The green line is the DC bus voltage. The grey line is the bus current. Figure 46 - Analysis Tab Table 39 - Analysis Tab Properties (refer to Figure 46) Parameters Simulation Parameters (1) (refer to Figure 46) Zoom window (refer to Figure 46) Shunt On Shunt Off Trip Resistance Power Capacitance Time From/ Voltage From Time Slice The voltage level where the shunt enables. The voltage level where the shunt turns off. The voltage level where the drive trips on an overvoltage fault by changing the trip volts. The shunt resistance level in ohms. Changing the power value modifies how much energy the shunt resistor can dissipate continuously. Changing the capacitance value changes the DC bus capacitance. Check these boxes to adjust the X- and Y-axis values for the plot. Click Plot to implement these changes. The Time Slice variable sets the time interval for the Analysis tab. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is equal to the longest axis cycle. (1) Click Apply to implement these changes. Rockwell Automation Publication MOTION-UM004B-EN-P - October

60 Chapter 1 Welcome to Motion Analyzer Software If the time is increased, the time slice error message often appears. This time slice message may also appear as soon as you click Solution on the main taskbar. In this case, clicking Yes or No still takes you to the Solution tab, but if you click No, some pre-calculations are not performed. This time slice message often appears if one of the motion cycles is a cam, which often has very short time segments. In this case, click No to ignore the message Energy Tab Click the Energy tab to display the main power supply parameters including input current, cost of system energy, and cost of shunt energy. Figure 47 - Energy Tab 60 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

61 Welcome to Motion Analyzer Software Chapter Configure Power Supply BOM Tab Click the Configure Power Supply BOM tab to complete the bill of materials (BOM) for the power supply after fully sizing the application. In this tab, you select options for the power rail, shunt module, filters, circuit breakers, and fuses. Figure 48 - Configure Power Supply BOM Tab Rockwell Automation Publication MOTION-UM004B-EN-P - October

62 Chapter 1 Welcome to Motion Analyzer Software Preferences Tab The Preferences tab contains three sections. Figure 49 - Preferences Tab Options Table 40 - Preferences Tab s Options Database (label 1 in Figure 49) Settings (label 2 in Figure 49) Options (label 3 in Figure 49) My Preferred Database (refer to Figure 50) User Defined Database (refer to Figure 51) Check for Updates User Information (refer to Figure 52) Key Status Units of Measure (refer to Figure 53) Operating Conditions (refer to Figure 54) Notes The product databases may be modified to restrict selections to those items marked by you. This may be used, for example, by a distributor to select from a range of popular stock items. Drives, Motors, and Gearboxes may all be marked. Creates a database of custom motors with your own specifications that can be sized and analyzed. Updates the Motion Analyzer database on your personal computer to the latest database available from the Motion Analyzer server. Enter details about the end-user. Entries appear on printouts. Lets privileged users select the electronic keys to provide additional features and functions. Lets you set default units for all data entry. Choice includes a user Custom set. Lets you set the operating conditions used to calculate Life calculations of Bearing Life, Ball Screw Life, Roller Screw Life, and Strip Seal Life in Motion Analyzer software. Launches system notes for the application. Figure 50 - Preferred Data Dialog Box 62 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

63 Welcome to Motion Analyzer Software Chapter 1 Figure 51 - User Defined Motors Dialog Box Figure 52 - Options - User Information Dialog Box Rockwell Automation Publication MOTION-UM004B-EN-P - October

64 Chapter 1 Welcome to Motion Analyzer Software Figure 53 - Options - Units of Measure Dialog Box Figure 54 - Options - Operating Conditions Dialog Box 64 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

65 Welcome to Motion Analyzer Software Chapter Export Import Tab The Export - Import tab contains two sections. Figure 55 - Export - Import Tab Options Table 41 - Export - Import Tab s Options Export (label 1 in Figure 55) Import (label 2 in Figure 55) Project Data to Word Profile Data BOM to Word BOM to Excel Export To RSLogix 5000 Axis Data Profile Data Exports the application data to a Microsoft Word document. Launches the export wizard to let you export the profile data of the selected axis. Refer to More Options Profile Editor Mode on page 142. Exports Bill of Material to Microsoft Word document. Exports Bill of Material to Microsoft Excel file. Exports motion system information to RSLogix 5000 software to use it in the next step of your design process. Imports the axis data from another axis either of current application or from any other Motion Analyzer application. Imports the Profile data for selected axis. Imported Profile Data must have been previously exported by Motion Analyzer software Export to RSLogix 5000 Wizard Once you have selected a motor and drive in Motion Analyzer software, you can export motion system information to RSLogix 5000 software and use it in the next step of your design process. You can generate an RSLogix 5000 file (.L5X), version 18.00, 19.00, 20.00, or Applications can be exported to RSLogix 5000 software as new.l5x files or as updates to existing.l5x files. Rockwell Automation Publication MOTION-UM004B-EN-P - October

66 Chapter 1 Welcome to Motion Analyzer Software Export Options - Create a New.L5X File 1. From the Export-Import menu, click Export To RSLogix The Output Format Selection dialog box opens. 2. Select Create a New L5X and from the pull-down menu and choose the RSLogix 5000 software version you intend to use. 3. Click Next. The Axis Mapping dialog box opens. 66 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

67 Welcome to Motion Analyzer Software Chapter Axis Mapping Information about.l5x file that Motion Analyzer generates is displayed at the top of the screen as read only information. Table 42 - Axis Mapping Properties Attribute Controller Name Controller Type Chassis Type Motion Analyzer software assigns a default name for the controller. You can edit this once the file has been loaded. Motion Analyzer software creates a file with a default controller type. You can edit this once the file has been loaded. Motion Analyzer software creates a file with a default Logix chassis. You may change your chassis type once the file has been loaded. The name you define for each axis in Motion Analyzer software is used to create a RSLogix 5000 axis tag. Underscore characters replace spaces in the name defined in Motion Analyzer software. To change these names you must exit the Export to RSLogix 5000 wizard and change the names by right-clicking each axis in the Motion Analyzer explorer tree. All axes in your Motion Analyzer (.mba) file appear in the table. If they will export without trouble, a green status check is displayed. Rockwell Automation Publication MOTION-UM004B-EN-P - October

68 Chapter 1 Welcome to Motion Analyzer Software Table 43 - Axis Mapping Symbols Attribute Axes will export without errors. Axes with warning icon only partially export to RSLogix 5000 software. A note at the bottom of the screen indicates what is wrong. Not recommended icon. A note at the bottom of the screen indicates what is wrong. If problems occur with selected catalog numbers, a warning icon and a note at the bottom of the dialog box appears. Figure 56 - Axis with Warning Icon If export isn t possible, a note at the bottom of the dialog box indicates what the problem is. This axis is not exported to RSLogix 5000 software. Figure 57 - Axis with Not Recommended Icon If the number of axes a sercos module can support is exceeded, a new sercos module is added into the pull-down menu in the third column. This is selectable for the rest of the axes. This new module is also exported to the.l5x file. 4. Click Next. 68 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

69 Welcome to Motion Analyzer Software Chapter 1 The Target Location dialog box opens Save and Import the L5X File 1. Click Browse to select a target location and save the.l5x file. IMPORTANT Do not use spaces or special characters in the name, or RSLogix 5000 software will not open the file. 2. Click Finish. Rockwell Automation Publication MOTION-UM004B-EN-P - October

70 Chapter 1 Welcome to Motion Analyzer Software 3. Open RSLogix 5000 software. 4. Browse to your.l5x file and open it. 70 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

71 Welcome to Motion Analyzer Software Chapter 1 5. Browse to the location where you would like to store your.acd file. 6. Click Import. Rockwell Automation Publication MOTION-UM004B-EN-P - October

72 Chapter 1 Welcome to Motion Analyzer Software Your motion system information imports from Motion Analyzer software. Exceptions include warnings noted on the Axis Mapping dialog box. 72 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

73 Welcome to Motion Analyzer Software Chapter Export Options - Update an Existing L5X File 1. From the Export-Import menu, click Export To RSLogix The Output Format Selection dialog box opens. 2. Select Update an Existing L5X and click browse to find the file you wish to update. 3. Click Next. Rockwell Automation Publication MOTION-UM004B-EN-P - October

74 Chapter 1 Welcome to Motion Analyzer Software The Axis Mapping dialog box opens. 4. Make changes as needed to the existing file. 5. Click Next. 74 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

75 Welcome to Motion Analyzer Software Chapter 1 The Target Location dialog box opens. Table 44 - Export Output Target Properties Attribute Save Save As Select Save to replace the old L5X file with the updated file. Select Save As to create an updated L5X file in a new location and/or with a new name. 6. Open the file in RSLogix 5000 software as described earlier and notice that the motion system information from your Motion Analyzer software file has been included. 7. Click Finish. Rockwell Automation Publication MOTION-UM004B-EN-P - October

76 Chapter 1 Welcome to Motion Analyzer Software Bill of Materials (BOM) Tab The Bill of Materials (BOM) tab contains two sections. Figure 58 - Bill of Materials (BOM) Tab Options Table 45 - Bill of Materials (BOM) Tab s Options Configure (label 1 in Figure 58) Export (label 2 in Figure 58) Axis System Module Software and Accessories Tab This is a combo item and contains the axis names of all the axes in the Drives Group that have a solution. It lets you navigate to the Configure Axis BOM tab of Axis view where you can configure the BOM for the axis chosen. This is a combo item for single-axis drive family and a button item for multi-axis drive family. For single-axis drive family, it contains the axis names of all the axes in Drives Group that have a solution. It lets you navigate to Configure Power Supply BOM tab of the Power Supply & Accessories view where you can configure the Power Supply BOM for the system. Navigate to the Software & Accessories tab of System BOM view on page 38. Additional Parts Tab Navigate to the Additional Parts tab of System BOM view on page 39. Configuration Summary Tab BOM to Word BOM to Excel Navigate to the BOM tab of System BOM view on page 37. Exports Bill of Material to Microsoft Word document. Exports Bill of Material to Microsoft Excel file Help Tab The Help tab contains one section. Figure 59 - Help Tab Options Table 46 - Help Tab s (refer to Figure 59) Options Motion Analyzer Help Activate Motion Analyzer Send Feedback Release Notes About Motion Analyzer Launches Motion Analyzer help. Launches the Motion Analyzer Activation wizard. You can Purchase License or Activate their Motion Analyzer installation (refer to Figure 60). Provides contact information for Motion Analyzer software support. Launches the Release Notes for the installed Motion Analyzer software revision. Launches the About Motion Analyzer dialog box that displays details of the installed copy of Motion Analyzer software (refer to Figure 61). 76 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

77 Welcome to Motion Analyzer Software Chapter 1 Figure 60 - Motion Analyzer Activation Wizard Figure 61 - About Motion Analyzer Rockwell Automation Publication MOTION-UM004B-EN-P - October

78 Chapter 1 Welcome to Motion Analyzer Software 1.3. Explorer View The Explorer view provides a Windows Explorer style graphical user interface for accessing components in your Motion Analyzer software application. For multi-axis drive systems, the axes are added under the Power Rail node in the Explorer hierarchy view. Figure 62 - Typical Multi-axis Drive Explorer View For single-axis drive systems, the axes are added under the Project node in the Explorer hierarchy view. Figure 63 - Typical Single-axis Drive Explorer View For drive families that allow stand alone as well as power sharing group (Kinetix 5500 drives), a mix of drive group and stand alone axes can be added under the Project Node. 78 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

79 Welcome to Motion Analyzer Software Chapter 1 Figure 64 - Typical AC/DC Power Sharing System (Kinetix 5500) Explorer View Table 47 - Explorer View Structure (refer to Figure 62) Options The project node contains two types of groups. The Power Rail/Drive Group (of the selected product family) and an unallocated group. Power Rail Node Drives Group Node Applies to multi-axis drive families. Shown is the power rail icon, drive family name, and power rail catalog number. The default name for this node is Drives Group 1, however, it is renamed when a solution for any axis under this group is defined. For single-axis family, the default name is Drives Group 1. For multi-axes family, the default name is Power Rail 1. Also, for multi-axis family, after the drive family is defined, the power rail displays many empty slots until each slot is allocated a module. Applies to drive families that allow AC and DC power sharing (Kinetix 5500). Shown is the drive group icon and drive name. Project Node Axis Module Node Axis Module Node IPIM Module Node IDM Unit Node Empty Slot Node Axis node consists of two levels. First level displays the slot number of the power rail (available only for multi-axis families), axis name, drive catalog number, and the solution status of the axis. Second level displays the motor catalog number for the selected solution. Additionally, if there is a warning in the axis, then a warning triangle is also displayed beside the solution status. When the solution is not yet selected, then only the axis node is displayed and instead of drive catalog number, Incomplete is displayed. This node displays the slot number that the IPIM module is assigned to on the power rail along with the name of the IPIM module, catalog number of the selected IPIM module, and the IPIM module status. IDM unit node is similar to axis module node except that the IDM unit node consists of only a single node representing the axis solution. Applies to multi-axis drive families. It is visible after a multi-axis drive family is selected. Unallocated Axis Node Status Symbols The Unallocated Axes Node is where axes independent of other axes can be created. An unallocated axis can be allocated to a Drive Group using the allocate button located in the Home Tab on the menu bar or by dragging and dropping the axis. Additionally, if the power supply solution is present, then the status of the selected power supply solution is also displayed, as described below. Indicates that the selected power supply solution and all children support the application requirement. Indicates that the selected power supply solution or any one of the children marginally support the application requirement. Indicates that the selected power supply solution or any one of the children is not recommended for the application. Additionally, this icon is also displayed when the IAM module for the power rail has not been sized. Rockwell Automation Publication MOTION-UM004B-EN-P - October

80 Chapter 1 Welcome to Motion Analyzer Software Notes: 80 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

81 Chapter 2 Sizing Your System Topic Page Identify Your Load 82 Linear Loads 83 Rotary Loads 86 Rotary Complex Loads 87 Application Template Loads 96 From SolidWorks 120 Define Your Profile 139 Less Options Profile Editor Mode 140 More Options Profile Editor Mode 142 Specify Your Linear Load Mechanism 178 Belt Drive 180 Lead Screw 181 Chain and Sprocket 182 Rack and Pinion 183 Linear Motor 184 Electric Cylinders 186 Linear Stages 187 Linear Thrusters 189 Specify Your Transmission 191 Compute Using Inertia and Ratio 193 Compute Using Pitch Circle Diameter 194 Compute Using Number of Teeth 195 Choose Your Motor Series 196 Choose Your Electric Cylinder Series 199 Choose Your Drive Family 201 Rockwell Automation Publication MOTION-UM004B-EN-P - October

82 Chapter 2 Sizing Your System 2.1. Identify Your Load A load is a device that transfers the actuator output to the desired end effectors. Loads do not affect the motion type. Figure 65 - Load Type Tab Table 48 - Load Type Options Load Type Page Linear Loads Load moves in a straight line. 83 Rotary Loads Load rotates and the system has no translation to linear motion. 86 Rotary Complex Loads Application Template Loads From SolidWorks Rotary motion can be translated to linear motion, and vise versa. Inertia, friction, and/or torque values for the system change with time. Simplify data entry dramatically where the application is appropriate. The Application Templates include Press Roll Feed (Constant Time or Angle), Carriage Cut Off, Cutter Knife Drive, Advanced Templates, and Power Speed. Used to obtain load data to aid in sizing your application for the appropriate motors, drives, and accessories Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

83 Sizing Your System Chapter Linear Loads For a Linear application, the load moves in a straight line. Figure 66 - Linear Load Type Table 49 - Linear Load Parameters Parameter Load Mass Applied Force Coeff of Friction Inclination Mass of the linear load. Any external force (+/-) acting on the load. Positive force acts to oppose positive movement; down the inclination surface if inclination is non-zero. The arrow on the graphic indicates the force direction. Coefficient of friction (μ). It is a unitless value, which is used to calculate the force of friction. It is largely dependent on the nature of the surfaces in contact with each other. Typical values for the coefficient of friction can be found in engineering tables. This value, along with the load mass (for example, Load weight + Table/Slide/Carriage weight), determines the amount of motor force or torque necessary to move a slide or table, for example. Angle of inclination from the horizontal. The limits for this value are 0 and 90. In the horizontal case (0 inclination), the Table Mass, Belt/Chain Mass, and/or Slide Mass are not affected by gravity, whereas in the vertical case (90 inclination), only the table mass is affected by gravity. Values for Table Mass, Belt/Chain Mass, and/or Slide Mass may be entered on the Mechanism tab (a future step in the workflow) if a Belt Drive, Lead Screw, Chain and Sprocket, or Rack and Pinion are selected. If the Inclination angle is between 0 and -90, you must enter the angle as a positive number and invert the motion profile. For example, enter a 45 angle value on the Load tab and a negative velocity in More Options Profile Editor Mode on page 142. Failure to do this will result in an under-calculation of the regenerative energy. Rockwell Automation Publication MOTION-UM004B-EN-P - October

84 Chapter 2 Sizing Your System Advanced Considerations - Counterbalances In a counterbalanced system, unbalanced mass should be entered as Table Mass and balanced mass as Belt/Chain Mass. Values for Table Mass, Belt/Chain Mass, and/or Slide Mass may be entered on the Mechanism tab (a future step in the workflow) if a Belt Drive, Lead Screw, Chain and Sprocket, or Rack and Pinion are selected. There are two main types of counterbalance. Table 50 - Counterbalance Types Type Mass Counterbalance Force Counterbalance A 100% counterbalance doubles the load mass entered on the Load tab. Friction is usually negligible and the net force is zero. Accelerations are normally limited to less than gravity (9.81 m/s 2 ) to maintain the suspension tension. A 100% counterbalance means there is zero net force, but usually adds significant friction, especially hydraulic types. For example, pneumatic, hydraulic, or spring. The increase in load mass is usually negligible. Figure 67 - Counterbalance Types Mass Counterbalance Force Counterbalance Counterbalance Mass Drive Belt Weight Load Mass Weight Drive Belt Load Mass Weight Motor Force Counterbalance Cylinder Air Pressure Motor 84 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

85 Sizing Your System Chapter Mass Counterbalance Vertical load with a 100% mass counterbalance Set the Inclination field to zero and enter a load mass two times greater than the load into the Load Mass field. Vertical load with less than 100% mass counterbalance. Set the Inclination field to zero and enter the load mass plus the counterbalance mass into the Load Mass field. Add an external positive force equal to the following into the Applied Force field: F = (M load - M counterbalance ) a where a = acceleration due to gravity = 9.81 m/s Force Counterbalance For a vertical load with a 100% force counterbalance, you have two choices: Set the Inclination field to zero and enter the load mass into the Load Mass field. Set the Inclination field to 90, and enter the load mass into the Load Mass field. Add an external negative force equal to the load weight into the Applied Force field. For a vertical load with less than 100% force counterbalance, set the Inclination field to 90 and put the load mass into the Load Mass field. Add an external negative force equal to the counterbalance force into the Applied Force field. Be sure to add some allowance for friction. Hydraulic type counterbalances are notorious for high friction, which is usually speed-dependent. Because a mass counterbalance cannot easily handle this directly, take the friction force at the maximum speed, convert the friction force to torque at the drive shaft and add this torque to the Losses field in the Actuator tab. Rockwell Automation Publication MOTION-UM004B-EN-P - October

86 Chapter 2 Sizing Your System Rotary Loads For a rotary application, the load rotates and the system has no translation to linear motion. Figure 68 - Rotary Load Type Table 51 - Rotary Load Parameters Parameter Primary Inertia (1) Friction This is the inertia of any balanced load about the axis of rotation. For example, if the main mass is a circular table which is driven about its own axis of symmetry, then primary inertia is equal to the table inertia. This is the force resisting the relative motion of two surfaces against each other. (1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. 86 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

87 Sizing Your System Chapter Rotary Complex Loads A complex rotary load is non-linear, which means that the load position is not directly proportional to the input shaft position as it is with standard actuator types. A simple example is a crank, where the load velocity is sinusoidal with a constant shaft speed. The Crank and Four Bar Linkage templates are available for these applications. The main challenge with non-linear mechanisms is that the inertia value varies with shaft angle. This means that even at constant shaft speed, a torque that varies with the rate of change of inertia is required to maintain that speed. The same is true of an unbalanced load in which external forces, such as gravity, induce torque values that depend only on shaft angle, not velocity or acceleration. The Rotary Complex load separates the dynamic inertia values from the motion profile so that, having calculated inertia for a range of shaft positions, the motion profile can be varied without having to re-calculate inertia at each shaft position. Figure 69 - Rotary Complex Load Type Rockwell Automation Publication MOTION-UM004B-EN-P - October

88 Chapter 2 Sizing Your System Table 52 - Complex Load Data Options Option Complex Load Data (label 1 in Figure 69) Motion (1) (label 2 in Figure 69) Graph tab (label 3 in Figure 69) User Defined Templates Repeating Limited Range Import load data from an external file into the Complex Load Data table on page 90. Use the Unbalanced Load and Crank templates to calculate load data and enter it in the Complex Load Data table on page 90. With this option, the first and last points should be identical so that the motion profile can be repeated (for example, zero and 360 ). Motion Analyzer software assumes that rotation may continue indefinitely in either direction. With this option, the first and last points indicate the maximum and minimum positions permitted. # Data point number; this number is arbitrary. Position Inertia Applied Torque Friction Torque Driving shaft angle with reference to the starting angle. Load inertia for the given shaft angle. Torque applied at the given position. Torque loss due to friction. Available for you to enter optional notes. The Graph tab of the display window shows the inertia, applied torque, and friction torque values as a function of shaft position based on the data entered in the table on the left (label 2 in Figure 69). (1) The complex load data (position, inertia, and torque, for example) is entered manually, imported, or calculated in the available Rotary Complex Templates. It is important to start with the mechanism in the appropriate position. Click Start Condition on the toolbar at the top of the More Options Profile Editor Mode dialog box to input the motion profile start condition. Figure 70 - Graph Tab 88 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

89 Sizing Your System Chapter 2 In this Crank application, the green applied torque curve shows a sharp peak around 180 when a high force is encountered near the end of the linear stroke. Figure 71 - Crank Application Example Rockwell Automation Publication MOTION-UM004B-EN-P - October

90 Chapter 2 Sizing Your System User Defined For the User Defined data entry option, calculations are typically made with a spreadsheet. Once the data is arranged in columns to match the Complex Load Data table, you can copy the data to the clipboard and paste it into the table. The columns are tab delimited, which is the default format for Microsoft Excel software. Alternatively, you can create and import a text file. IMPORTANT Before pasting data make sure that the column units match those of the data Templates The Rotary Complex templates can be used to calculate Complex Load Data for Unbalanced Load and Crank application types. Figure 72 - Rotary Complex Loads There are two Rotary Complex templates available to assist in calculating data for the Complex Load Data table (label 2 in Figure 72). Table 53 - Template Options (label 1 in Figure 72) Template Page Unbalanced Load Template Lets you enter parameters for an Unbalanced Load application. 91 Crank Template Lets you enter parameters for Crank applications Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

91 Sizing Your System Chapter Unbalanced Load Template This template lets you enter parameters for an unbalanced load application. Figure 73 - Unbalanced Load Template Motion Analyzer software assumes that the axis of rotation is parallel to the ground if no axis angle is entered and that unbalanced masses create a gravity related torque. Secondary Inertia, Secondary Mass and Axis Separation parameters are required to take into account gravity induced torque values. Figure 74 - Axis of Rotation Parallel to Ground with No Axis Angle Defined Rockwell Automation Publication MOTION-UM004B-EN-P - October

92 Chapter 2 Sizing Your System If the gravity torque (Secondary Mass * 9.81 m/s 2 * Axis separation 2 ) is known to be small as compared to the acceleration torque or motor nominal torque, then it may not be necessary to include the unbalanced mass effects. ATTENTION: If the angle of movement in any profile segment is such that the gravity torque changes significantly during that segment (a common occurrence) then break the segment into smaller portions. Table 54 - Unbalanced Load Parameters (refer to Figure 73) Parameter Primary Inertia (1) Losses Secondary Inertia (1) Secondary Mass Axis Separation Axis Angle The inertia of any balanced load about its own axis of rotation. For example, if the main mass is a circular table which is driven about its own axis of symmetry, then Primary Inertia is equal to the table inertia. The losses consist of the torque lost in the system due to friction. The moment of inertia of the unbalanced mass about its own center of gravity. The unbalanced mass. The distance between the secondary mass center of gravity and the axis of rotation. The starting angle of rotation. Zero indicates that at the start of the motion profile, the center of gravity lies vertically below the center of rotation. This is the position of the load if it is allowed to swing freely. Positive rotation is clockwise. (1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. 92 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

93 Sizing Your System Chapter Crank Template The Crank template is used to calculate the load profile for a given application, based on either input shaft velocity or linear load velocity. IMPORTANT This template should only be used for constant inertia. Do not set secondary mass or secondary inertia when using this template. Figure 75 - Crank Template Figure 76 - Animated Display (for reference) TIP Parameter entry descriptions are displayed when the cursor is held over an entry field for several seconds. Rockwell Automation Publication MOTION-UM004B-EN-P - October

94 Chapter 2 Sizing Your System Table 55 - Crank Template Parameters Parameter Animated Display (label 1 in Figure 75) Template Options (inside red box in Figure 75) Mechanical Data (label 2 in Figure 75) Export to Complex Load (label 3 in Figure 75) For reference to make sure that entered data is accurate and particularly that the orientation of the crank is correct. The animation rotates the crank so that the system can be better visualized. The X/Y plane is horizontal. Vertical Slider (Left) Sets the crankshaft inclination. Set this parameter before starting the animation. The 0y button sets the angle to 90. The current angle is displayed in the Mechanical Data window. Horizontal Slider (Top) Sets the linear slide inclination. The 0z button sets the angle to 0. The current angle is displayed in the Mechanical Data window. The true angle to the horizontal is dependent on both slider positions since it is a compound angle. Horizontal Slider (Scale) Sets the display scale. Horizontal Slider (Speed) Sets the animation speed. Black Arrow Represents the external force and the arrow length is proportional to the applied force. 2D/3D Toggles between two and three-dimensional representations of the crank. Thick Lines Check this box if you would like the graphical displays to be shown with a thicker line. Animate Stop Calculate Crank Radius Crank Inertia (1) Connecting Rod Length (2) Connecting Rod Mass Conrod C of G from Crankpin Conrod Inertia about C of G (1) Linear (Load) Mass Linear (Load) Offset Force Start Position Force End Position Force at End (3) Force v Angle Box Draw Logix Cam Crankshaft Inclination Crank Plane Inclination Start Angle End Angle Points Click to run the simulated crank image through the specified motion profile. Click to stop the animation. Click to calculate the external torque and reflected inertia values. The distance between crank shaft and crank pin. The inertia of the crank alone, when the connecting rod is disconnected. The distance from the crank pin center to the gudgeon (wrist) pin center. The total mass of the connecting rod. The distance between the crank pin and the connecting rod center of gravity. The inertia of the connecting rod about its own center of gravity. The mass of the load attached to the connecting rod at the gudgeon pin. The distance from the linear motion center line to the crankshaft axis. The distance between gudgeon (wrist) pin and crank shaft center when force is applied. The distance between the gudgeon (wrist) pin and crank shaft center when force stops. The magnitude of the force at the ending point. When this box is checked, the force varies according to shaft angle rather than linear position. Click this button to show the geometry at the start angle/position. Click this button to transfer the geometrical data to the clipboard for pasting into the RSLogix 5000 Cam Editor. The master axis is a virtual axis and the slave axis is the crank axis. A trapezoidal move of the virtual axis produces a trapezoidal load profile at the gudgeon pin. The master data must increase positively so only that part of the cam that satisfies this requirement is exported. This displayed value is the angle of the crank shaft with respect to the XY (horizontal) plane. 90 indicates vertical and gravity has no effect. This displayed value is the angle with respect to the horizontal plane along which the linear mass moves. Zero degrees indicates horizontal and gravity has no effect. The starting angle for the Crank load profile. The ending angle for the Crank load profile. The number of points you would like to divide the load profile into. 94 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

95 Sizing Your System Chapter 2 Table 55 - Crank Template Parameters (continued) Parameter Results (label 4 in Figure 75) Chart Display (label 5 in Figure 75) Peak Inertia Peak Ext. + Grav. Torque Apply Cancel The calculated maximum reflected inertia at the crankshaft. The Peak External Force + Gravity Torque is the calculated peak torque, generated from the external linear force and gravity. Click to apply the load profile data and close the window. Click to close the window without applying any data. The Chart Display displays the crank velocity, the inertia that is reflected to the crankshaft, and the crank torque due to external influences such as gravity and applied force. These are the parameters which will be applied. (1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. (2) Setting this length to zero configures the mechanism as a Scotch Yoke, where the linear load follows a simple harmonic motion. (3) If the Force at Start is different from the Force at End, the force varies between these two limits according to gudgeon pin position or crank angle. If the values are equal, a constant force is applied. Rockwell Automation Publication MOTION-UM004B-EN-P - October

96 Chapter 2 Sizing Your System Application Template Loads The application templates let you enter pre-configured mechanism application data. Figure 77 - Application Template Load Type Table 56 - Application Template Options Template Type Page Press Roll Feed (constant time/constant angle) Carriage Cut Off Cutter Knife Drive Advanced Templates Power/Speed Templates This application is typically cutting strip material into pre-set lengths with a Press Shear (heavy-duty knife). The material must be stationary when the cut is made and the cut takes place over a fixed amount of time or a fixed angle of the driving crank whose speed is varied to match the cut rate. This application is typically cutting strip material into pre-set lengths with a Flying Shear (heavy-duty knife on a moving carriage). The shear must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes a fixed time. This application is typically cutting strip material into pre-set lengths with a Rotary Knife (heavy-duty knife blades mounted on a pair of rotating drums). The blades must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes place over a fixed drum angle. These templates let you enter data for complex mechanisms. Advanced Templates include the Inertia Calculator, Crank, Winder/Unwinder, and Four Bar Linkage. These templates let you enter torque and speed values that are used to calculate the power requirement for the application Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

97 Sizing Your System Chapter Press Roll Feed (constant time/constant angle) This application is typically cutting strip material such as steel into pre-set lengths by means of a press shear (heavy-duty knife). The material must be stationary when the cut is made and the cut takes place over a fixed amount of time or a fixed angle of the driving crank whose speed is varied to match the cut rate. Strip material is unwound from a reel at constant surface speed and fed via separately driven leveler rolls into one end of a looping pit (a free-hanging loop of material providing storage). On the other side of the loop, a pair of feeder rolls grips the material and moves it forward the required cut length and then stops. After the cut is complete, the material is moved again. The average velocity of the nip/feeder rolls must be equal to the constant velocity of the unwinder and leveler rolls. Figure 78 - Press Roll Feed - Constant Time Figure 79 - Press Roll Feed - Constant Angle Rockwell Automation Publication MOTION-UM004B-EN-P - October

98 Chapter 2 Sizing Your System Table 57 - Press Roll Feed Parameters Parameter Load (label 1 in Figure 78 or Figure 79) Critical Preferences (1) (label 2 in Figure 78 or Figure 79) System Properties (label 3 in Figure 78 or Figure 79) Motion Type Properties (label 4 in Figure 78 or Figure 79) Moving Material Mass The mass of the material in the loop and on the flat before the Nip/Feed rolls. (3) Bias Force The force required to overcome the force of gravity on the loop. (3) Drive Roll Diameter Total Roll Inertia (2) Cut (Waiting) Time Cut (Waiting) Angle Max Average Line Speed Cuts/min Settling Time Cosine Compensation Linear S-Curve Triangular Move The diameter of the roll in direct contact with the strip, driven from the motor. The total inertia of the strip material at the drive shaft. The time during which the material must be stationary in an accurate position. This value is only required for Press Roll Feed - Constant Time applications (refer to the red boxes in images above). The crank angle during which the material must be stationary in an accurate position. This value is only required for Press Roll Feed - Constant Angle applications (refer to the red boxes in images above). Select this option for data entry when the maximum design speed of the constant-speed sections of the line is known. This speed does not refer to the peak velocity of the feeder section, which is determined by Motion Analyzer software. Min. Cut length at Max line speed When you select the option to enter data based on Max Average Line Speed, this data is required. This is the critical condition on which the sizing process is performed. To cut shorter lengths than this critical length, the line speed must be reduced. Select this option for data entry when the number of cuts made by the system per minute is known. Max. Cut length at Cuts/min When you select the option to enter data based on Cuts/min, this data is required. This is the critical condition on which the sizing process is performed. To cut longer lengths than this critical length, the line speed must be reduced. This is the time required for the system to achieve the required position accuracy before the cut commences. The finer the required accuracy, the longer the settling time value. This time is typically 20 to 75 ms for an A servo system. This option is only required for Press Cutter Knife Drive applications. The Cosine Compensation is used to make sure that while the press cutter knife is in contact with the material being cut, the horizontal component of the knife s velocity matches the material speed. Select this option for standard linear acceleration and deceleration ramps. Select this option for S shaped acceleration and deceleration ramps that are used to produce smoother motion. You need to enter the percent jerk value for this option. Select this option for a triangular load profile. This option is only required for Press Roll Feed - Constant Angle applications (see red box in Figure 79). (1) At very long cut lengths, the limiting factor, determined by the design speed of the leveler rolls and unwinder, is the maximum line speed. As cut length is reduced, the servo has to index more and more rapidly until the peak or RMS (root mean squared) torque limit is reached. To cut shorter lengths than this critical length, the line speed must be reduced. Sizing is based on this critical length, maximum line speed and cut time, which are typically specified. (2) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. (3) You can enter this data manually or use the Loop Calculator on page 99, to determine the value. 98 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

99 Sizing Your System Chapter 2 Click in Figure 78 or Figure 79 to determine the Moving Mass and Bias Force parameters by using the Loop Calculator. Figure 80 - Loop Calculator Table 58 - Loop Calculator Parameters Parameter Material (label 1 in Figure 80) Loop (label 2 in Figure 80) Computed Parameters (label 3 in Figure 80) Density Thickness Width Flat Length Loop Length Loop Depth Moving Mass Bias Force Choose strip material from the pull-down menu or enter the density value manually. Strip material thickness. Strip material width. Strip material flat length as defined in the Press Roll Feed Diagram. Strip material loop length as defined in the Press Roll Feed Diagram. Strip material max loop depth as defined in the Press Roll Feed Diagram. When you click Compute, the Loop Calculator displays the Moving Mass and Bias Force values based on the values you entered for the parameters above. These values are entered in the Application Template when you click OK. Rockwell Automation Publication MOTION-UM004B-EN-P - October

100 Chapter 2 Sizing Your System Carriage Cut Off This application is typically cutting strip material such as steel into pre-set lengths by means of a Flying Shear (heavy-duty knife mounted on a moving carriage). The shear must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes a fixed time. Strip material is unwound from a reel at constant surface speed and fed via separately driven leveler rolls. After the cut is complete, the shear is stopped then moved back to its start position. It must accelerate to match the line speed at the correct position to cut the required length of material. Figure 81 - Carriage Cut Off Template 100 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

101 Sizing Your System Chapter 2 Parameter Load (label 1 in Figure 81) Critical Preferences (1) (label 2 in Figure 81) System Properties (label 3 in Figure 81) Motion Type Properties (label 4 in Figure 81) Mass of Carriage Drive Roll Diameter Friction Coefficient Cut Time Max Average Line Speed Cuts/min Settling Time Linear S-Curve Table 59 - Carriage Cut Off Parameters Total mass of the linear moving parts. Diameter of the roll, driven from the motor. Coefficient of friction of the sliding bearing. Time the carriage must be synchronized accurately with the material. Select this option for data entry when the maximum design speed of the constant-speed sections of the line is known. This speed does not refer to the peak velocity of the feeder section, which is determined by Motion Analyzer software. Min Cut length at Max line speed When you select the option to enter data based on Max Average Line Speed, this data is required. This is the critical condition on which the sizing process is performed. To cut shorter lengths than this critical length, the line speed must be reduced. Select this option for data entry when the number of cuts made by the system per minute is known. Max Cut length at Cuts/min When you select the option to enter data based on Cuts/min, this data is required. This is the critical condition on which the sizing process is performed. To cut longer lengths than this critical length, the line speed must be reduced. This is the time required for the system to achieve the required position accuracy before the cut commences. The finer the required accuracy, the longer the settling time value. This time is typically 20 to 75 ms for an A servo system. Select this option for standard linear acceleration and deceleration ramps. Select this option for S shaped acceleration and deceleration ramps that are used to produce smoother motion. You need to enter the percent jerk value for this option. (1) At very long cut lengths, the limiting factor, determined by the design speed of the leveler rolls and unwinder, is the maximum line speed. As cut length is reduced, the servo has to index more and more rapidly until the peak or RMS (root mean squared) torque limit is reached. To cut shorter lengths than this critical length, the line speed must be reduced. Sizing is based on this critical length, maximum line speed and cut time, which are typically specified. Rockwell Automation Publication MOTION-UM004B-EN-P - October

102 Chapter 2 Sizing Your System Cutter Knife Drive This application is typically cutting strip material such as steel into pre-set lengths by means of a rotary knife (heavy-duty knife blades mounted on a pair of rotating drums). The blades must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes place over a fixed drum angle. Strip material is unwound from a reel at constant surface speed and fed via separately driven leveler rolls. After the cut is complete, the drum is adjusted forward or backward relative to the material in order to cut the required length. It must return to line speed at the position required to cut the required length of material. When the cut-length is equal to the circumference of the locus of the knife blade tip, it is said to be the synchronous cut length. In this special case, the knife drums rotate at a steady speed. Figure 82 - Cutter Knife Drive Template 102 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

103 Sizing Your System Chapter 2 Parameter Load (label 1 in Figure 82) Critical Preferences (1) (label 2 in Figure 82) System Properties (label 3 in Figure 82) Motion Type Properties (label 4 in Figure 82) Total Knife Inertia (2) Effective Diameter Contact Angle (Before BDC) Number of Blades/Knife Cutting Force Max Average Line Speed Cuts/min Settling Time Cosine Compensation Linear S-Curve Table 60 - Cutter Knife Drive Parameters Inertia of the knife assembly at the drive shaft. As illustrated in the Cutter Knife Drive (Rotary Knife) diagram, this is the diameter of the circle passing through the cutting edge. Time the material must be stationary in an accurate position. Number of blades around the circumference of the knife. Maximum force required to cut through the material. Cutting force is essentially constant while maximum torque occurs at the first point of knife contact. Select this option for data entry when the maximum design speed of the constant-speed sections of the line is known. This speed does not refer to the peak velocity of the feeder section, which is determined by Motion Analyzer software. Min Cut length at Max line speed When you select the option to enter data based on Max Average Line Speed, this data is required. This is the critical condition on which the sizing process is performed. To cut shorter lengths than this critical length, the line speed must be reduced. Select this option for data entry when the number of cuts made by the system per minute is known. Max Cut length at Cuts/min When you select the option to enter data based on Cuts/min, this data is required. This is the critical condition on which the sizing process is performed. To cut longer lengths than this critical length, the line speed must be reduced. This is the time required for the system to achieve the required position accuracy before the cut commences. The finer the required accuracy, the longer the settling time value. This time is typically 20 to 75 ms for an A servo system. This option is only required for Press Cutter Knife Drive applications. The Cosine Compensation is used to make sure that while the press cutter knife is in contact with the material being cut, the horizontal component of the knife s velocity matches the material speed. Select this option for standard linear acceleration and deceleration ramps. Select this option for S shaped acceleration and deceleration ramps that are used to produce smoother motion. You need to enter the percent jerk value for this option. (1) At very long cut lengths, the limiting factor, determined by the design speed of the leveler rolls and unwinder, is the maximum line speed. As cut length is reduced, the servo has to index more and more rapidly until the peak or RMS (root mean squared) torque limit is reached. To cut shorter lengths than this critical length, the line speed must be reduced. Sizing is based on this critical length, maximum line speed and cut time, which are typically specified. (2) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. Rockwell Automation Publication MOTION-UM004B-EN-P - October

104 Chapter 2 Sizing Your System Advanced Templates The Advanced Templates tab let you enter data for complex mechanisms. The templates convert the complex mechanisms into Motion Analyzer mechanism data and load profiles with additional inertia and loads. Figure 83 - Advanced Templates Dialog Box Table 61 - Advanced Template Options Template Type Page Inertia Calculator Calculates the inertia for your application. 105 Crank Template Lets you enter parameters for Crank applications. 93 Winder/Unwinder Four Bar Linkage Enter required inputs to calculate the load profile for Winder or Unwinder applications. Enter required inputs to calculate the load profile for Four Bar Linkage applications Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

105 Sizing Your System Chapter Inertia Calculator The Inertia Calculator has several options for inputting parameters to calculate inertia for an application. Figure 84 - Inertia Calculator Template Table 62 - Inertia Calculator Template Options Template Type Page Less Options Inertia Mode More Options Inertia Mode SolidWorks Import This is the default mode when you open the Inertia Calculator. You can also enter this mode by clicking Less Options in the lower left corner of the calculator in More Options Inertia Mode. Use this mode to calculate inertia for a single cylindrical component. The center of mass/center of gravity of the cylinder must coincide with the axis of rotation. Enter this mode by clicking More Options in the lower left corner of the calculator in Less Options Inertia mode. Use this mode to enter data for more complex shaped components. By assembling cylinders, cuboids, and prisms, any largely three dimensional shape can be constructed. Use this mode to directly import inertia data from SolidWorks. Enter SolidWorks mode by choosing SolidWorks from the Type pull-down menu in the Element Properties window Rockwell Automation Publication MOTION-UM004B-EN-P - October

106 Chapter 2 Sizing Your System Less Options Inertia Mode The Less Options Inertia mode is the default mode when you open the Inertia Calculator. Use this mode to calculate inertia for a single cylindrical component. The center of mass/center of gravity of the cylinder must coincide with the axis of rotation. Figure 85 - Less Options Inertia Mode Parameter Element Properties (label 1 in Figure 85) Element Properties (label 2 in Figure 85) Results (label 3 in Figure 85) Type Name Calculate Using Diameter Length Mass Material Density Element Mass Element Inertia Total Inertia Mass Table 63 - Less Options Inertia Mode Properties Choose the type of cylinder (solid or hollow) you would like to calculate the inertia for. Enter a meaningful name for the item you are calculating inertia for. Select the type of data (mass or density) you would like to use to calculate inertia. This is the diameter of the cylinder. When calculating inertia for a hollow cylinder, you also need to enter inner and outer diameter as defined in the Element Image window. This is the length of the cylinder. This parameter is not required when calculating based on mass. This is the cylinder mass. This parameter is not required when calculating based on density. Choose the material of the cylinder from the pull-down menu. If Other is selected as the material type, the density value also needs to be entered. This parameter is not required when calculating based on mass. When the cylinder material is not available in the Material pull-down menu, the density value must be entered here. This parameter is not required when calculating based on mass or when the material is selected from the pull-down menu. Once the element properties are entered, the Element Mass and Element Inertia properties are displayed (see label 2) and in the Results window (see label 3). The Element Mass and Element Inertia, and the Total Mass and Total Inertia are equivalent in Less Options Inertia mode, because data is only entered for a single cylindrical element. Because the Less Options Inertia mode is used to calculate the inertia of a single cylindrical component, the options in the Add Element toolbar are not available. 106 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

107 Sizing Your System Chapter More Options Inertia Mode In More Options Inertia mode you can calculate the mass and inertia of complex shapes. By assembling cylinders, cuboids and prisms, you can construct any largely three dimensional shape. Figure 86 - More Options Inertia Mode Table 64 - More Options Inertia Mode Properties Parameter Add Element Toolbar (label 1 in Figure 86) Add Element Insert Delete Cut Copy Paste Segment Selector Pull-down menu that lets you add an inertia element at the bottom of the Element List. You have the option of adding a solid cylinder, hollow cylinder, cuboid, or prism. Pull-down menu that lets you insert an inertia element above the selected inertia element in the Element List. Deletes the selected inertia element in the Element List. Removes the selected inertia element in order to place it in another location in the Element List. Create a copy of the selected inertia element in order to replicate the element in another location in the Element List. This button lets you replace the selected inertia element with a cut or copied inertia element. Use the Inertia Element Selector arrows (red box in Figure 86) to navigate through the various inertia elements in the Element List. As you navigate to an inertia element, the associated Element Properties window and Element Image tab are displayed. Rockwell Automation Publication MOTION-UM004B-EN-P - October

108 Chapter 2 Sizing Your System Table 64 - More Options Inertia Mode Properties (continued) Parameter Element Properties (label 2 in Figure 86) Element List (label 5 in Figure 86) Results (label 6 in Figure 86) Error List Once the Element Properties are entered, the Element Mass and Element Inertia values are displayed at the bottom of the Element Properties window (label 4 in Figure 86). Type Name Calculate Using X Y Diameter Inner Diameter Length Quantity Mass Material Density Select the type of element (solid cylinder, hollow cylinder, cuboid, or prism) you would like to add to the Element List. Enter a meaningful name for the element you are editing. Select the type of data (mass or density) you would like to use to calculate inertia. This is the position for the inertia element in the X (horizontal) direction. For a prism you will need to enter X1, X2 and X3 positions. This is the position for the inertia element in the Y (vertical) direction. For a prism you will need to enter Y1, Y2 and Y3 positions. This is the diameter of the inertia element if it is cylindrical. For a cuboid you will need to enter width and height. This is the inner diameter of the inertia element if it is a hollow cylinder. This is the length of the inertia element. This parameter is not required when calculating based on mass. This is the number of identical elements. This is the mass of the inertia element. This parameter is not required when calculating based on density. Select the material of the cylinder from the pull-down menu. If Other is selected as the material type, the density value also needs to be entered. This parameter is not required when calculating based on mass. When the inertia element material is not available in the Material pull-down menu, the density value must be entered here. This parameter is not required when calculating based on mass or when the material is selected from the pull-down menu. Summary list of the elements that make up the component with the current element highlighted in blue. Motion Analyzer software takes gravity into account only if an unbalanced load is entered as secondary inertia. Gravity is taken to act from top to bottom of the Component Plot window. In the event of incorrect input data, a list of errors is displayed. Figure 87 - Element Image Tab (label 3 in Figure 86) Use this tab to verify the correct placement of the various inertia elements. 108 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

109 Sizing Your System Chapter SolidWorks Import You can use the SolidWorks Inertia Calculator to import inertia data directly from SolidWorks software when the part geometry is complex and a SolidWorks model is readily available. The part must be balanced about the axis of rotation. For unbalanced loads, a SolidWorks Motion Study must be completed and users must interface with SolidWorks, using the resulting torque data to appropriately size a motor. Refer to From SolidWorks on page 120 for more information on the SolidWorks Interface Wizard. Figure 88 - SolidWorks Inertia Calculator The density, volume, and surface area of the element (label 1 in Figure 88) are displayed in the middle. The mass and inertia (label 2 in Figure 88) are displayed at the bottom of the Element Properties window and in the Results window at the bottom right (label 3 in Figure 88). Receive inertia data from SolidWorks software by selecting SolidWorks from the Type pull-down menu in the Element Properties window. Rockwell Automation Publication MOTION-UM004B-EN-P - October

110 Chapter 2 Sizing Your System Click Import to open the SolidWorks - Data Import dialog box. Figure 89 - Import SolidWorks Data Table 65 - SolidWorks - Data Import (refer to Figure 89) Parameter Load/Change Refresh Select Axis (1) Load or change the SolidWorks model. Update the data returned to Motion Analyzer software if changes are made to the model while the part is open in SolidWorks software. Click the radio button corresponding to the model s axis of rotation in the Inertia Details section. This step is critical to determining the inertia since the model needs to be balanced about the correct axis. (1) The axis of rotation corresponds to the inertia value that is different from the other two values. Since the model is balanced about the axis of rotation, the inertia is the same about two axes, and different about one. Click OK to import the data from SolidWorks into Motion Analyzer software. 110 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

111 Sizing Your System Chapter 2 The SolidWorks Data Import window closes and returns to the Inertia Calculator window and the imported element image. Figure 90 - Imported Element Image Rockwell Automation Publication MOTION-UM004B-EN-P - October

112 Chapter 2 Sizing Your System Winder/Unwinder Use this template to enter required inputs to calculate the load profile for Winder or Unwinder applications. Figure 91 - Winder/Unwinder Template For a Winder or Unwinder application, two index moves are created: Maximum diameter, minimum rotation speed (= maximum torque for center driven) Minimum diameter, maximum rotation speed (= minimum torque for center driven) The maximum torque condition is the worst case for winding temperature so the move time for this index is made large enough to dominate the temperature calculations. The maximum speed case is included to check that the specified speed can be reached. If the application requires a different acceleration for the full roll compared to the core, this can be done in Define Your Profile on page 139 after you click Apply. 112 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

113 Sizing Your System Chapter 2 Table 66 - Input Data (label 1 in Figure 91) Parameter Center Driven The roll is driven directly via a shaft at its center of rotation. For a Center Driven application, Rotary Load is selected and the roll is modeled as Inertia and Torque in a Multi-segment profile. No further load information needs be added. The roll is driven by the friction of rollers pressing onto the circumference of the web. For a Surface Driven application, Linear Load and Belt Drive are selected and the roll is modeled as Mass and Force in a Multi-segment profile. Surface Driven IMPORTANT The driving roll/rolls data should be added as Drive Roll and Idler Roll. Empty Diameter Empty Inertia Full Diameter Material Inertia (1) Maximum Web Tension Minimum Web Tension Maximum Web Speed Acceleration Time Deceleration Time S-curve Wind/Unwind Profile Mirror You will be asked if you want to reset the Actuator parameters to zero. Click Yes, if this is the first time you applied this Winder. If you already applied it and added the drive roll data in the Belt Actuator, the drive roll data will be deleted. Minimum reel diameter, when the roll is completely unwound. Inertia of the reel when it is completely unwound. Maximum reel diameter, when the roll is completely wound. Inertia of the reel when it is at full diameter or completely wound. Maximum allowable web tension for the material. The value is used for sizing purposes. Minimum web tension for the application. It is used to calculate the Tension Ratio. Design speed of the material running through the machine. Shortest required acceleration time from zero to maximum web speed. Shortest required deceleration time from maximum web speed to zero. Check this box if the acceleration and deceleration follow a smooth S-curve. If this box is not checked, acceleration is considered trapezoidal. Select either Wind or Unwind for your application. This setting determines the direction of pull from the web tension. This option is used only when a Wind and Unwind axis share a DC power rail. The two axes are first sized as normal (for example, Profile Mirror is set to Off). The Winder is then set to Profile Mirror. This matches the two axis motion profiles as if they were connected by the web. This is necessary only to check the system sizing. In this mode the motor winding temperature of the Winder axis will be underestimated. (1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. Click Calculate to display the following values in the Results portion of the window (label 2 in Figure 91). Table 67 - Calculated Parameters (label 2 in Figure 91) Parameter Buildup Ratio Inertia Range Tension Ratio Maximum Web Power Ratio of the Maximum/ Minimum diameter of the roll. Ratio of Maximum/Minimum inertia values. A large inertia range value is more difficult to control. Ratio of the Maximum/Minimum tension values. Maximum web tension multiplied by the maximum web speed. This power is regenerated continuously during unwind and should be catered for by suitably rated dump resistors or a regenerative power supply. Motion Analyzer software underestimates this rating by approximately 10%. Rockwell Automation Publication MOTION-UM004B-EN-P - October

114 Chapter 2 Sizing Your System Four Bar Linkage You can use this template to enter required inputs to calculate the load profile for Four Bar Linkage applications. Figure 92 - Four Bar Linkage Template Figure 93 - Animated Diagram (for reference) TIP Parameter entry descriptions are displayed when the cursor is held over an entry field for several seconds. 114 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

115 Sizing Your System Chapter 2 Table 68 - Four Bar Linkage Properties Parameter Animated Display (1) (label 1 in Figure 92) Mechanical Data (label 2 in Figure 92) Vertical Slider (left) Horizontal Slider (top) Horizontal Slider (scale) Horizontal Slider (Speed) Animate Stop Analyze Calculate This slider sets the crankshaft inclination and should be set before starting the animation. Click 0y to set the angle to 90. The current angle is displayed in the Mechanical Data window. This slider sets the linear slide inclination. Click 0z to set the angle to 0. The current angle is displayed in the Mechanical Data window. The true angle to the horizontal is dependent on both slider positions because it is a compound angle. This slider sets the display scale. This slider sets the animation speed. The black arrow in the plot represents the external force, and the arrow length is proportional to the applied force. Click to run the simulated crank image through the specified motion profile. Click to stop the animation. Click to display the bar graphs that show the contribution of each mechanical component to the inertia and torque values. Click to calculate the external torque and reflected inertia values that will be applied. Link 1 Length Distance between Pivot 1 and Pivot 2. Link 1 Inertia (2) Inertia of Link 1. Link 1 Start Angle Initial angle between Link 1 and X Axis. Angular load profile only. Link 2 Length Distance between Pivot 2 and Pivot 3. Link 2 Mass Mass of Link 2. Link 2 CG Link 2 Center of Gravity with respect to Pivot 2. Link 2 Inertia (1) Inertia of Link 2 about its own center of gravity. Load Pivot X X distance between Pivot 1 and Pivot 4. Load Pivot Y Y distance between Pivot 1 and Pivot 4. Load Link Length Distance between Pivot 3 and Pivot 4. Load Inertia Inertia of the load (Link 3) about its own center of gravity. Load Mass Mass of the load (Link 3.) Load G of G Radius Distance between Pivot 4 and center of gravity of the load (Link 3.) Load G of G Angle Angle between the lines that make up the center of gravity of the load (Link 3), Pivot 4, and Pivot 3. Link 1 Start Angle Link 1 angle when force is applied. Force at Start Magnitude of the force at the starting point. Magnitude of the force at the ending point. If the Force at Start is different from the Force at End, the force varies between these two Force at End limits according to gudgeon pin position or crank angle. If the values are equal, a constant force is applied. Force Orientation Force orientation from the X axis. Draw Start Position Click to show the geometry at the start angle/position. Export Logix Cam Pivot 1 Axis Inclination Click to transfer the geometrical data to the clipboard for pasting into the RSLogix 5000 Cam Editor. The master axis is a virtual axis while the slave axis is the crank axis. A trapezoidal move of the virtual axis then produces a trapezoidal profile at the gudgeon pin. The master data must increase positive so only that part of the cam that satisfies this requirement is exported. Displayed value is the angle of the crank shaft with respect to the XY (horizontal) plane. 90 indicates vertical, and gravity has no effect. Rockwell Automation Publication MOTION-UM004B-EN-P - October

116 Chapter 2 Sizing Your System Table 68 - Four Bar Linkage Properties (continued) Parameter Profile Window (label 3 in Figure 92) Results Window (label 4 in Figure 92) Chart Display Window (label 4 in Figure 92) Coarse Data Fine Data Profile Table Insert Delete Clear All Display Maximum Fine Segments Peak Inertia Peak Ext. + Grav. Torque Cycle Time Minimum Time Slice Apply Cancel Select this option if the size of the profile segments is sufficient to detect significant changes to force or inertia during each time slice. Select this option if a finer resolution of the profile segments is needed to detect significant changes to force or inertia during each time slice. You can copy spreadsheet data and paste into this grid. Click the Time column, Row zero, and then press Ctrl + v. Delta T Column Velocity Column Acc. Pk/Ave Profile segment duration (dt). Final velocity at the end of the profile segment. Row zero is reserved for the start velocity only, hence the time and S-curve cells are grayed out. Acceleration Peak/Average. The following values apply: 1 = Trapezoidal acceleration 2 = S-curve acceleration >1 or <2 = partial S-curve Insert a new, blank row at the highlighted position. Delete the row at the highlighted position. Remove all profile data. Click to show the load profile for checking purposes. Specify the maximum number of profile segments that you would like the coarse segments divided into. Calculated maximum reflected inertia at the crankshaft. Peak External Force + Gravity Torque is the calculated peak torque, generated from the external linear force and gravity. Calculated cycle time for the specified load profile. Minimum time slice required for the simulation. Click to apply the load profile and close the window. Click to close the window without applying any data. Shows the crank velocity, the inertia that is reflected to the crankshaft, and the crank torque due to external influences such as gravity and applied force. These are the parameters that are applied. By checking Show Resultant Load Torque, the associated value can also be displayed. (1) The Animated Display at the upper left corner of the template is provided for reference to make sure that entered data is accurate and particularly that the orientation of the crank is correct. The animation rotates the crank so that the system may be better visualized. In this example, the X/Y plane is horizontal. (2) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. 116 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

117 Sizing Your System Chapter 2 Click to use the Quick Profile tool. A trapezoidal load profile is entered into the data grid after clicking Apply. Figure 94 - Quick Profile Tool Table 69 - Quick Profile Tool (refer to Figure 94) Parameter Move Angle Move Time Wait Time Velocity Pk/Ave Accel.Pk/Ave Angle through which the load profile takes place. Time through which the load profile takes place. Length of time to wait before the specified index move repeats. Velocity Peak/Average. The following values apply: 2 = triangle; minimum peak torque 1.5 = equal trapezoid; minimum RMS (root mean squared) torque 1 = infinite acceleration; not useable If the start velocity is non-zero, the peak velocity may be adjusted by the program to avoid crossing the zero line. Acceleration Peak/Average. The following values apply: 1 = Trapezoidal acceleration 2 = S-curve acceleration >1 or <2 = partial S-curve Rockwell Automation Publication MOTION-UM004B-EN-P - October

118 Chapter 2 Sizing Your System Power/Speed Templates You can use the Power/Speed templates to enter torque and speed values that are used to calculate the power requirements for the application. Figure 95 - Power/Speed Templates Table 70 - Power/Speed Template Options Template Type Page Power/Speed Template (label 1 in Figure 95) Constant Power Range Template (label 2 in Figure 95) Use this template when the torque and speed values are known at the load for the application. Use this template when three of the following values are known: maximum torque, minimum torque, maximum speed, or minimum speed Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

119 Sizing Your System Chapter Power/Speed Template Use this template (label 1 in Figure 95) when the torque and speed values are known for the application. Click to access the Power Calculator. Figure 96 - Power Calculator Table 71 - Input Properties (refer to Figure 96) Parameter Torque Speed Torque value for your application. Speed for your application. Rockwell Automation Publication MOTION-UM004B-EN-P - October

120 Chapter 2 Sizing Your System Constant Power Range Template Use this template (label 2 in Figure 95) when three of the following four values are known for the application. Click values. to use the Power Calculator and enter the known torque and speed Figure 97 - Power Calculator Table 72 - Input Properties (refer to Figure 97) Parameter Max Torque Min Torque Min Speed Max Speed Maximum torque value for your application. Minimum torque value for your application. Minimum speed for your application. Maximum speed for your application. Click Apply to display the Power value and other missing value From SolidWorks Integration with SolidWorks software can be used to obtain data to accurately size motors, drives, and accessories for mechanically complex applications. SolidWorks Motion has built-in tools that let users obtain accurate inertia and force/torque data. Rather than manually recalculating or simply estimating these values for motor sizing, Motion Analyzer software integrates with SolidWorks software for consistency throughout the design process. SolidWorks software calculates torque/force information for the following two load types. Table 73 - Enter Motion Profile Workflow Method Page Independent Axis Workflow Inter-dependent Axes Workflow Select From SolidWorks as the load type. 122 Launch the SolidWorks Simulation tool from the System View page Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

121 Sizing Your System Chapter 2 Each load type requires a slightly different workflow in Motion Analyzer software to obtain the data from SolidWorks software. Both workflows support linear and rotational motion. IMPORTANT A SolidWorks Assembly must be open in SolidWorks software when launching the SolidWorks Interface Wizard from Motion Analyzer software. IMPORTANT A SolidWorks Motion Study must be set up before launching the SolidWorks Interface Wizard. Gravity, SolidWorks motors, material properties, and any additional external forces must be defined in the SolidWorks Motion Study before integration. Velocity and force/torque Results Plots must be created in SolidWorks software for the simulation to return results to Motion Analyzer software. IMPORTANT TIP Define reference geometry in SolidWorks software to define the axis of rotation for the component the SolidWorks motor is attached to. Using component faces to attach SolidWorks motors will work, but may inadvertently define motion about an incorrect location for some mechanisms. If you disable animation before SolidWorks software performs calculations the solver speed improves. This is because the software is not attempting to show the motion of the assembly while performing calculations. Follow these steps to improve SolidWorks software solver speed. 1. From the SolidWorks Motion Study explorer bar, click the Motion Study Properties icon. 2. Clear the Animate during simulation checkbox. Rockwell Automation Publication MOTION-UM004B-EN-P - October

122 Chapter 2 Sizing Your System Independent Axis Workflow With independent motors, each motor works alone to move the load in the single-axis, independent workflow, so the force/torque output stands isolated. An example is the single-axis lifter mechanism (Figure 98) where one motor drives the load. Figure 98 - Independent Motors SolidWorks Motion software supports linear and rotary motors. For an independent motor workflow, there are two options for motion: Translational (linear motion) Rotational (rotary motion) 122 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

123 Sizing Your System Chapter 2 Follow these steps for an independent axis workflow. 1. Click the Load tab. Select Translational (Linear) if a linear load is defined or Rotational (Rotary) if a rotary load is defined in the SolidWorks Motion Study. 2. Click Next. Rockwell Automation Publication MOTION-UM004B-EN-P - October

124 Chapter 2 Sizing Your System 3. Click Edit Profile to specify the motion profile that the mechanism will move through. This motion profile is placed at the output of the motor or gearbox shaft, if a gearbox is included in the motion system. Refer to Define Your Profile on page 139 for more information. Once you specify the motion profile for the axis, the SolidWorks integration begins. 4. Click Launch SolidWorks Simulator to obtain force/torque results from SolidWorks software. 124 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

125 Sizing Your System Chapter 2 The Selected SolidWorks Assembly dialog box opens. 5. Verify the following conditions: The SolidWorks assembly must be open in SolidWorks software before the SolidWorks integration wizard is launched. The SolidWorks file must be an assembly and not simply a part. Only one instance of SolidWorks software can be running in order for integration to work. 6. Click Refresh when changes are made to the associated SolidWorks model to make sure Motion Analyzer software is interfacing with the most recent version of the SolidWorks assembly. 7. Verify this is the correct model and click Next. If the model is not correct, open the correct assembly in SolidWorks software and click Refresh. Rockwell Automation Publication MOTION-UM004B-EN-P - October

126 Chapter 2 Sizing Your System The Motion Study Setup dialog box opens. 8. From the Motion Study Name pull-down menu, choose a SolidWorks Motion Study for the data. 9. Click Next. If you need to create a new motion study, return to SolidWorks software. a. Return to the opening window and click Refresh to register the changes. b. Click Next. 126 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

127 Sizing Your System Chapter 2 The SolidWorks Motor Setup dialog box opens. This dialog box lets you verify the SolidWorks Motor Setup. For interdependent motors, you assign Motion Analyzer motion profile data to each SolidWorks motor during this step. The Motor Setup dialog box is repeated for each axis of motion. 10. From the Motion Analyzer Axis pull-down menu, choose the Motion Analyzer axis. IMPORTANT If all axes have the same name and this causes confusion, go to Options >Application Info to rename the axes. 11. Check Reverse Direction if you find that the load moves in the wrong direction. Play the animation in SolidWorks software after the motion profile has been sent across in a future step. Return to this step using the Back button and check this box to reverse the direction of the motion profile. If the motion is incorrect, select the Reverse Direction checkbox to switch the direction of motion. 12. From the SolidWorks Motor Name pull-down menu, choose the name of the SolidWorks motor that runs in the motion profile with the chosen Motion Analyzer axis. The SolidWorks Moving Part pull-down menu, is for information only. This states the component that the SolidWorks motor is attached to and the motion profile it will be applied to. If the component is not correct, return to SolidWorks to attach the motor to the correct component. 13. Click Next. Rockwell Automation Publication MOTION-UM004B-EN-P - October

128 Chapter 2 Sizing Your System The Summary dialog box opens. 14. Enter a value in the Frames/Second field. This value indicates the number of frames per second the motion profile is divided into. A large number yields fine resolution while a small number yields coarse resolution. 15. Click Modify Selections. Use this feature to edit a specific Motion Analyzer Axis. a. Select an axis in the table. b. Click Modify Selections to jump back to the SolidWorks Motor Setup window for the selected axis. 16. Click Next. 128 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

129 Sizing Your System Chapter 2 SolidWorks software calculates the force/torque required to move the load through the specified motion profile and the Results dialog box opens. 17. From the Results pull-down menu, choose the axis of motion you wish to display. 18. Click the View Graph tab. This tab displays the data in graphical format. 19. Click the View Data tab. This tab displays the data in list format. 20. Click Export Data. The data exports into a spreadsheet. 21. Click Apply to transfer force/torque data to Motion Analyzer software for use in sizing a motion system. 22. Go to SolidWorks software and click Play from Start in the SolidWorks Motion Study explorer. View the motion profile as applied to your mechanism. 23. Verify that the mechanism is moving in the right direction. If you find that the load moves in the wrong direction, return to step 11 by clicking Back and check Reverse Direction. Rockwell Automation Publication MOTION-UM004B-EN-P - October

130 Chapter 2 Sizing Your System The SolidWorks Load Data dialog box opens. This dialog box lets you compare the actual Motion Analyzer velocity profile to the velocity profile returned from SolidWorks. 24. Check Invert SolidWorks Output Data if the velocity profiles were reversed to resolve the discrepancy and correct your model. The discrepancy is due to different coordinate systems, which are arbitrarily defined. 25. Click Proceed to Transmissions. This step changes depending upon the application. IMPORTANT With these versions of SolidWorks and Motion Analyzer, the inertia data is not brought out automatically. This means that Motion Analyzer has no knowledge of the inertia ratio, and therefore cannot do the Motion Analyzer Simulation on the Solution tab. 130 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

131 Sizing Your System Chapter Inter-dependent Axes Workflow With inter-dependant motors, several motors work to move one load, so although the motors have separate force/torque outputs, they depend on each other to collectively move the load. An example is the two-axis linear pick and place mechanism (Figure 99) where two motors drive the load. Figure 99 - Inter-dependant Motors Once the motion profile for each axis has been specified, the SolidWorks integration begins. Refer to Define Your Profile on page 139 for more information on defining a motion profile. Follow these steps for an inter-dependent axis workflow. 1. Click to access the Motion Analyzer/SolidWorks integration tool, Motion Analyzer software launches a new window and displays the model that is open in SolidWorks software. Use the integration tool to send motion profile data to more than one SolidWorks motor simultaneously, thereby letting SolidWorks software accurately calculate the effect of multiple motors working together to drive one load. Rockwell Automation Publication MOTION-UM004B-EN-P - October

132 Chapter 2 Sizing Your System The Selected SolidWorks Assembly dialog box opens. 2. Verify the following conditions: The SolidWorks assembly must be open in SolidWorks software before the SolidWorks integration wizard is launched. The SolidWorks file must be an assembly and not simply a part. Only one instance of SolidWorks software can be running in order for integration to work. 3. Click Refresh when changes are made to the associated SolidWorks model to make sure Motion Analyzer software is interfacing with the most recent version of the SolidWorks assembly. 4. Verify this is the correct model and click Next. If the model is not correct, open the correct assembly in SolidWorks software and click Refresh. 132 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

133 Sizing Your System Chapter 2 The Motion Study Setup dialog box opens. 5. From the Motion Study Name pull-down menu, choose the SolidWorks motion study to be used for simulation. If you need to create a new motion study, return to SolidWorks. Return to the opening dialog box and click Refresh to register the changes. 6. Click Next. Rockwell Automation Publication MOTION-UM004B-EN-P - October

134 Chapter 2 Sizing Your System The SolidWorks Motor Setup dialog box opens. 7. Enter the number of axes you would like to study. Motion Analyzer detects the number of SolidWorks motors present in the chosen SolidWorks motion study. IMPORTANT The number of Motion Analyzer axes to be studied must be less than or equal to the number of SolidWorks motors. Also, the number of motion profiles sent to SolidWorks software cannot exceed the number of SolidWorks motors waiting to consume the motion profile data. The number of SolidWorks motors defined in the SolidWorks motion study can be changed by returning to SolidWorks software to add or delete motors. After adding or deleting SolidWorks motors, return to the opening window and click Refresh to register the changes. 8. Click Next. 134 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

135 Sizing Your System Chapter 2 The SolidWorks Motor Setup dialog box opens. This dialog box lets you verify the SolidWorks Motor Setup. For interdependent motors, you assign Motion Analyzer motion profile data to each SolidWorks motor during this step. The Motor Setup dialog box is repeated for each axis of motion. 9. From the Motion Analyzer Axis pull-down menu, choose the Motion Analyzer axis. IMPORTANT If all axes have the same name and this causes confusion, go to Options >Application Info to rename the axes. 10. Check Reverse Direction if you find that the load moves in the wrong direction. Play the animation in SolidWorks software after the motion profile has been sent across in a future step. Return to this step using the Back button and check this box to reverse the direction of the motion profile. If the motion is incorrect, select the Reverse Direction checkbox to switch the direction of motion. 11. From the SolidWorks Motor Name pull-down menu, choose the name of the SolidWorks motor that runs in the motion profile with the chosen Motion Analyzer axis. The SolidWorks Moving Part pull-down menu, information only, this states the component that the SolidWorks motor is attached to and the motion profile will be applied to. If the component is not correct, return to SolidWorks to attach the motor to the correct component. 12. Click Next. Rockwell Automation Publication MOTION-UM004B-EN-P - October

136 Chapter 2 Sizing Your System The SolidWorks Summary dialog box opens. 13. Enter a value in the Frames/Second field. This value indicates the number of frames per second the motion profile is divided into. A large number yields fine resolution while a small number yields coarse resolution. 14. Click Modify Selections. Use this feature to edit a specific Motion Analyzer Axis. a. Select an axis in the table. b. Click Modify Selections to jump back to the SolidWorks Motor Setup window for the selected axis. 15. Click Next. 136 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

137 Sizing Your System Chapter 2 SolidWorks software calculates the force/torque required to move the load through the specified motion profile and the Results dialog box opens. 16. From the Results pull-down menu, choose the axis of motion you wish to display. 17. Click the View Graph tab. This tab displays the data in graphical format. 18. Click the View Data tab. This tab displays the data in list format. 19. Click Export Data. The data exports into a spreadsheet. 20. Click Apply to transfer force/torque data to Motion Analyzer software for use in sizing a motion system. 21. Go to SolidWorks software and click Play from Start in the SolidWorks Motion Study explorer. View the motion profile as applied to your mechanism. 22. Verify that the mechanism is moving in the right direction; if you find that the load moves in the wrong direction, return to step 10 by clicking Back and check Reverse Direction. Rockwell Automation Publication MOTION-UM004B-EN-P - October

138 Chapter 2 Sizing Your System The System View dialog box in Motion Analyzer software opens. 23. Click the Motor and Drive icons to continue the sizing process. With these versions of SolidWorks and Motion Analyzer software, the inertia data is not brought out automatically. This means that Motion Analyzer has no knowledge of the inertia ratio and therefore cannot do the Motion Analyzer Simulation on the Solution tab. 138 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

139 Sizing Your System Chapter Define Your Profile There are two ways to enter your Motion Profile into Motion Analyzer software. Begin by clicking Edit Profile in the Cycle Profile Data dialog box. Table 74 - Motion Profile Options Template Type Page Less Options Profile Editor Mode More Options Profile Editor Mode This is the default mode. This mode is also accessed by clicking Less Options in the More Options Profile mode. This mode lets you enter a simple profile which consists of an acceleration, coast/dwell, and deceleration. This mode is accessed by clicking More Options in the Less Options Profile mode. This mode lets you enter more complex motion profiles by providing you with the ability to enter data for individual profile segments, import or export profile data, and apply external loads to the individual profile segments Rockwell Automation Publication MOTION-UM004B-EN-P - October

140 Chapter 2 Sizing Your System Less Options Profile Editor Mode The Less Options Profile mode is the default mode. This mode is also accessed by clicking Less Options when in the More Options Profile mode. Figure Simple Index Motion Parameters Table 75 - Less Options Profile Editor Properties When using this mode to enter motion profile data, a trapezoidal velocity index profile segment (see Automatic Index Type below) is the default motion profile. This motion profile is optimized for minimal motor heating. Parameter Simple Index Motion Parameters (label 1 in Figure 100) Move Distance Move Time Dwell Time Index Type Smoothness IMPORTANT Total distance for the motion profile. Total time for the motion profile. Total dwell time, if any, for the motion profile before the motion profile repeats. From the pull-down menu, choose one of three available index types. Automatic This is a 1/3 acceleration, 1/3 coast, 1/3 deceleration trapezoidal motion profile. This is the default setting. Triangular Trapezoidal This is a motion profile where ½ the time is spent accelerating and ½ is spent decelerating. This index type lets you use sliders to adjust the velocity and time axes of the motion profile. As you mouse over a slider, the axis value is displayed. This is used to decrease the discontinuity in the transition from a dwell to motion. From the pull-down menu, choose one of three available smoothness options. Automatic 0% Jerk time (Trapezoidal) Standard 40% Jerk time (Partial S-curve) Maximum 100% Jerk time (Full S-curve) Smoothness is used to reduce mechanical wear and tear. Due to display limitations, the More Options Profile Editor Mode does not show infinite jerk at points of velocity discontinuity. Using 0% jerk time may lead to premature mechanical failure. 140 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

141 Sizing Your System Chapter 2 Table 75 - Less Options Profile Editor Properties Parameter Segment Plot (refer to label 2 in Figure 100 and the example in Figure 101) Reset Zoom (1) Resets the zoom to 1x. Zoom (1) Magnifies 1x, 2x, 6x, or 8x. Grid (1) Select Normal, Fine or Remove Grid to change the display. Color (1) Adjust the background, curve and grid colors. Show Curve (1) Select which curves you would like to display on the plot. Show Y Axis (1) Toggle the Y-axis labels on and off when more than one curve is shown. Vertical Bar Horizontal Bar This adjusts the height/velocity component of the motion profile. As you increase the value of this slider, more time is spent accelerating and decelerating the load and less time is spent dwelling at a constant velocity. This adjusts the ratio of the time spent accelerating to the time spent decelerating for the motion profile. A negative value on the slider indicates that more time is spent decelerating the load than accelerating it. A positive value on the slider indicates that more time is spent accelerating the load than decelerating it. (1) In addition to the parameters in Figure 100, these options are also available when you right-click the Segment Plot window. Figure Segment Plot Example Rockwell Automation Publication MOTION-UM004B-EN-P - October

142 Chapter 2 Sizing Your System More Options Profile Editor Mode The More Options Profile Editor mode helps you create a variety of industrystandard motion profiles. To access this mode, click More Options when in the Less Options Profile mode. Figure Profile Editor - More Options Mode These windows are displayed by default when you open the More Options Profile Editor Mode. Table 76 - More Options Mode Features Feature Page Profile Toolbar Segment Load Window Segment Plot Window Profile Plot This toolbar (label 1 in Figure 102) contains buttons and pull-down menus for adding, moving, and removing profile segments or an entire motion profile. Each profile segment type has an associated Segment Parameters window (label 2 in Figure 102. As you highlight a particular profile segment in your motion profile, that segment s parameter window becomes available for entering data. The default profile segment type is an Index profile segment. This window (label 3 in Figure 102) displays a plot for a single profile segment in the motion profile. The x-axis is time, and the y-axis can be adjusted to display various motion curves (for example, Distance, Velocity, or Acceleration. This window (label 5 in Figure 102) displays the entire motion Profile Plot that consists of a series of profile segments. The plot can be adjusted and analyzed with the two sub-windows that accompany the plot Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

143 Sizing Your System Chapter 2 In addition to the windows that are opened by default, there are several tabs along the bottom (label 6 in Figure 102) and left side (red arrow in Figure 102) of the More Options Profile Editor Mode that open other windows. Table 77 - Additional More Options Mode Features Feature Page Profile Grid Derived Parameters Lets you quickly input parameters into a table for each segment of your motion profile. Displays various calculated values related to Time, Position, Speed, Acceleration, and Jerk. Comments Window Enter comments for the motion profile or for particular profile segments. 154 Error List Window Contains a list of errors as they occur. 155 Segment Parameters Window Enter load values for individual profile segments or for the entire motion profile. In these windows, you can click the thumb-tack icon to toggle between Fixed mode and Auto-hide mode. In Fixed mode, the window is held in place and in Auto-hide mode, the window is displayed when you hover over the window tab. The window reverts back to a tab when the mouse pointer is moved off of the window. When you have completed your motion profile and have entered the relevant parameters, you can export the data from the More Options Profile Editor Mode to external programs. Prior to exporting the data, make sure that the master and slave units are properly designated. From the Settings menu, choose Custom Units to change these. Table 78 - Export Options (refer to Figure 102) Feature Logix CAM Profile Editor Logix Ladder Add-On Instructions SolidWorks Motion Study Move Profile User Defined With this option you can export the motion profile data to RSLogix 5000 software as a fixed cam profile. When using this export option, you must choose whether to export the data as a Motion Axis Time Cam (MATC) or a Motion Axis Position Cam (MAPC) profile. With this option you can export the motion profile data as a rung of RSLogix 5000 code that dynamically builds the cam at run time. When using this export option, you choose whether to export the data as a Motion Axis Time Cam (MATC) or a Motion Axis Position Cam (MAPC) profile. This type of instruction lets you adjust portions of the motion profile. With this option you can export the motion profile data that SolidWorks uses for its animations. With this option you can export the motion profile data to the clipboard or to a specified file type. Rockwell Automation Publication MOTION-UM004B-EN-P - October

144 Chapter 2 Sizing Your System You also have the option to import motion profile data from external programs. The following import options are available. Table 79 - Import Options (refer to Figure 102) Feature Feature Logix CAM Profile Editor Logix Ladder Add-On Instructions User Defined This option lets you import motion profiles created in the RSLogix 5000 Cam Editor. A Logix Elements type profile segment is created and populated. You have four import options available for this type of import. Before Selected Seg The imported motion profile is placed before the profile segment you selected in More Options Profile Editor Mode. After Selected Seg Replace Selected Seg Replace Profile The imported motion profile is placed after the profile segment you selected in More Options Profile Editor Mode. The imported motion profile replaces the profile segment you selected in More Options Profile Editor Mode. The imported motion profile replaces the entire profile in More Options Profile Editor Mode. This option lets you import motion profiles created as RSLogix 5000 Ladder Add-On Instructions. This option lets you import a motion profile directly from a program of your choice. 144 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

145 Sizing Your System Chapter Profile Toolbar The Profile toolbar contains buttons and pull-down menus for adding, moving, and removing profile segments or an entire motion profile. Figure Profile Toolbar Features Table 80 - Profile Toolbar Features (label 1 in Figure 103) Feature Segment Selector Profile Start Condition Add Use the Segment Selector arrows (red box in Figure 103) to navigate through the various segments in your motion profile. As you navigate to a profile segment, the associated Segment Parameters Window and Segment Plot Window are displayed. The Zero profile segment is the start condition. Lets you copy a motion profile from another axis in your Motion Analyzer project. It also lets you go to the More Options Profile Editor Mode for another axis in your Motion Analyzer project. Opens the Segment Parameters window and the Segment Plot window for the start condition. Lets you add profile segments to the end of your motion profile. Also, refer to the Segment Parameters section for information about the various profile segments that are available in the More Options Profile Editor Mode. Rockwell Automation Publication MOTION-UM004B-EN-P - October

146 Chapter 2 Sizing Your System Figure Add Feature Pull-down Menu Table 81 - Add Feature Properties (refer to Figure 104) Feature Edit Delete Cut Copy Paste Invert Lets you change the selected profile segment to another segment type. Deletes the selected profile segment. You can also click the drop-down arrow and select the Delete All option to delete all of the segments in your motion profile. Lets you remove the selected profile segment in order to place it in another location in the motion profile. Lets you create a copy of the selected profile segment in order to replicate the segment in another location in the motion profile. Lets you replace the selected profile segment with a cut or copied profile segment. Lets you invert an index profile segment about the x-axis. 146 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

147 Sizing Your System Chapter Segment Load Window Each profile segment type has an associated Segment Parameters window (label 2 in Figure 102. As you highlight a particular profile segment in your motion profile, that segment s parameter window becomes available for entering data. The default profile segment type is an Index profile segment. Figure Segment Load Properties Table 82 - Segment Load Properties Parameters Apply All Segments External Force Payload Mass Mass X, Y & Z - Offset Payload Animation Lets you apply the current profile segment load parameters to all existing profile segments. The load values are not applied to any profile segments that are added after you apply this feature. However, you can return to this window and click Apply All Segments again to apply the load values to new profile segments. This is the external force that exists for the selected profile segment. This is the payload mass that exists for the selected profile segment. These Load Mass Offsets generate moments that are used in the calculation of Life for Bulletin MPAS stages. Moments are generated when the Load Mass is off-line with the actuator. They arise as a consequence of forces generated by acceleration or deceleration of the load mass and gravity acting on the load mass being multiplied by the offset distance. The offsets and moments are resolved into the three cartesian coordinates. The load can be divided into either a fixed load or a load that changes by segment throughout the profile. Motion Analyzer software analyzes the sum of the fixed loads and moments (entered in Mechanism Type on page 178) and segment wise loads and moments generated by these offsets. Starts a simple animation that demonstrates a pick-and-place machine where a heavy load is picked up and moved forward. The return stroke has no load. Refer to Figure 106. Figure Payload Animation Example Rockwell Automation Publication MOTION-UM004B-EN-P - October

148 Chapter 2 Sizing Your System Segment Plot Window The Segment Plot window displays a plot for a single profile segment in the motion profile. The x-axis is time, and the y-axis can be adjusted to display various motion curves (for example, Distance, Velocity, or Acceleration). Figure Profile Editor - Segment Plot Window Right-click the Segment Plot window to display the properties. Figure Segment Plot Properties (label 3 in Figure 107) Table 83 - Segment Plot Properties (refer to Figure 108) Parameters Reset Zoom Resets the zoom to 1x. Zoom Lets you zoom in 1x, 2x, 6x or 8x. Grid Select Normal, Fine or Remove grid. Color Adjust the background, curve, and grid colors. Show Curve Select which curves you would like to display on the plot. Show Y Axis Toggle the Y-axis labels on and off when more than one curve is shown. 148 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

149 Sizing Your System Chapter Profile Plot The Profile Plot window lets you view the entire motion profile and quickly navigate to specific segments within the profile. Figure Profile Editor - Main Profile Plot Right-click the Main Profile Plot window to display the properties. Figure Main Profile Plot Properties (label 4 in Figure 109) Rockwell Automation Publication MOTION-UM004B-EN-P - October

150 Chapter 2 Sizing Your System Table 84 - Main Profile Plot Properties (refer to Figure 110) Parameters Copy Cut Paste Delete Reset Zoom Zoom Show Segment Selection Grid Color Show Curve Show Y Axis Create a copy of the selected profile segment to reuse in another location in the motion profile. Remove the selected profile segment to use in another location in the motion profile. Replace the selected profile segment with a cut or copied profile segment. Deletes the selected profile segment. Also, from the pull-down menu, you can choose the Delete All option to delete all of the profile segments in the Profile Plot window. Resets the zoom to 1x magnification. Zoom in 1x, 2x, 6x or 8x magnification. Select whether or not you would like to highlight the selected profile segment within the Profile Plot window. Select Normal, Fine, or Remove grid. Adjust the background, curve, and grid colors. Select which curves you would like to display on the plot (for example, Distance or Velocity). Toggle the Y-axis labels on and off when more than one curve is shown. The Plot Parameters sub-window appears to the left of the Main Profile Plot window. Click the arrows, left of the Main Profile Plot window, to open it. Click the arrows again to close the window. Clicking the motion curves (for example, Distance or Velocity) toggles them on and off. From the motion curve pull-down menu, you can change the color for the curve in both the Main Profile Plot window and the Segment Plot window. Figure Plot Parameters In addition, as you hover over the Main Profile Plot window with the mouse pointer, the Plot Parameters sub-window provides a display of the numeric values of the time (x-axis), and active motion curves (y-axis) associated with the mouse pointer position. 150 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

151 Sizing Your System Chapter 2 Figure Main Profile Plot X and Y-axis Values The Profile Zoom Plot sub-window appears below the Main Profile Plot window. Click the arrows, below the Main Profile Plot window, to open it. Click the arrows again to close the window. The Profile Zoom Plot window contains a slider (refer to the red box in Figure 113) that you can move along the motion profile by clicking and dragging it. As the slider moves, the Main Profile Plot window displays a magnified view of the portion of the plot that is selected by the slider. You can resize the slider by clicking and dragging from either edge. Figure Profile Zoom Plot Window Right-click the Profile Zoom Plot sub-window to display these options. Figure Profile Zoom Plot Options Table 85 - Profile Zoom Plot Options Parameters Grid Color Select Normal, Fine, or Remove grid. Adjust the background, curve, and grid colors. Rockwell Automation Publication MOTION-UM004B-EN-P - October

152 Chapter 2 Sizing Your System Profile Grid Click Profile Grid (label 5 in Figure 115) to use a table to input parameters for each segment of your motion profile. Figure Profile Grid Window If you click a row in the Profile Grid window, the Segment Parameter window and the plot for that profile segment are opened at the top of the More Options Profile Editor Mode dialog box. You have the option to enter the parameters in the Segment Parameters window or the Profile Grid. Refer to Segment Parameters on page 167 for detailed descriptions of the parameters. The parameter values are automatically shared between the two windows. As you enter the profile segment parameters, calculated Peak Acceleration and Peak Deceleration values are displayed for reference in the Profile Grid window. Click Table Setup in the Profile Grid window to adjust column width preferences. 152 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

153 Sizing Your System Chapter Derived Parameters Click Derived Parameters (label 5 in Figure 116) to display various calculated values related to Time, Position, Speed, Acceleration, and Jerk for the highlighted profile segment. Refer to the Segment Parameters windows on page 167 to adjust these values. Figure Derived Parameters Rockwell Automation Publication MOTION-UM004B-EN-P - October

154 Chapter 2 Sizing Your System Comments Window Click Comments (label 5 in Figure 117) to enter notes about the overall motion profile in the Profile Comments window. For specific profile segments in the last comment of the table labeled Segment Comments. Highlight the row for a particular profile segment and the segment plot is displayed at the top of the More Options Profile Editor Mode dialog box. Figure Profile Editor - Comments Window 154 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

155 Sizing Your System Chapter Error List Window Click Error List (label 5 in Figure 118) to display errors in the Error List window. Errors are listed as they occur. Figure Error List Window An example of a common error is a negative value for time in Absolute mode. Figure Error List Example Rockwell Automation Publication MOTION-UM004B-EN-P - October

156 Chapter 2 Sizing Your System Profile Export When you have completed your motion profile and have entered the relevant parameters, you can export the data from the More Options Profile Editor Mode to external programs. Prior to exporting the data, make sure that the master and slave units are properly designated. From the menu bar go to Settings>Custom Units to change these. The Profile Export wizard is designed to help you successfully export your profile. 1. From the Profile Editor dialog box, click Export. The Profile Export Wizard dialog box opens. 2. Click Next. The Types of Exports dialog box opens. 156 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

157 Sizing Your System Chapter 2 Table 86 - Type of Export Options Parameters Page Logix CAM Profile Editor Logix Ladder Add-On Instructions SolidWorks Motion Study Move Profile User Defined Logix CAM Profile Editor With this option you can export the motion profile data to RSLogix 5000 software as a fixed cam profile. When using this export option, you choose whether to export the data as a Motion Axis Time Cam (MATC) or a Motion Axis Position Cam (MAPC). With this option you can export the motion profile data as a rung of RSLogix 5000 code that dynamically builds the cam at run time. When using this export option, you choose whether to export the data as a Motion Axis Time Cam (MATC) or a Motion Axis Position Cam (MAPC). This type of instruction lets you adjust portions of the motion profile. With this option you can export the motion profile data that SolidWorks software uses for its animations. With this option you can export the motion profile data to the clipboard or to a specified file type. 1. On the Types of Exports dialog box, select Logix CAM Profile Editor. 2. Click Next. The CAM Set-up dialog box opens Select whether your CAM in RSLogix 5000 software is time or position based. In this example, an MATC export was selected. 4. Click Next. Rockwell Automation Publication MOTION-UM004B-EN-P - October

158 Chapter 2 Sizing Your System The Export Options - Logix CAM dialog box opens and a preview of the data for export is displayed. 5. Click Next. The Target Location for Export dialog box opens. 6. Select how you would like to store the data. Table 87 - Target Location Options Parameters Clipboard File The clipboard stores the data until you copy something else and it is useful if you are going to paste the data into RSLogix 5000 software immediately. Save the data to a file location if you wish to the file or save it for future use. 7. Click Next. 158 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

159 Sizing Your System Chapter 2 The Profile Export Successful dialog box opens. TIP If the Start and End Slope values are non-zero in your application, enter them into the Cam Editor manually. 8. Click Finish. 9. Open your RSLogix 5000 software application program to your MATC instruction. 10. Click the Cam Profile ellipse Rockwell Automation Publication MOTION-UM004B-EN-P - October

160 Chapter 2 Sizing Your System The Cam Editor dialog box opens. 11. Right-click the first row entry arrow and from the window choose Paste. Your move data appears in the Cam Editor dialog box. TIP Click the magnifier icon to adjust the zoom. 12. Click OK. 160 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

161 Sizing Your System Chapter Logix Ladder Add-On Instructions To use this function it is necessary to have the following suite of cam-building Add-On Instructions installed with your RSLogix 5000 project: Table 88 - CAM-building Add-On Instructions File Name AOI_CG_00_Import_then_delete_this.L5X AOI_CG_00_Controller_Tags.CSV AOI_CG_00_Cam Generator Setup.doc Cam_Generator_V2_1_Example.ACD Add-On Instructions files Installation instructions Generic (blank) project file 1. On the Types of Exports dialog box, select Logix CAM Profile Editor. 2. Click Next. The CAM Set-up dialog box opens. 3. Select whether your CAM in RSLogix 5000 software is time or position based. In this example, an MATC export was selected. 4. Click Next. Rockwell Automation Publication MOTION-UM004B-EN-P - October

162 Chapter 2 Sizing Your System The Export Options - Logix Ladder dialog box opens. 5. Click Next. The Target Location for Export dialog box opens. 6. Select how you would like to store the data. Table 89 - Target Location Options Parameters Clipboard File The clipboard stores the data until you copy something else and it is useful if you are going to paste the data into RSLogix 5000 software immediately. Save the data to a file location if you wish to the file or save it for future use. 7. Click Next. 162 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

163 Sizing Your System Chapter 2 The Profile Export Successful dialog box opens. TIP If the Start and End Slope values are non-zero in your application, enter them into the Cam Editor manually. 8. Click Finish. 9. Open your RSLogix 5000 software application program and paste the data into an empty rung. IMPORTANT Make sure the entry type is In Neutral Text. Rockwell Automation Publication MOTION-UM004B-EN-P - October

164 Chapter 2 Sizing Your System The Add-On Instruction appears on the rung. In this example, the Add-On Instruction is a simple index move. 164 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

165 Sizing Your System Chapter SolidWorks Motion Study Move Profile 1. On the Types of Exports dialog box, select SolidWorks Motion Study Move Profile. This is not the preferred workflow. A direct link using API calls has been developed and is described in From SolidWorks on page Click Next. The Export Options - SolidWorks dialog box opens. 3. Define the number of segments you would like to export the data in. For example, a 2 second motion profile would be broken into 50 frames/ second if 100 segments are defined. 4. Click Next. A preview of the data and success dialog box is displayed, similar to the workflow in Logix CAM Profile Editor beginning on page 157. Rockwell Automation Publication MOTION-UM004B-EN-P - October

166 Chapter 2 Sizing Your System User Defined 1. On the Types of Exports dialog box, select User Defined. 2. Click Next. The Export Options - User Defined dialog box opens. 3. Select the unit options. You can export data in your application units or in SI units. In this example, application units are chosen. 4. From the pull-down menu, choose the delimiter. In this example, TAB was chosen. TAB delimited is a standard format for Microsoft Excel software. 5. Click Next. A preview of the data and success dialog box is displayed, similar to the workflow in Logix CAM Profile Editor beginning on page Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

167 Sizing Your System Chapter Segment Parameters Window Each profile segment type has a different associated Segment Parameters window. The default profile segment type is an Index profile segment (label 2 in Figure 120). Figure Segment Parameters The following basic profile segments are available in the More Options Profile Editor Mode dialog box. Table 90 - Basic Profile Segment Options Parameters Page Start Condition Sets the start conditions for your motion profile. The start condition is the initial time, position, and velocity of the motion profile. Accel/Decel Where you enter parameters for an Acceleration or Deceleration profile segment. 168 Cruise/Dwell Index Where you enter parameters for a Cruise or Dwell profile segment. The profile segment is considered a cruise if the velocity at the end of the previous profile segment is non-zero and is considered a dwell if that velocity is zero. Where you enter parameters for an Index profile segment. An Index profile segment consists of an acceleration, a cruise, and a deceleration. In addition to the basic profile segments, the following advanced profile segments are available in the More Options Profile Editor Mode dialog box. Table 91 - Advanced Profile Segment Options Parameters Page Index Advance Selects more advanced velocity, acceleration, and jerk profiles for an Index profile segment. Logix Element Contains parameters that you can easily import or export into RSLogix 5000 software. 174 Motion Axis Move (MAM) Where you enter parameters for a Motion Axis Move command. The parameters are easily exported into a MAM instruction in RSLogix 5000 software Rockwell Automation Publication MOTION-UM004B-EN-P - October

168 Chapter 2 Sizing Your System Start Condition Start Condition (refer to Figure 120) sets the start conditions for your motion profile. The start condition is the initial time, position, and velocity of the motion profile. Figure Start Condition Dialog Box Enter the following parameters for the Start Condition, if relevant. Table 92 - Start Condition Properties Parameters Time Position Velocity The initial time that the motion profile begins. The initial position that the motion profile begins. The initial velocity that the motion profile begins Accel/Decel Where you enter parameters for an acceleration or deceleration profile segment (refer to Figure 120). Figure Acceleration/Deceleration Dialog Box 168 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

169 Sizing Your System Chapter 2 Enter the following parameters for Acceleration/Deceleration, if relevant. Table 93 - Acceleration/Deceleration Properties Parameters Segment Name Data Entry Permutation Increment/Absolute Parameter Entry Jerk - Percentage Jerk - Skew Enter a meaningful name for the profile segment. Select an option for entering the profile segment parameters based on two data types (for example, Time and Distance or Time and Velocity). Select whether to input Incremental or Absolute parameter values. Incremental values represent the change in either the distance or time that occurs during the profile segment. Absolute values represent the total distance or time elapsed throughout the entire motion profile. Enter the parameter values for the two data types selected from the Data Entry Permutation pull-down menu, located below the Increment and Absolute buttons. This value sets the amount of S-curve of the Acceleration/Deceleration profile segment. Increasing the percent jerk increases the amount of S-curve. You can manually enter a value or adjust the value with the slider in the pull-down menu or the slider along the right side of the Segment Plot window (refer to Figure 123). Changing the skew of jerk alters the time in the Acceleration/Deceleration profile segment at which the S-curve occurs. You can manually enter a value or adjust the value with the slider in the pull-down menu or the slider along the right side of the Segment Plot window (refer to Figure 123). IMPORTANT Due to display limitations, the More Options Profile Editor Mode dialog box does not show infinite jerk at points of velocity discontinuity. Using 0% jerk may lead to premature mechanical failure. Figure Segment Plot Window Rockwell Automation Publication MOTION-UM004B-EN-P - October

170 Chapter 2 Sizing Your System Cruise/Dwell The profile segment is considered a cruise if the velocity at the end of the previous profile segment is non-zero and is considered a dwell if that velocity is zero. Figure Cruise/Dwell Dialog Box Enter the following parameters for a Cruise/Dwell profile segment, if relevant. Table 94 - Cruise/Dwell Properties Parameters Segment Name Velocity Increment/Absolute Distance/Time Enter a meaningful name for the profile segment. This is the velocity of the profile segment. This value is non-zero for cruise and zero for dwell. Select whether to input Incremental or Absolute parameter values. Incremental values represent the change in either the distance or time that occurs during the profile segment. Absolute values represent the total distance or time elapsed throughout the entire motion profile. Select and enter either the Distance or Time parameter to define your Cruise/Dwell profile segment. 170 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

171 Sizing Your System Chapter Index An Index profile segment consists of an acceleration, a cruise, and a deceleration. Figure Index Motion Parameters Dialog Box Enter the following parameters for a Index profile segment, if relevant. Table 95 - Index Properties Parameters Segment Name Increment/Absolute Distance/Time Index Type Enter a meaningful name for the profile segment. Select whether to input Incremental or Absolute parameter values. Incremental values represent the change in either the distance or time that occurs during the profile segment. Absolute values represent the total distance or time elapsed throughout the entire motion profile. Enter either the Distance or Time parameter to define your Cruise/Dwell profile segment. From the pull-down menu, choose one of the three available index types. Automatic 1/3 acceleration, 1/3 coast, and 1/3 deceleration trapezoidal motion profile. This is the default setting. Triangular ½ acceleration and ½ deceleration motion profile. Trapezoidal This index type lets you use sliders to adjust the velocity and time axes of the motion profile. Vertical Bar: Adjusts the height/velocity component of the motion profile. As you increase the value of this slider, more time is spent accelerating and decelerating the load and less time is spent dwelling at a constant velocity. Horizontal Bar: Adjusts the ratio of the time spent accelerating to the time spent decelerating for the profile segment. A negative value on the slider indicates that more time is spent decelerating the load than accelerating it. A positive value on the slider indicates that more time is spent accelerating the load than decelerating it. Rockwell Automation Publication MOTION-UM004B-EN-P - October

172 Chapter 2 Sizing Your System Figure Trapezoidal Profile Parameters Smoothness Used to decrease the discontinuity in the transition from a dwell to motion. Select the smoothness from the pull-down menu. Three smoothness options are available. Automatic 0% Jerk (Trapezoidal) Standard 40% Jerk (Partial S-curve) Maximum 100% Jerk (Full S-curve) The percent of time for Acceleration/Deceleration Jerk increases the peak acceleration (and therefore current) above that of a trapezoidal motion profile. The following values illustrate the effect of Acceleration/Deceleration Jerk on current. The acceleration of a trapezoidal motion profile is taken to be 100%. Accel/Decel Jerk Apply +ve/-ve Velocity Limit 0% Jerk 100% acceleration and current (Linear or Trapezoidal). 18% Jerk 110% acceleration and current. 33% Jerk 120% acceleration and current. 66% Jerk 150% acceleration and current. 100% Jerk 200% acceleration and current (S-curve). When you enter the Positive or Negative Velocity Limit for the profile, Motion Analyzer adjusts the acceleration and deceleration times required to reach the desired velocity limits. IMPORTANT Smoothness is used to reduce mechanical wear and tear. Due to display limitations, the More Options Profile Editor Mode dialog box does not show infinite jerk at points of velocity discontinuity. Using 0% Jerk time may lead to premature mechanical failure. 172 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

173 Sizing Your System Chapter Index Advance Index Advance selects more advanced velocity, acceleration, and jerk profiles for an Index profile segment. Figure Index Advance Parameters Dialog Box Enter the following parameters for a Index Advance profile segment, if relevant. Table 96 - Index Advance Properties Parameters Advance Index Type Segment Name Increment/Absolute Distance Time No. of Elements Index SHM Harmonic Motion. Index Poly Fifth order polynomial. Index Mod Sine Modified Sine wave. Index 2 3 Poly Third order polynomial. Index Poly Seventh order polynomial. Index Adjusted Sine Industry standard cam profile. Index Modified Trapezoidal Industry standard cam profile. Enter a meaningful name for the profile segment. Select whether to input Incremental or Absolute parameter values. Incremental values represent the change in either the distance or time that occurs during the profile segment. Absolute values represent the total distance or time elapsed throughout the entire motion profile. Distance for the Index profile segment. Time for the Index profile segment. Number of Elements for the profile segment. Rockwell Automation Publication MOTION-UM004B-EN-P - October

174 Chapter 2 Sizing Your System Logix Element Use this dialog box to import or export Logix elements into RSLogix 5000 software. Figure Logix Element Dialog Box The Logix Element Motion Parameter table is essentially the same as the RSLogix 5000 cam editor. These profile segments can be mixed with any other types available in the More Options Profile Editor Mode dialog box, thus a small section of non-linear motion profile (for example, a cosine compensation profile segment) can be created in a spreadsheet and combined with a simple index profile segment. It is important to distinguish between the terms segment and element. Term Element Segment Definition Term used for each row of the RSLogix 5000 cam editor. These are indivisible or raw elements. Term used for all the profile pieces available in More Options Profile Editor Mode. Each of these typically create one or many elements when exported to RSLogix 5000 software. 174 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

175 Sizing Your System Chapter 2 Enter the following parameters for a Logix Element profile segment, if relevant. Table 97 - Logix Element Properties Parameters Segment Name Master Slave Slope Type Enter a meaningful name for the profile segment. This is directly equivalent to the Master column in RSLogix 5000 software. These values can be entered only as Master and Slave Custom Units. From the Settings menu, choose Custom Units to change these. This is directly equivalent to the Slave column in RSLogix 5000 software. These values can be entered only as Master and Slave Custom Units. From the Settings menu, choose Custom Units to change these. Only the final row allows a value to be entered directly and then only if the corresponding element is cubic. This is equivalent to the Type column in RSLogix 5000 software except that the Cubic/Linear format is applied to the element defined by the current line and the previous line. While in RSLogix 5000 software it is applied to the element defined by the current line and the next line. The first row (row zero in RSLogix 5000 software) displays the start conditions. These cannot be entered directly, but are defined either by the end conditions of the previous profile segment or, if this is the first segment in the motion profile, by the Start Condition on page 168. Each subsequent row completely defines the respective element. Table 98 - Logix Element Properties Parameters Export to Logix Editor Logix Element Import from Logix Editor This button places the data onto the clipboard in order to be pasted into the RSLogix 5000 cam editor. In the cam editor, click the * to highlight the first row then right-click in the box and choose paste to paste the Logix Element. The start and end slopes must be entered manually in RSLogix 5000 software. The start and end slopes must be entered manually in RSLogix 5000 software. This button pastes data from the clipboard that was copied from the RSLogix 5000 cam editor. In the cam editor, click the [] column and drag down to highlight all rows containing data. Then press Ctrl + c to copy the element. The Start and End Slopes must be entered manually. Rockwell Automation Publication MOTION-UM004B-EN-P - October

176 Chapter 2 Sizing Your System Motion Axis Move (MAM) This window lets you enter data as if for a Motion Axis Move (MAM) instruction. For detailed information regarding a MAM, refer to the RSLogix 5000 software help files. Figure MAM Dialog Box Enter the following parameters for a MAM profile segment, if relevant. Table 99 - MAM Instruction Properties Parameters Position Units Axis Motion Control Move Type Position Speed Speed Units Export MAM Select the required position units in the pull-down menu above the MAM profile segment. From the Settings menu, choose Custom Units to change these. This is the Axis name for the RSLogix 5000 MAM instruction. This is the control tag for the instruction. Select either 0 or 1 from the pull-down menu. The profile segment is inverted when this option is changed. This is the final position after the Motion Axis Move profile segment. This is the final velocity after the Motion Axis Move profile segment. These units cannot be adjusted here. To change the units, choose an option from the Position Units pull-down menu at the top of the MAM Segment Parameters window. This places the information onto the clipboard. Clicking on a rung of an RSLogix 5000 project creates a MAM instruction with this data already filled in; only the Axis and a unique instruction tag need to be created. 176 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

177 Sizing Your System Chapter 2 Click More and enter the following parameters for a MAM profile segment, if relevant. Table More MAM Instruction Properties Parameters Accel Rate Accel Units Decel Rate Decel Units Profile Accel Jerk Decel Jerk Jerk Units Merge Merge Units This is the acceleration rate for the MAM profile segment. These units cannot be adjusted here. To change the units, choose an option from the Position Units pull-down menu at the top of the MAM Segment Parameters window. This is the deceleration rate for the MAM profile segment. These units cannot be adjusted here. To change the units, choose an option from the Position Units pull-down menu at the top of the MAM Segment Parameters window. From the pull-down menu, choose Trapezoidal or S-curve. This is the jerk for the acceleration of the MAM profile segment. This is the jerk for the deceleration of the MAM profile segment. These units cannot be adjusted here. To change the units, choose an option from the Position Units pull-down menu at the top of the MAM Segment Parameters window. From the pull-down menu, choose Enabled or Disabled. Refer to the RSLogix 5000 help files for more information. From the pull-down menu, choose Current or Programmed. Refer to the RSLogix 5000 help files for more information. Rockwell Automation Publication MOTION-UM004B-EN-P - October

178 Chapter 2 Sizing Your System 2.3. Specify Your Linear Load Mechanism A linear load mechanism is used to convert rotary motor torque to linear motion through a transmission (belt drive, lead screw, chain and sprocket, or rack and pinion), where thrust from a linear motor, electric cylinder, or linear stage produces linear motion directly. Figure Mechanism Type The following mechanisms are available in Motion Analyzer software. Table Mechanism Types Type Page Belt Drive Lead Screw Chain and Sprocket Rack and Pinion Linear Motor A rotary motor coupled to a timing pulley that drives a flexible toothed belt, with its coupled load, back and forth between two idler pulley guides. A lead screw is coupled to a rotary motor and causes relative linear motion between a rotating screw and its non-rotating nut. A chain and sprocket is a rotary motor coupled to a sprocket wheel that drives a linked chain, with its coupled load, back and forth between idler sprocket guides. A rack and pinion is a rotary motor coupled to a toothed pinion wheel that engages a toothed rack to create relative motion between the two elements. Linear motors are either iron-core and ironless motors that directly create linear thrust. Their separate sections (coil and magnet channel) produce relative motion between a carriage and its base along the user-supplied linear bearing guides Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

179 Sizing Your System Chapter 2 In addition to the many linear mechanisms in Table 101, a few fully-integrated linear mechanisms, listed in Table 104, are also included. Figure Integrated Linear Mechanisms Table Additional Mechanism Types Linear Options Page Electric Cylinders Linear Stages Linear Thrusters These electric cylinders provide flexible, digital servo control of a rod actuator (linear control of force/clamping or position). They provide an electromechanical system for applying digital servo control with a familiar fluid power format. The cylinders are integrated into machines with the same fluid power application principals, mounting methods (trunnion mounts, rear clevis attachment kits, and front flanges, for example.) and rod-end attachments for connected loads (rod eye and rod clevis, for example). A linear stage is used to restrict the load to a single axis of motion. It contains all the elements required to produce linear motion: base and carriage; drive (linear motor or lead screw); linear bearings; and position feedback. A linear thruster is used to provide a completely integrated linear motor-driven system Rockwell Automation Publication MOTION-UM004B-EN-P - October

180 Chapter 2 Sizing Your System Belt Drive A belt drive is a rotary motor coupled to a timing pulley that drives a flexible toothed belt, with its coupled load, back and forth between two idler pulley guides. Figure Mechanism Type - Belt Drive Enter the following parameters for belt drive mechanisms, if relevant. Table Belt Drive Properties Parameters Mechanism Type Mechanism Data (label 1 in Figure 132) Belt Drive and Application (1) (label 2 in Figure 132) Additional Loads (label 3 in Figure 132) From the pull-down menu, choose the mechanism type. The load, stroke, speed, and acceleration values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference. Diameter Inertia (2) Friction Torque No. of Rollers Table Mass Belt Mass Losses The diameter of the drive shaft and idler shafts that make contact with the belt. The inertia of the driver and idler groups. Torque loss due to friction at the driver or idler shaft. You can obtain this value from the supplier or Engineering tables. The number of rollers for each idler group. The mass of the linear load table. This mass is affected by gravity if the inclination in the Load Type Tab on page 82 is non-zero. The mass of the belt. This mass is not affected by gravity. The total torque loss due to friction at the driver and the idler groups is calculated and displayed here. (1) The Driver is the shaft that is driven by the motor through optional gearbox and transmission stages. The Idlers are the rotary elements driven by the belt. You may enter data for up to three Idler Groups. Check the corresponding box to add a second or third group of idlers. A graphic is displayed to help visualize the orientation of the additional idler groups and rollers. (2) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. 180 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

181 Sizing Your System Chapter Lead Screw A lead screw is coupled to a rotary motor and causes relative linear motion between a rotating screw and its non-rotating nut. Figure Mechanism Type - Lead Screw Enter the following parameters for lead screw mechanisms, if relevant. Table Lead Screw Properties Parameters Mechanism Type Mechanism Data (label 1 in Figure 133) Lead Screw Parameters (label 2 in Figure 133) Additional Load (label 3 in Figure 133) From the pull-down menu, choose the mechanism type. The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference. Lead Inertia (1) Pre Load Efficiency Slide Mass The distance that the slide moves per one full rotation of the screw shaft. Pitch is sometimes used loosely to describe this parameter. Pitch is actually the distance between adjacent threads and is equal to lead only for single start threads. The inertia of the lead screw in the event that the lead screw rotates and the nut is stationary. Enter the inertia of the nut when the lead screw is stationary and the nut rotates. The friction torque produced by pre-loading the two nuts of a ball screw against each other. This is done to reduce backlash and increase stiffness in the system. Seal friction should be included in this value. This value can be obtained from the manufacturer s data and is normally quoted in data sheets. The efficiency of the lead screw. This value is available from the manufacturer. Plain Acme screw = typically 40 60% Precision screw (with rolling elements) = typically 85 90% The mass of the slide that travels along the lead screw. This mass is affected by gravity if the inclination in the Load Type Tab on page 82 is non-zero. (1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. Rockwell Automation Publication MOTION-UM004B-EN-P - October

182 Chapter 2 Sizing Your System Chain and Sprocket A chain and sprocket is a rotary motor coupled to a sprocket wheel that drives a linked chain, with its coupled load, back and forth between idler sprocket guides. Figure Chain and Sprocket Dialog Box Enter the following parameters for chain and sprocket mechanisms, if relevant. Table Chain and Sprocket Properties Parameters Mechanism Type Mechanism Data (label 1 in Figure 134) Chain and Sprocket Application (label 2 in Figure 134) Additional Loads (label 3 in Figure 134) From the pull-down menu, choose the mechanism type. The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference. PCD Inertia (1) Friction Torque No. of Sprockets Table Mass Chain Mass Losses Pitch Circle Diameter. This can be calculated by multiplying the link pitch by the number of teeth on the sprocket and dividing by pi. The inertia of the driver and idler groups. The torque loss due to friction at the driver or idler shaft. This value can be obtained from the supplier or Engineering tables. The number of sprockets for each idler group. The mass of the linear load table. This mass is affected by gravity if the inclination in the Load Type Tab on page 82 is non-zero. The mass of the chain. This mass is not affected by gravity. The total torque loss due to friction at the driver and the idler groups is calculated and displayed here. (1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. 182 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

183 Sizing Your System Chapter Rack and Pinion A rack and pinion is a rotary motor coupled to a toothed pinion wheel that engages a toothed rack to create relative motion between the two elements. Figure Rack and Pinion Dialog Box Enter the following parameters for rack and pinion mechanisms, if relevant. Table Rack and Pinion Properties Parameters Mechanism Type Mechanism Data (label 1 in Figure 135) Pinion Application (label 2 in Figure 135) Additional Loads (label 3 in Figure 135) From the pull-down menu, choose the mechanism type. The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference. Pinion PCD Inertia (1) Friction Torque Table Mass Pinion Pitch Circle Diameter. The pitch circle diameter value can be obtained from standard catalogue data. The value can also be calculated by multiplying the tooth pitch by the number of teeth on the sprocket and dividing by pi. The inertia of the pinion. The torque loss due to friction at the pinion shaft. This value can be obtained from the supplier or Engineering tables. The mass of the linear load table. This mass is affected by gravity if the inclination in the Load Type Tab on page 82 is non-zero. (1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. Rockwell Automation Publication MOTION-UM004B-EN-P - October

184 Chapter 2 Sizing Your System Linear Motor Linear motors are either iron-core and ironless motors that directly create linear thrust. Their separate sections (coil and magnet channel) produce relative motion between a carriage and its base along the user-supplied linear bearing guides. Figure Linear Motor Dialog Box 184 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

185 Sizing Your System Chapter 2 Enter the following parameters for linear motor mechanisms, if relevant. Table Linear Motor Properties Parameters Mechanism Type Mechanism Data (label 1 in Figure 136) From the pull-down menu, choose the mechanism type. The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference. Relative motion between the two motor elements is directed horizontally. Horizontal Orientation (label 2 in Figure 136) Vertical Relative motion between the two motor elements is directed vertically. Custom Relative motion between the two motor elements is directed at this angle relative to the horizontal plane. Configuration (label 3 in Figure 136) Load and Application (label 4 in Figure 136) Ironless Iron Core Overtravel Length Carriage Mass Payload Mass External Force Heat Sink Type Bearing Friction Coefficient Counter Balance Type Due to its non-cogging and low magnetic attraction characteristics, direct-drive ironless linear motors are typically used for lighter duty bearings, smooth motion, and/or high precision applications. At slightly lower cost relative to the Ironless configuration (one row of magnets versus two with ironless), these high magnetic attraction motors are typically used with heavy-duty bearings to produce high dynamic thrust performance. The additional length of travel at each end of the motion profile to allow for user-defined machine movements outside of the motion profile (for example, setup of a mechanism or tool change spacing). It also provides room for the motor to stop if it accidentally exceeds the nominal travel envelope. Switches (physical or software) detect this and the drive performs a controlled stop. Click the Axis Stop tab to determine the minimum stopping distance required. The value is added to both ends of the calculated motion profile travel to make sure the proper length motor is specified and selected for the application. User input that specifies the mass of the moving carriage, including its support bearing pucks. This mass should not include the mass of the moving motor elements. The constant mass of the moving parts of the load. This value does not include profile loads that are entered in the Load Type Tab on page 82. This represents any linear force that the motor must overcome (both during motion and while at rest). It does not include frictional loads that are calculated elsewhere. From the Heat Sink Type pull-down menu, choose a heat sink type. The heat sink affects the motor thermal continuous operation ratings. The friction coefficient between the linear moving parts and the fixed parts of the system. You can edit this value in the Load Type Tab on page 82. From the Counter Balance Type pull-down menu, choose a Counterbalance Type (refer to page 84). Counter Balance The mass of the Counterbalance (refer to page 85). Rockwell Automation Publication MOTION-UM004B-EN-P - October

186 Chapter 2 Sizing Your System Electric Cylinders The MP-Series and TL-Series electric cylinders provide flexible, digital, servo control of a rod actuator (linear control of force/clamping or position). They provide an electromechanical system for applying digital servo control with a familiar fluid power format. The cylinders are integrated into machines with the same fluid power application principals, mounting methods (for example, trunnion mounts, rear clevis attachment kits, front flanges) and rod end attachments for connected loads (for example, rod eye and clevis). Figure Electric Cylinders Dialog Box Enter the following parameters for electric cylinder mechanisms, if relevant. Table Electric Cylinder Properties Parameters Mechanism Type Mechanism Data (label 1 in Figure 137) Electric Cylinder (label 2 in Figure 137) From the pull-down menu, choose the mechanism type. The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered previously in the Load Type Tab and Profile Tab, and displayed here for reference. Rod Guide Overtravel Length This accessory is used when the cylinder shaft is exposed to moment (Mx, My, Mz) and/or lateral side loading (Fy, Fz). This is the additional length of travel at each end of the motion profile to allow for user-defined machine movements outside of the motion profile (for example, setup of a mechanism or tool change spacing). It also allows room for the motor to stop if it accidentally exceeds the nominal travel. Switches (physical or software) detect this and the drive performs a controlled stop. Once you have entered your motor and drive requirements, and have searched for possible solutions for your system, click the Axis Stop tab to determine the minimum stopping distance required. This is added to both ends of the calculated motion profile travel to make sure the proper length electric cylinder is specified and selected for the application. 186 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

187 Sizing Your System Chapter Linear Stages The MP-Series integrated linear stage actuators are used to restrict the load to a single axis of motion. They contain all of the elements required to produce linear motion: base and carriage; drive (linear motor or lead screw); linear bearings; and position feedback. Figure Linear Stage Dialog Box Rockwell Automation Publication MOTION-UM004B-EN-P - October

188 Chapter 2 Sizing Your System Enter the following parameters for linear motor mechanisms, if relevant. Table Linear Motor Properties Parameters Mechanism Type Mechanism Data (label 1 in Figure 138) From the pull-down menu, choose the mechanism type. The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference. Horizontal Table Mount The actuator lies flat on a table. Orientation (1) (label 2 in Figure 138) Vertical Wall Mount The actuator moves up and down on a vertical wall. Horizontal Wall Mount The actuator moves horizontally on a vertical wall. Configuration (label 3 in Figure 138) Constant Load (label 4 in Figure 138) Direct Drive Ball Screw Cover Overtravel Length Actuator Stroke Constant Mass External Force X, Y, and Z - Offset Profile Based Loads Edit Payload Payload Animation Linear brushless motor. Conventional rotary brushless motor driving a screw. An actuator cover provides protection from dust and dirt. The addition length of travel at each end of the motion profile to allow for user-defined machine movements outside of the motion profile (for example, setup of a mechanism or tool change spacing). It also allows room for the stage to stop if it accidentally exceeds the nominal travel. Switches (physical or software) detect this and the drive performs a controlled stop. Click the Axis Stop tab to determine the minimum stopping distance required. From the Select Actuator Stroke pull-down menu, choose the required stroke length. If the option Automatic is selected, the next largest value above Required Stroke + (2 x Overtravel) is selected. Larger sizes may be selected at will if additional stroke is required for a function not considered in the motion profile. Any unchanging mass attached to the actuator. The actuator mass itself is automatically taken into account. This value is editable in the Load Type Tab on page 82. Any unchanging force, other than gravity, acting on the load. It is also known as static force. This value is editable in the Load Type Tab on page 82. These offsets allow for a load that has a center of gravity that is not close to the mounting plate of the actuator. This value is significant for linear stage life calculations. Any mass or force that changes during the cycle. The values must be entered for each segment of the motion profile. These are entered in More Options Profile Editor Mode, under the Profile toolbar. Lets you quickly access More Options Profile Editor Mode. Displays a simple example of an application with a varying load. (1) Only horizontal and vertical mounts are permitted corresponding to 0 and 90 inclination in the Load Type Tab on page 82. Any other inclination in the Load tab is converted to horizontal mount. 188 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

189 Sizing Your System Chapter Linear Thrusters The Bulletin LDAT linear thruster is a new type of Allen-Bradley linear actuator product being developed by Rockwell Automation. Its purpose is to provide a completely integrated linear motor driven system. The Bulletin LDAT product is integrated with linear motor, mechanical bearings, high-resolution linear encoder, and standard circular DIN connectors for easy integration with Bulletin 2090 extension cables. Figure Linear Thrusters Dialog Box Rockwell Automation Publication MOTION-UM004B-EN-P - October

190 Chapter 2 Sizing Your System Table Linear Thruster Properties Parameters Mechanism Data (label 1 in Figure 139) Orientation (label 2 in Figure 139) Configuration (label 3 in Figure 139) The Constant/Peak Load Mass, Constant/Peak Applied Force, and Stroke values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference. Only horizontal and vertical mounts are allowed, corresponding to 0 and 90 inclination in the Load tab. Any other inclination in the Load tab is converted to horizontal mount. Select the appropriate thruster orientation image for your application: Horizontal table base mounting Horizontal table side mounting Horizontal wall base mounting Horizontal wall side mounting Vertical wall base mounting Vertical wall side mounting Overtravel Length Actuator Stroke Length Mounting Surface This is the additional length of travel at each end of the motion profile to allow for user-defined machine movements outside of the motion profile For example, setup of a mechanism or tool change spacing. It also allows room for the motor to stop if it accidentally exceeds the nominal travel envelope. Switches (physical or software) detect this and the drive performs a controlled stop. Click the Axis Stop tab to determine the minimum stopping distance required. The value is added to both ends of the calculated motion profile travel to make sure the proper length motor is specified and selected for the application. From the Actuator Stroke pull-down menu, choose the required actuator stroke length. If Automatic is chosen, the next largest value above Required Stroke + (2 x Overtravel) is selected. Larger sizes may be selected if additional stroke length is required for a function not considered in the motion profile. From the Mounting Surface pull-down menu, choose the type of surface the thruster is mounted to. 190 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

191 Sizing Your System Chapter Specify Your Transmission A transmission helps to provide a speed-torque conversion, such as a gear reduction or speed reduction, from a higher speed to a slower, more forceful output. Figure Transmissions Tab Enter the following parameters for transmissions, if relevant. Table Transmission Properties Parameters Required Components (label 1 in Figure 140) Type (label 2 in Figure 140) Define Parameters (label 3 in Figure 140) Select the transmission components for your application. You may add up to two transmission components and one gearbox by checking the boxes above the appropriate component. Belt Drive Chain and Sprocket Spur Gear Coupling A belt drive consists of a loop of flexible material that is used to mechanically link two or more rotating shafts with pulleys. A sprocket is a profiled wheel with teeth that mesh with a chain. A spur gear consists of a rod or disk with the teeth extruding radially. These gears can be meshed together correctly only if they are fitted to parallel shafts. A coupling is a device used to connect two shafts together at their ends for the purpose of transmitting power. The inertia, stiffness, and backlash of couplings can be found in Manufacturers Data Sheets. Click Edit for each transmission selected to enter data. Rockwell Automation Publication MOTION-UM004B-EN-P - October

192 Chapter 2 Sizing Your System Figure Transmission Data Dialog Box There are three options for entering transmission component parameters to calculate the transmission component Ratio, Efficiency, Inertia and Friction Torque values. The applicability of these options change depending upon the type of transmission component. Table Calculate the Transmission Component Ratio Parameters Page Compute Using Inertia and Ratio Compute Using Pitch Circle Diameter Compute Using Number of Teeth Directly enter the transmission component ratio and effective inertia. This option is available for all transmission components. Compute the desired data (ratio and inertia values) by using the pitch circle diameter. This option is not available for a coupling transmission. Compute the desired data (ratio and inertia values) by using the number of teeth. This option is not available for a coupling transmission Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

193 Sizing Your System Chapter Compute Using Inertia and Ratio Use this mode to directly enter the transmission component ratio and effective inertia. This option is available for all transmission components. Figure Compute Using Inertia and Ratio Dialog Box Enter the following parameters for inertia and ratio, if relevant. Table Compute Using Inertia and Ratio Properties Parameters Inertia and Ratio (label 1 in Figure 142) Efficiency and Losses (label 2 in Figure 142) Ratio Inertia Efficiency Friction Torque Transmission component ratio. If a straight-through coupling is being modeled, set Ratio = 1. Inertia on the motor side (the rotor inertia and if a gearbox is present, the inertia of the pinion attached to the rotor). Efficiency is widely misused. It refers to the ratio of output power to input power for a single operating condition, but a servo system typically operates over a wide range of operating conditions. A gearbox supplier normally specifies the efficiency at an optimum point such as full load and full speed. For example, a gearbox that has an output rating of 100 N m (885 lb in) and an efficiency of 98%. This means that the losses at full load are 2 N m (18 lb in). But because most of the losses in a gearbox are due to shaft seal friction and churning of the lubricant, this would not reduce significantly at a lower load torque. In using this gearbox, a well-matched servo motor only has a continuous rating around one third of the peak torque, and it is quite likely that the average torque over the motion cycle would be even lower, for example about 20 N m (177 lb in) at the gearbox output. The losses of 2 N m (18 lb in) amount to 10% of the load on the motor, which can have a significant effect on the temperature rise of the motor. Motion Analyzer software overcomes this problem by dynamically computing the real losses throughout the motion cycle, and thereby avoids underestimating the effect of losses on the motor. This is the torque caused by friction on the motor side between the rotor and the transmission component. This value can be obtained from the supplier or Engineering tables. Rockwell Automation Publication MOTION-UM004B-EN-P - October

194 Chapter 2 Sizing Your System Compute Using Pitch Circle Diameter Use this mode to compute the desired data (Ratio and Inertia values) by using the pitch circle diameter. This option is not available for a coupling transmission. Figure Compute Using Pitch Circle Diameter Dialog Box Enter the following parameters for pitch circle diameter, if relevant. Table Compute Using Pitch Circle Diameter Properties Parameters Inertia and Ratio (label 1 in Figure 143) Efficiency and Losses (label 2 in Figure 143) Belt/Chain Transmission component ratio. If a straight-through coupling is being modeled, set Ratio = 1. Motor Side Pulley/ (1) Sprocket/Gear Load Side Pulley/ (1) Sprocket/Gear Efficiency Friction Torque These values are the Pitch Circle Diameter (PCD) and Inertia for the transmission component on the motor side. These values are the Pitch Circle Diameter (PCD) and Inertia for the transmission component on the load side. Efficiency is widely misused. It refers to the ratio of output power to input power for a single operating condition, but a servo system typically operates over a wide range of operating conditions. A gearbox supplier normally specifies the efficiency at an optimum point such as full load and full speed. For example, a gearbox that has an output rating of 100 N m (885 lb in)and an efficiency of 98%. This means that the losses at full load are 2 N m (18 lb in). But because most of the losses in a gearbox are due to shaft seal friction and churning of the lubricant, this would not reduce significantly at a lower load torque. In using this gearbox, a well-matched servo motor only has a continuous rating around one third of the peak torque, and it is quite likely that the average torque over the motion cycle would be even lower, for example about 20 N m (177 lb in) at the gearbox output. The losses of 2 N m (18 lb in) amount to 10% of the load on the motor, which can have a significant effect on the temperature rise of the motor. Motion Analyzer software overcomes this problem by dynamically computing the real losses throughout the motion cycle, and thereby avoids underestimating the effect of losses on the motor. This is the torque caused by friction on the motor side between the rotor and the transmission component. This value can be obtained from the supplier or Engineering tables. (1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. 194 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

195 Sizing Your System Chapter Compute Using Number of Teeth Use this mode to compute the desired data (ratio and inertia values) by using the number of teeth. This option is not available for a coupling transmission. Figure Compute Using Number of Teeth Dialog Box Enter the following parameters for number of teeth, if relevant. Table Compute Using Number of Teeth Properties Parameters Inertia and Ratio (label 1 in Figure 144) Efficiency and Losses (label 2 in Figure 144) Belt/Chain Motor Side Pulley/ (1) Sprocket/Gear Load Side Pulley/ (1) Sprocket/Gear Efficiency Friction Torque This is the mass and tooth pitch for the belt/chain. This value is required for belt drive and chain and sprocket transmission components only. These values are the Number of Teeth and Inertia for the transmission component on the motor side. These values are the Number of Teeth and Inertia for the transmission component on the load side. Efficiency is widely misused. It refers to the ratio of output power to input power for a single operating condition, but a servo system typically operates over a wide range of operating conditions. A gearbox supplier normally specifies the efficiency at an optimum point such as full load and full speed. For example, a gearbox that has an output rating of 100 N m (885 lb in)and an efficiency of 98%. This means that the losses at full load are 2 N m (18 lb in). But because most of the losses in a gearbox are due to shaft seal friction and churning of the lubricant, this would not reduce significantly at a lower load torque. In using this gearbox, a well-matched servo motor only has a continuous rating around one third of the peak torque, and it is quite likely that the average torque over the motion cycle would be even lower, for example about 20 N m (177 lb in) at the gearbox output. The losses of 2 N m (18 lb in) amount to 10% of the load on the motor, which can have a significant effect on the temperature rise of the motor. Motion Analyzer software overcomes this problem by dynamically computing the real losses throughout the motion cycle, and thereby avoids underestimating the effect of losses on the motor. This is the torque caused by friction on the motor side between the rotor and the transmission component. This value can be obtained from the supplier or Engineering tables. (1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. Rockwell Automation Publication MOTION-UM004B-EN-P - October

196 Chapter 2 Sizing Your System Figure Gearbox Data Dialog Box Enter the Manufacturer, Configuration, Series, and Frames gearbox data Choose Your Motor Series Use the Motor Series Selection tab to enter application requirements and then select a compatible motor series. Figure Motor Series Selection Dialog Box 196 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

197 Sizing Your System Chapter 2 Enter the following parameters to further narrow the motor options and help you decide which motor is best for your application. Table Motor Series Selection Properties Parameters Applications Requirements (label 1 in Figure 146) Display Window (label 2 in Figure 146) Maximum Speed Continuous Torque Peak Torque Ambient Temperature Altitude Brake Values are based on the information you entered in the previous tabs. These values cannot be changed in this tab. Ambient temperature for the application environment. Altitude for the application environment. From the Brake pull-down menu, choose YES or NO depending on your application. Displays the available motor series. As application requirements are entered or motor series are selected, incompatible motors are dimmed and crossed-out (boxed in red in Figure 147). Figure Compatible Motor Series Table Motor Series Legend (refer to Figure 147) Symbol By hovering over this symbol, the particular motor series voltage ratings are displayed. Indicates that the motor series supports the application. Indicates that the motor series support for the application is marginal. Indicates that the motor series is not recommended for the application. Indicates that the motor series is incompatible with the application. Rockwell Automation Publication MOTION-UM004B-EN-P - October

198 Chapter 2 Sizing Your System Select the List View option to view details regarding Key Features and Applications, Voltage/Travel & Speed, Feedback Options, and Continuous Stall Torque/Force. Click Compatibility List to view a comprehensive table containing Motor Series Voltage Compatibility and Motor Series-Drive Family Compatibility. 198 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

199 Sizing Your System Chapter Choose Your Electric Cylinder Series Use the Electric Cylinder Selection tab to enter application requirements and select a viable electric cylinder series. Figure Electric Cylinder Selection Dialog Box Enter the following parameters to further narrow the electric cylinder options and help you decide which actuator is best for your application. Table Electric Cylinder Selection Properties Parameters Applications Requirements (label 1 in Figure 148) Display Window (label 2 in Figure 148) Maximum Speed Continuous Force Peak Force Ambient Temperature Altitude Brake Values are based on the information you entered in the previous tabs. These values cannot be changed in this tab. Ambient temperature for the application environment. Altitude for the application environment. Displays the available electric cylinder options. From the Brake pull-down menu, choose YES or NO depending on your application. Rockwell Automation Publication MOTION-UM004B-EN-P - October

200 Chapter 2 Sizing Your System Table Electric Cylinders Legend (refer to Figure 148) Symbol By hovering over this symbol, the particular electric cylinder voltage ratings are displayed. Indicates that the electric cylinder supports the application. Indicates that electric cylinder support for the application is marginal. Indicates that the electric cylinder is not recommended for the application. Indicates that the electric cylinder is incompatible with the application. Select the List View option to view details regarding Key Features and Applications, Voltage/Travel & Speed, Feedback Options, and Continuous Stall Torque/Force. Click Compatibility List to view a comprehensive table containing Actuator Series Voltage Compatibility and Actuator Series-Drive Family Compatibility. 200 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

201 Sizing Your System Chapter Choose Your Drive Family Use the Drive Family Selection tab to enter application requirements and select a viable drive family. Figure Drive Family Selection Assistant Dialog Box Enter the following parameters to further narrow the drive family options and help you decide which drive is best for your application. Table Servo Drive Family Selection Properties Parameters Applications Requirements (label 1 in Figure 149) More Options (1) (Figure 150) Display Window (label 2 in Figure 149) Supply Type Nominal Voltage Average Motoring Power Voltage Type Lower Nominal Upper Nominal Tolerance Displays the available electric cylinder options. Select Single phase AC (AC1ph), 3-phase AC (AC3ph), or DC supply type. From the Nominal Voltage pull-down menu, choose the nominal voltage value. This value is displayed for reference. Click Details to view more information. Select an option to enter a single value for voltage or a range of voltages. This parameter is required when you select the option to enter a range for the voltage type. Enter the lower value for the voltage range. This parameter is required when you select the option to enter a range for the voltage type. Enter the upper value for the voltage range. This is the high and low tolerance for the voltage range. (1) Click More Options to further narrow the drive parameters and help you decide which motor is best for your application. Rockwell Automation Publication MOTION-UM004B-EN-P - October

202 Chapter 2 Sizing Your System Figure Additional Servo Drive Selection Properties Figure Compatible Drive Families Table Drive Family Legend (refer to Figure 149) Symbol By hovering over this symbol, the particular drive family s voltage ratings are displayed. Indicates that the motor series supports the application. Indicates that the motor series support for the application is marginal. Indicates that the motor series is not recommended for the application. Indicates that the motor series is incompatible with the application. 202 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

203 Sizing Your System Chapter 2 Select the List View option to view details regarding Key Features and Applications, Voltage/Travel & Speed, Feedback Options, and Continuous Stall Torque/Force. Click Details to view a comprehensive table containing Motor Series and Drive Family Compatibility. Rockwell Automation Publication MOTION-UM004B-EN-P - October

204 Chapter 2 Sizing Your System Notes: 204 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

205 Chapter 3 Understanding Your System Solution Topic Page Selection 206 Automatic 207 Manual 208 Solution 208 Solution List 209 View Solution 211 Axis Stop 250 Controlled Stop 250 Resistive Brake Module 252 Load Data 252 RBM Selection 253 Apply RBM Selection 255 Life Estimate 256 Configure Axis BOM 258 Super Review 260 Summary View 260 Details View 265 Rockwell Automation Publication MOTION-UM004B-EN-P - October

206 Chapter 3 Understanding Your System Solution 3.1. Selection In the Selection tab, you perform a search for the drive/motor solution for your application, based on the drive and motor families you selected previously. The search also includes a gearbox, if gearbox was selected in the Transmission tab. Figure Sizing and Selection Dialog Box The search for possible drives and motors is performed based on these two options: Select Full if you want the search performed on the entire database of motors, drives, and gearboxes. Select My Preferred if you want the search performed on motors, drives, and gearboxes that you have selected within My Preferred Database on page 62. Searching methods include these two options: Select Automatic if you want Motion Analyzer software to perform the search based on the selected database option (refer to page 207). Select Manual if you want to select the components (motor, drive, and/or gearbox) from a list (refer to page 208). 206 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

207 Understanding Your System Solution Chapter Automatic Follow these steps to have Motion Analyzer software to make the motor, drive, and/or gearbox selections for you. 1. In the Automatic field, select Motor, Drive, and Gearbox (if present). 2. Click Search. The Search in Progress dialog box opens. When the search is complete, the Solution List opens with a list of motor/ drive combinations and a selection based on the application requirements that you entered previously. 3. Click View Solution. The Component Details and Axis System Performance windows open. If the automatic selection process does not find a solution, it means that no motor or drive in the specified family is capable of performing the task. When this happens, the result is No Solution Found, which means you should try one or more of the following: Select a Motor Mounted Gearbox in the Transmissions Tab on page 191. Try a bigger family of motors and drives. Reduce application requirements until a solution is found. Use Torque Analysis, within the Efficiency Analysis tool on page 227, to determine which parameters are dominant. This may indicate which factor to investigate. Use Tolerance/Design Analysis on page 222 to explore how much a parameter should change to obtain a passing solution. Rockwell Automation Publication MOTION-UM004B-EN-P - October

208 Chapter 3 Understanding Your System Solution Manual Follow these steps to select the components yourself (motor, drive, and/or gearbox) from a list. 1. In the Manual field, select Motor, Drive, and Gearbox (if present). 2. Click Select. The Manual Selection dialog box opens. 3. Select the motor/actuator required for your application from the MotorID column. For each motor/actuator selected, the compatible drives appear below in the Drive column. 4. Select a drive. 5. Click View Solution. The Component Details and Axis System Performance windows open Solution When using the automatic method of selecting components, the Solution tab opens providing a solution list of motor/drive combinations and a selection, based on the application requirements that you entered previously. If you are using the manual method of selecting components go directly to View Solution on page Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

209 Understanding Your System Solution Chapter Solution List You can organize the solutions by using the List Categories pull-down menu, or by clicking one of the headings in the table. The column data is sorted in descending order the first time the heading is clicked and ascending order when you click the heading a second time. You can also rearrange the columns by clicking and dragging them. Figure Solution List Dialog Box Table Solution Tab Properties Parameters View Utilizations as Solution View Setup View Solution System Notes Text Data in columns appear only as text (for example, 17%). Graphically Data in columns appears as text and graphic ally to enhance the view (this is the default setting). Click to adjust display options for the solution list. Click to open the View Solution dialog box. Enter system notes for the application (optional). Table Solution List Legend Symbol Status Definition Supports Marginal Not Recommended All parameters passed. One or more parameters exceeded the recommended limit, but the solution is viable provided all customer data is accurate. One or more parameters exceeds 100%. The solution is not viable as entered, but may respond to optimization. For more information, refer to Automatic on page 207. Rockwell Automation Publication MOTION-UM004B-EN-P - October

210 Chapter 3 Understanding Your System Solution Preferred Product A preferred product is a top selling product of Rockwell Automation that is guaranteed to ship from the factory within five days. The preferred status is displayed in the Preferred Product column in the solution list. Figure Preferred Product Solution List Dialog Box Table Preferred Product Status (refer to Figure 154) Preferred Product Status Motor & Drive Drive Motor - Definition The drive is a preferred product and has a shorter lead time/quicker delivery. The motor may be a preferred product depending on options (for example, encoder option, brake, key, and others). Please view the complete catalogue number in the ProposalWorks application for preferred product status. The drive is a preferred product and has a shorter lead time/quicker delivery. The motor may be a preferred product depending on options (for example, encoder option, brake, key, and others). View the complete catalogue number in the ProposalWorks application for preferred product status. Neither the motor nor the drive is a preferred product. Contact your local Rockwell Automation distributor for the lead time/delivery schedule of these products. 210 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

211 Understanding Your System Solution Chapter View Solution The View Solution dialog box contains information and tools that you can use to to evaluate system performance and efficiency. Figure View Solution Dialog Box View the following parameters for your solution. The Component Details portion of the detailed solution view provides an overall summary of the performance characteristics for the various components of the system. Table Component Details (label 1 in Figure 155) Parameters Motor Cat. No. Forward/Backward Arrows Click to access the product specifications for that catalog number. Navigate to the View Solution information for the next component in the solution list. When a solution includes a gearbox, the inertia ratio is not simply the Reported Application Inertia divided by the Reported Motor Inertia (rotor inertia), as with systems that do not include a gearbox. When a system includes a gearbox, the Input Pinion of the gearbox is rigidly attached to the rotor, while the rest of the gears in the gearbox remain connected to the application. Most of the backlash in the system occurs between the input pinion and the rest of the system. Rockwell Automation Publication MOTION-UM004B-EN-P - October

212 Chapter 3 Understanding Your System Solution To correctly calculate the inertia ratio, the Input Pinion Inertia must be removed from the Reported Application Inertia and added to the Reported Motor Inertia. For example, the system in Figure 156 with an MPL-B680F motor and a VDT100-MF1 gearbox has a 6.50:1 inertia ratio. Figure Inertia Ratio Calculation Reported Application Inertia - Input Pinion Inertia = Inertia Ratio Reported Motor Inertia + Input Pinion Inertia Click the Motor tab to view the Reported Application Inertia and the Reported Motor Inertia. Figure Motor Tab 212 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

213 Understanding Your System Solution Chapter 3 The Motion Analyzer database contains the Input Pinion Inertia for every available gearbox. In this example, the Input Pinion Inertia is kg-m 2. To obtain a correct inertia ratio, Motion Analyzer software adds the Input Pinion Inertia to the Reported Motor Inertia, which decreases the application inertia and increases the motor inertia. Division produces the correct inertia ratio of 6.50:1. The individual component tabs (for example, Motor, Drive, Gearbox and Transmission) provide detailed performance information. Figure Motor Tab = In the Motor tab, the brake rating compares the maximum static torque that can be applied to the brake with the quoted holding torque of the brake. This normally occurs when the drive is disabled with the motor/load stationary. This static torque arises from any applied load torques or forces, including gravitational effects. It does not take into account friction. If a high proportion of the brake torque (or force) is used for static loads, then little may be left in case the brake is required to stop motion suddenly. Brakes reduce performance if operated during motion. The motor brake is intended as a holding brake applied when motion is stopped and cannot be relied upon to stop a moving load when the drive fails or loses power. An independent method of stopping is recommended for all emergency situations where there is a gravitational load or applied force/torque. A resistive brake module provides some braking but will never stop a mechanism with a gravitational load or applied force/torque. If available, Get Engineering Data opens a webpage with the Product and Supplementary Documents for the selected product. Rockwell Automation Publication MOTION-UM004B-EN-P - October

214 Chapter 3 Understanding Your System Solution The Axis System Performance portion of the detailed Solution view provides graphical representations of the performance characteristics for the system. If you click the graph, the graph expands to fill your screen. In addition, as you mouse over the graph, the X- and Y-values are displayed below the graph. The Torque-Speed tab contains the torque/speed graph for the selected motor/ drive combination. This graph is created dynamically, which means that if the supply voltage changes in the Motor or Drive tab, the graph will change accordingly. Figure Torque-Speed Graph Table Axis System Performance (label 2 in Figure 155) Parameters Quadrant Graph Detail X-/Y- Axis Button Single Displays single quadrant graph. Four Displays four quadrant graph. Opens the Torque Speed Details dialog box. Summary Displays only the critical profile segment data on the graph. All Segments Displays the data for all profile segments on the graph. Segmentwise Displays the data for one profile segment at a time. Use the Forward and Backward arrows to navigate between profile segments. Show RMS Torque Auto Cycle Flips the X- and Y-axes on the graph. Check to display the RMS (root mean squared) torque value on the graph. Check to highlight each data point, in order, at the specified update rate. 214 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

215 Understanding Your System Solution Chapter 3 The Power-Speed tab (label 2 in Figure 155) contains the power/speed graph for the selected motor and drive combination. This graph is typically used for Variable Frequency Drive (VFD) applications where power is more appropriate than torque as a measure of performance. Figure Power-Speed Graph Rockwell Automation Publication MOTION-UM004B-EN-P - October

216 Chapter 3 Understanding Your System Solution The Load tab displays the characteristics of the load alone without the influence of the motor or drive. It may be viewed before selecting motor or drive. For rotary loads, the influence of transmission/gear component ratio may be investigated by moving the ratio slider. This is a preliminary test no transmission losses are included at this stage. For example, efficiency as defined on the Transmission tab is not factored into transmissions. Figure Load Graph Table Axis System Performance (label 2 in Figure 155) Parameters Summary All Segments Segmentwise Show RMS Torque Gearbox Ratio Quadrant Displays the data only for the critical profile segment. Displays the data for all profile segments on the graph. Displays the data for one profile segment at a time. Use the Forward and Backward arrows to navigate between profile segments. Select to display the RMS (root mean squared) torque value on the graph. Use the slider to adjust the Gearbox Ratio and observe the effect on the Torque-Speed graph. Select the option to view either the Single or Four quadrant graph. 216 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

217 Understanding Your System Solution Chapter 3 The Thermal tab displays the output of drive and motor thermal models that reside in the drive firmware. Figure Thermal Graph Table Axis System Performance (label 2 in Figure 155) Parameters Motor/Drive Capacity Steady State/Single Cycle Full/Auto Scale RBM tab Power-Supply Select the thermal curves you would like displayed on the graph. Select whether to view thermal data for Steady State or for a Single Cycle. Select whether to view the data on the Full Scale graph (y-axis values from zero to the maximum value) or Auto Scale graph (y-axis values from the minimum value to the maximum value). This graph is available after a Resistive Brake Module (RBM) has been added to the System BOM (bill of materials) in the Axis Stop tab. The graph displays the Velocity versus Time data for the RBM module. This graph is available after a Power Supply Analysis has been performed on the system in the Power Supply/Accessories View. This graph displays the Voltage and Current Simulation data. Rockwell Automation Publication MOTION-UM004B-EN-P - October

218 Chapter 3 Understanding Your System Solution The Data Analysis Toolbar provides tools that can be used to analyze and optimize the system. Use these tools to quickly evaluate the effect of changing the application parameters, without having to build physical prototypes. When an optimized system is realized, return to the appropriate parameter to manually update it. Figure Data Analysis Toolbar Table Data Analysis Toolbar (label 3 in Figure 155) Parameters Page Ratio/Design Analysis Tolerance/Design Analysis Efficiency Analysis Dynamic Simulation Provides information that you can use to optimize the mechanical advantage and/or transmission stages for the system. Provides information that you can use to determine the sensitivity of the design to changes. Provides information that you can use to determine the efficiency of the system. Provides information that you can use to determine the dynamic performance of the system. Segment Data Provides detailed performance data for each profile segment. 249 These parameters can be used to view data for other solutions. Table Additional Tools (label 3 in Figure 155) Parameters Page Solution List Click to return to the Solution List. This feature is dimmed if there is only one solution for the system configuration Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

219 Understanding Your System Solution Chapter Ratio/Design Analysis You can use the Ratio/Design Analysis tool to analyze the effect of the transmission or gear component ratios on the system performance and quickly optimize the ratio values. This tool is not applicable for linear actuators. When you click Ratio/Design Analysis, the following dialog box opens. Depending on your system configuration, the following Ratio Analysis options may be available to you: Gearbox Transmission 1 Transmission 2 Lead Sprocket PCD (sprocket pitch circle diameter) Pinion PCD (pinion pitch circle diameter) Drive Diameter For more information, refer to Ratio Analysis on page 220. The Cut Length Analysis option is available when you use the Press Roll Feed (constant time/constant angle), Carriage Cut Off, or Cutter Knife Drive application templates. For more information, refer to Cut Length Analysis on page 221. Rockwell Automation Publication MOTION-UM004B-EN-P - October

220 Chapter 3 Understanding Your System Solution Ratio Analysis When you select a Ratio Analysis option, the following dialog box opens. Motor Speed an Ratio Value Motor Speed and ratio values are displayed above the graph for reference. The slider below the chart is available to adjust the ratio you are optimizing. As you mouse over the slider, the ratio value is displayed. The buttons below the Ratio Analysis chart select which curves are displayed. When you click Selected Curves, the motor and drive parameters to the right of the chart are displayed. If you select another button below the chart, only that parameter is shown. Table Ratio Analysis Options Parameters Motor/Drive Parameters Graph Scale Available Solutions Return Check which motor and drive parameters are displayed when you click Selected Curves. The value for each parameter is listed for the particular gearbox or transmission component ratio indicated by the slider. From the Graph Scale pull-down menu, choose the X-axis scale for the chart. You can set the Graph Scale to 1, 2 or 3 decades or the scale can be defined. When the User Defined option is selected, the lower and upper limits for the X-axis of the graph must be entered. Once the axis limit values are entered, click Recompute to refresh the chart. Click the forward or backward arrow to scroll through the various available solutions. Click Return to exit. 220 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

221 Understanding Your System Solution Chapter Cut Length Analysis When you select a Cut Length Analysis option, the following dialog box opens. Table Cut Length Analysis Options Parameters Range Parameters Critical Parameters Print Enter the Minimum Cut Length, Maximum Cut Length, and Increment values and click Compute. The calculated parameters are displayed in the table and Line Speed versus Cut Length chart. The Minimum Cut Length at Max. Line Speed and Max Line Speed values are displayed here for reference. To adjust these values, return to the Application Template Loads tab on page 96. Print the Cut Length Analysis in a project report. Rockwell Automation Publication MOTION-UM004B-EN-P - October

222 Chapter 3 Understanding Your System Solution Tolerance/Design Analysis When you click Tolerance/Design Analysis, the following dialog box opens. The buttons below the Tolerance Analysis chart are available to select which curves are displayed. When you click Selected Curves, the parameters selected on the Graph tab (right of the chart) are displayed. If you select another button below the chart, only that parameter appears. The slider below the chart is available to adjust the selected Profile, Load, or Actuator parameter. As you mouse over the slider, the parameter value is displayed. 222 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

223 Understanding Your System Solution Chapter Profile Tab Follow these steps to adjust the profile parameters. 1. From the Segment No. pull-down menu, choose the profile segment number you would like to analyze. 2. Select the motion profile parameter. This becomes the parameter corresponding to the X-axis on the graph. The value next to each parameter indicates the parameter value based on the current system configuration. 3. Adjust the selected profile parameter range and number of steps in the Low, High, and Steps text boxes, as needed. 4. Click Plot Graph to refresh the chart when you have finished entering the values. 5. Click Setup to designate a parameter to vary by checking the adjacent box and/or clicking the radio button. Designate an upper and lower limit for the parameter and the number of steps to observe on the graph within the specified range. 6. Click Plot to see the graph of the selected parameter versus time. 7. Click OK. Rockwell Automation Publication MOTION-UM004B-EN-P - October

224 Chapter 3 Understanding Your System Solution Load Tab Follow these steps to adjust the load parameters. 1. Select the Load parameter you would like to analyze. This becomes the parameter corresponding to the X-axis on the graph. The number next to each parameter indicates the parameter value based on the current system configuration. 2. Adjust the selected load parameter range and number of steps in the Low, High, and Steps text boxes, as needed. 3. Click Plot Graph to refresh the chart when you have finished entering the values. 4. Click Setup to enter all of the ranges and numbers of steps for the Load parameters in the Tolerance Analysis - Setup dialog box. 5. Select whether to enter data ranges as Percentages of nominal values or as actual Values. 6. Enter the Low, High, and Steps values in the text boxes. 7. Click OK. 224 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

225 Understanding Your System Solution Chapter Actuator Tab Follow these steps to adjust the actuator parameters. 1. Select the Actuator parameter you would like to analyze. This becomes the parameter corresponding to the X-axis on the graph. The number next to each parameter indicates the parameter value based on the current system configuration. 2. Adjust the selected actuator parameter range and number of steps in the Low, High, and Steps text boxes, as needed. 3. Click Plot Graph to refresh the chart when you have finished entering the values. This tab is not available for the Rack and Pinion and Sprocket loads. 4. Click Setup to enter all of the ranges and numbers of steps for the Actuator Tolerance Parameters in the Tolerance Analysis - Setup dialog box. 5. Select whether to enter data ranges as Percentages of nominal values or as actual Values. 6. Enter the Low, High, and Steps values in the text boxes. 7. Click OK. Rockwell Automation Publication MOTION-UM004B-EN-P - October

226 Chapter 3 Understanding Your System Solution Graph Tab This tab is not available for the Rack and Pinion and Sprocket loads. Follow these steps to decide which parameters are displayed. 1. Check the Motor Parameter curves to display. 2. Check the Drive Parameter curves to display. 3. Click Setup to enter all the ranges and numbers of steps for the Profile, Load, and Actuator tolerance parameters. 4. Click Return to exit. 226 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

227 Understanding Your System Solution Chapter Efficiency Analysis Click Efficiency Analysis to analyze the contribution of various system parameters to the overall efficiency of the system. You can use this information to optimize the system configuration and reduce the torque, power consumption, or energy loss in the system. For example, if more torque is applied toward overcoming the preload on a ball screw than towards moving the load, this may indicate a good place for further analysis Torque Tab Click the Torque tab to identify the torque contributions of the various system components. Figure Torque Tab Click either the Peak Torque Analysis or RMS Torque Analysis option to display the data. The torque analysis for the critical profile segment is displayed by default when you open the Efficiency Analysis dialog box. To change the Segment Number, click the Forward or Backward arrows. The torque contributions of each system parameter are listed in descending order. To view the torque contribution of a particular system parameter for all profile segments, click the arrow next to the system parameter. Rockwell Automation Publication MOTION-UM004B-EN-P - October

228 Chapter 3 Understanding Your System Solution Power Tab Click the Power tab to display aids in identifying how the system s power is distributed. Figure Efficiency Analysis Dialog Box Click Segment Average to display the various power contributions for each profile segment or Cycle Average to display the power contributions for the entire motion profile. The Power Consumption analysis for the critical profile segment is displayed by default when you open the Efficiency Analysis dialog box. To change the Segment Number, click the Forward or Backward arrow. The power consumption contributions of each system parameter are listed in descending order. To view the power consumption contribution of a particular system parameter for all profile segments, click the arrow next to the system parameter. 228 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

229 Understanding Your System Solution Chapter Energy Tab Click the Energy tab to identify how the system s energy consumption is distributed. Figure Efficiency Analysis Dialog Box Click Return to exit. Rockwell Automation Publication MOTION-UM004B-EN-P - October

230 Chapter 3 Understanding Your System Solution Dynamic Simulation Motion Analyzer dynamic simulation lets you predict the dynamic performance of an axis at the sizing stage. The Dynamic Simulator contains similar functionality in gains and behavior as RSLogix 5000 software. Figure Dynamic Simulation Dialog Box Table Dynamic Simulation Options Options Page Simulation Inputs (label 1 in Figure 167) Simulation Analysis (label 2 in Figure 167) Control Loop Gains and other Parameters (label 3 in Figure 167) Consists of Controller, Drive, Motor, Load, and Test Disturbances specifications and lets you define the parameters for each. Consists of Simulation Plots, Simulation Data, and Control Loop Diagram tabs and lets you run simulation and analyze output simulation plots and data. Lets you manually enter control loop gains or perform auto-tuning Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

231 Understanding Your System Solution Chapter Simulation Inputs Click inputs. to toggle between the expanded and collapsed view of the simulation Figure Simulation Inputs Collapsed View Expanded View Rockwell Automation Publication MOTION-UM004B-EN-P - October

232 Chapter 3 Understanding Your System Solution Table Simulation Input Parameters Parameters Controller (label 1 in Figure 168) Drive (label 2 in Figure 168) Motor (label 3 in Figure 168) Load (label 4 in Figure 168) Test Disturbances (label 5 in Figure 168) Coarse Update Rate Sercos Update Rate Counts Per Motor Revolution Counts Per User Unit Coarse update rate of the Logix controller. Sercos update rate of the Logix controller. Drive feedback counts per motor revolution. Drive feedback counts per user unit. The combination may be chosen arbitrarily to make sure that the user units are exact. The user unit is the unit selected for Angular Distance from Preferences->Units of Measure in the main Motion Analyzer window. Displays drive catalog number as selected in sizing. Parameters cannot be edited. Continuous Current Peak Current Current that may be drawn indefinitely. Maximum current that may be drawn briefly. Displays motor catalog number as selected in sizing. Parameters cannot be edited. Motor Inertia Motor rotor inertia. Continuous Torque Nominal or continuous torque (100%). Peak available torque from the motor in %. Dynamic simulation assumes that this Peak Torque Limit peak torque is available at all speeds required by the specified profile. It does not model bus voltage limit behavior. Feedback Feedback Counts/ Revolution Motion Analyzer Load SolidWorks Load You can select the feedback device available to the base motor (for example, selected in sizing). Selecting the feedback device changes the motor catalog number to reflect the feedback device. This motor catalog number also reflects in the BOM area. Feedback resolution in counts per motor revolution. This field is updated by selecting a feedback device. Select to use the load defined in the Motion Analyzer software. This is the default selection when you open Dynamic Simulation. Select SolidWorks software to model a more complex load and use SolidWorks integration to perform simulation. Dynamic Simulation uses SolidWorks results to predict the dynamic behavior of the load. If SolidWorks is not installed on your personal computer, the SolidWorks Load option is dimmed. Test disturbances test the stability of the system. The defined step torque value is added to the system for the specified duration. Step Torque Simulates a step torque occurring part way through the cycle. Step Start Time Defines the point in the cycle that the step occurs. Step Duration Defines the length of time that the torque is applied. 232 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

233 Understanding Your System Solution Chapter Motion Analyzer Load Selecting the Motion Analyzer load provides simulation using the Motion Analyzer software load sizing definitions. Figure Motion Analyzer Software Load Inertia A Inertia B The load is modelled as two inertias coupled by compliance (the spring in this example diagram). Inertia A is rigidly coupled to the motor and so effectively becomes part of the motor. If backlash is selected, it replaces the spring in this diagram. The two friction components are not yet supported. From the Coupling pull-down menu, choose the Coupling type. Figure Coupling Type Table Coupling Type Options Options Page Rigid Coupling The load is rigidly coupled to the motor. 234 Backlash Simulates backlash such as gearbox. 234 Compliance A spring is connected between motor and load. 235 Rockwell Automation Publication MOTION-UM004B-EN-P - October

234 Chapter 3 Understanding Your System Solution Rigid Coupling Rigid coupling occurs when the load is rigidly coupled to the motor. Figure Rigid Coupling Table Rigid Coupling Options Options Total Inertia Rigid Inertia (Inertia A in Figure 169) Decoupling Factor Maximum load inertia reflected to the motor shaft. Any part of the load inertia that is rigidly attached to the motor shaft. This becomes significant only when resonance or backlash is present because it becomes effectively part of the motor. Any inertia entered here is subtracted from the Load inertia leaving the total (system) inertia unchanged. For example, a gearbox always has backlash, but its input shaft/pinion is normally coupled rigidly to the motor shaft. This effectively becomes part of the motor, creating a higher inertia motor. This can significantly alter the performance of an axis. This factor is much more indicative of potential dynamic performance than the conventional Inertia Ratio. Velocity Bandwidth is increased by this factor when the load is decoupled. Instability typically results beyond 2 unless gains are reduced. Anything greater than 1 starts to impact performance. DF = Jdc / (Jm + Jrc) + 1 Where, DF = Decoupling Factor, Jdc = decoupled load inertia, Jm = motor inertia, Jrc = rigidly coupled load inertia Backlash Backlash occurs (for example) when a gearbox is added to the motor. Choosing Backlash enables an additional field, in addition to the Rigid coupling fields, where you can enter a backlash value. Figure Backlash Coupling 234 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

235 Understanding Your System Solution Chapter Compliance Choosing Compliance enables the following additional fields, in addition to the Rigid coupling fields. Figure Compliance Coupling Table Compliance Coupling Options (refer to Figure 173) Options Damping Ratio Stiffness Stiffness Calculator Natural Frequency Enter a system damping ratio. The damping ratio provides a means of expressing the level of damping in a system relative to critical damping. The Stiffness entry is useful when Natural Frequency is not known, but stiffness is. Click Stiffness to launch the stiffness calculator and calculate stiffness from Shear Modulus, diameter and length. Simulates a resonance between load and motor (0 = infinitely stiff). Figure Stiffness Calculator Rockwell Automation Publication MOTION-UM004B-EN-P - October

236 Chapter 3 Understanding Your System Solution SolidWorks Load Selecting SolidWorks Load provides simulation of complex loads modeled in SolidWorks software. Using the SolidWorks interface, the Dynamic Simulator sends the torque value to the load in SolidWorks software and brings back the position of the load for each time slice. The time slice is the smallest update rate. For example, Kinetix 6000 drives have the smallest update rate of ms. This position feedback is used to compute the position error and to plot the various feedbacks such as load position, load velocity, position errors, for example. Figure SolidWorks Integration Use these tips before clicking SolidWorks Integration: A SolidWorks Assembly must be open in SolidWorks software before the SolidWorks Load Definition dialog box opens. A SolidWorks Motion Study must be set up before opening SolidWorks Load Definition dialog box. SolidWorks Force element must be defined in the SolidWorks Motion Study before integration. Define reference geometry in SolidWorks software to define the axis of rotation for the component the SolidWorks force is attached to. Using component faces to attach SolidWorks force will work, but may inadvertently define motion about an incorrect location for some mechanisms. Follow these steps to improve solver speed. 1. Click Motion Study Properties on the SolidWorks Motion Study explorer bar. 236 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

237 Understanding Your System Solution Chapter 3 2. Clear the Animate during simulation check box. This increases the speed of the solver (and in turn the speed of Dynamic Simulation) since SolidWorks software is not attempting to show the motion of the assembly while performing calculations. Animation is not necessary because it can be played after the study has been calculated. 3. Set Frames per second to This should match the smallest update rate of the Kinetix 6000 drive (0.125 ms). 4. Click SolidWorks Integration (Figure 175) to open the SolidWorks Load Definition dialog box. The Dynamic Simulation launches the SolidWorks Load Definition dialog box and displays the model that is open in SolidWorks software: The SolidWorks assembly must be open in SolidWorks software before the SolidWorks Load Definition dialog box will open. The SolidWorks file must be an assembly and not simply a part. Only one instance of SolidWorks software may be running in order for integration to work. Rockwell Automation Publication MOTION-UM004B-EN-P - October

238 Chapter 3 Understanding Your System Solution 5. Click Refresh when changes are made to the associated SolidWorks model to make sure Motion Analyzer software is interfacing with the most recent version of the SolidWorks assembly. 6. After verifying that this is the correct model, select the desired motion study and force element. Table SolidWorks Load Definitions Options Selected SolidWorks Assembly Selected SolidWorks Study SolidWorks Force Element Displays the location of the selected SolidWorks model. From the pull-down menu, select the desired SolidWorks motion study from the existing motion studies in the currently selected assembly. From the pull-down menu, select the SolidWorks force element. 7. Click OK to confirm the desired selections and go back to Dynamic Simulation. 8. Click Run Simulation to invoke SolidWorks based simulation. 9. Click Stop Simulation to stop the analysis. 238 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

239 Understanding Your System Solution Chapter Simulation Analysis Simulation Analysis lets you invoke simulation and analyze various reports displayed as plots and data. It also lets you enter control loop gains in the Control Loop Diagram tab. Figure Simulation Analysis Dialog Box Table Simulation Analysis Tab Definitions (refer to Figure 176) Options Page Simulation Plots Graphical representation of the simulation output data. 240 Simulation Data Control Loop Diagram Displays the simulation output data in a tabular format and provides data export. Displays control loop diagram of motion control system. You can enter loop gain and other parameters here Rockwell Automation Publication MOTION-UM004B-EN-P - October

240 Chapter 3 Understanding Your System Solution Simulation Plots Simulation plots can be drawn and displayed for position, velocity, and torque. Figure Simulation Plots Tab 240 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

241 Understanding Your System Solution Chapter 3 Table Simulation Plots Tab Definitions Options Position (label 1 in Figure 177) Velocity (label 2 in Figure 177) Torque (label 3 in Figure 177) Motor Position Target Position Load Position Position (Δ): Target-Motor Position (Δ): Target-Load Position (Δ): Motor-Load Motor Velocity Target Velocity Load Velocity Velocity Reference Velocity (Δ): Target-Motor Velocity (Δ): Target-Load Velocity (Δ): Motor-Load Target Torque Motor Torque (Default ON) Position of the motor, measured by the feedback device. (Default ON) Position target from motion planner in the controller to the drive. Simulated position of the load. (Default ON) Difference between Command Position and Actual Position (when simulation Position Feedback is the same as Actual Position). Difference between Command Position and Load Position. Difference between Actual Position and Load Position. (Default ON) Velocity of the motor. Velocity command in the drive (output of position loop plus velocity feed forward). Simulated velocity of the load. Velocity command in the drive (magnitude & rate limited) Difference between Command Velocity and Velocity Feedback (velocity feedback is a filtered derivative approximate of position feedback). (Default ON) Difference between Command Velocity and Load Velocity. Difference between Actual Velocity and Load Velocity. (Default ON) Torque target in the drive. (Default ON) Actual Motor Torque. Figure Position Plots Figure Velocity Plots Rockwell Automation Publication MOTION-UM004B-EN-P - October

242 Chapter 3 Understanding Your System Solution Figure Torque Plots Use check boxes to show or hide the simulation curves. From the color pull-down menu, choose a color for each plot. Figure Simulation Plot Pens The software displays up to four plots at a time. If there are more than four curves, then use pull-down menus to select desired plot. The selected plots are dimmed in the pull-down menus. Figure Choose Curves to Plot 242 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

243 Understanding Your System Solution Chapter Simulation Data The Simulation Data tab displays the simulation output data in a tabular format and provides data export. Figure Simulation Data Tab Table Simulation Data Options Options Simulation Data Filters (label 1 in Figure 183) Data Grid (label 2 in Figure 183) Export Data (label 3 in Figure 183) As there are numerous records of simulation output data, the following data filters can be used to view more records. Time Step Use to increase or decrease the time step to view records in larger or small time spans. Time Span Apply Define start and end time of the records being displayed in the grid. Click to see your changes in the data grid. Displays the simulation data records. Up to 10,000 records are shown. Click to launch the Export Data dialog box (refer to Figure 184). Rockwell Automation Publication MOTION-UM004B-EN-P - October

244 Chapter 3 Understanding Your System Solution You can select the export settings (such as data elements, time step, time span, units, delimiter, and target location for the file export) before exporting the simulation data. Figure Simulation Data - Export Data 244 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

245 Understanding Your System Solution Chapter Control Loop Diagram The Control Loop Diagram tab is a graphical representation of the control loops. You can enter loop gains and other parameters, just as in the Control Loop Gains and other Parameters window (refer to page 246). Figure Control Loop Diagram Tab If you enter any gains parameters here, it also updates in the Control Loop Gains and other Parameters window. Figure Updating Loop Gains Rockwell Automation Publication MOTION-UM004B-EN-P - October

246 Chapter 3 Understanding Your System Solution Control Loop Gains and other Parameters Control loop gains and other parameter windows let you manually enter control loop gains or perform auto-tuning. Figure AutoTune Options (expanded) AutoTune Options simulate the Logix function by setting the Load Inertia Ratio and the appropriate gains based on measured system inertia. As per the Logix convention, there are five different application types for AutoTune. Selecting an application type selects the gain parameters. Table AutoTune Options (refer to Figure 187) Options Basic Constant Speed Point to Point Tracking Custom Damping Ratio Position Bandwidth When selected, position proportional and velocity proportional gains and load inertia ratio are calculated. When selected, velocity integral and velocity feedforward are calculated apart from the position proportional, velocity proportional, and load inertia ratio. When selected, position integral is calculated apart from the position proportional, velocity proportional, and load inertia ratio. When selected, velocity integral, velocity feedforward, and acceleration feedforward are calculated apart from the position proportional, velocity proportional, and load inertia ratio. Use for custom/manual selection of the gain parameters to be calculated. The default damping ratio value is 0.8. This is the classic single-overshoot setting. Higher values cause the system to be softer. This may help if the standard value results in an axis that is too hot or even unstable. This sets to the default for the drive/motor combination selected. It may be overridden downwards to soften the response or get to a stable condition. 246 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

247 Understanding Your System Solution Chapter 3 You can perform AutoTune in the collapsed state also. This state shows the selected application types and parameters to be autotuned. Figure AutoTune Options (collapsed) Figure Output Parameters Table Output Parameter Options (refer to Figure 189) Options Load Inertia Ratio Torque Offset Low Pass Filter Notch Filter Ratio of load inertia over motor inertia. Used to inject a constant torque command into the torque loop, typically used to offset gravity. Used to limit the torque command frequency response. Used for eliminating a spot frequency. When you change parameters in any section, Reset appears in the title bar of that section. For example, the Test Disturbances section is shown in Figure 190. Click Reset to reset all parameters to default values. Figure Reset Feature Rockwell Automation Publication MOTION-UM004B-EN-P - October

248 Chapter 3 Understanding Your System Solution Figure Position and Velocity Gains Table Position and Velocity Parameter Options (refer to Figure 191) Options Position Gain Velocity Gain Proportional Gain Integral Gain Proportional Gain Integral Gain Figure FeedForward Options Position proportional gain creates a velocity reference proportional to position error. In Logix this is actually Position Loop Bandwidth (regardless of system inertia). The unit of proportional gain is radians/s. Position integral gain creates an increasing velocity reference when any position error exists. Velocity proportional gain creates a torque reference proportional to velocity error. In Logix this is actually Position Loop Bandwidth. Velocity integral gain creates an increasing torque reference when any velocity error exists. Integral Hold Integral Hold When checked, the integral terms are ignored if command velocity is zero. Table FeedForward Parameter Options (refer to Figure 192) Options Velocity Feedforward Acceleration Feedforward Velocity feedforward creates a velocity reference equal to the theoretical value required. It reduces position error to zero at constant velocity. Acceleration feedforward creates a torque reference equal to the theoretical value required. It reduces position error to zero at constant acceleration. Figure Limits Table Limits Parameter Options (refer to Figure 193) Options Position Error Tolerance Position Lock Tolerance Two red lines are displayed if the magnification is appropriate. Two green lines are displayed if the magnification is appropriate. If this value is exceeded, the axis decelerates to zero speed at peak torque. When Position Lock Tolerance is exceeded, a warning icon appears next to it. When you mouse over the icon, a message also appears (Limit for Lock tolerance). 248 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

249 Understanding Your System Solution Chapter Segment Data Click Segment Data to view various system parameters for each individual profile segment. Figure Segment Data Dialog Box The Initial and Final Velocity, Acceleration, Position, Time, Thrust, and Load values are listed by profile segment in the Segment Data table. Various system parameters are listed for the selected profile segment in the Segment Analysis window. The overall motion profile is displayed in the Segment Profile window. Click Return to exit. Rockwell Automation Publication MOTION-UM004B-EN-P - October

250 Chapter 3 Understanding Your System Solution 3.3. Axis Stop The Axis Stop tab is used to determine the time and distance that the system takes to come to a stop. Figure Axis Stop Dialog Box For each profile segment, Motion Analyzer software finds the highest velocity and evaluates the time and distance the axis takes to stop from that speed using the maximum available axis current (for example, at maximum permissible current limit for the axis). Motion Analyzer software displays the worst possible scenario Controlled Stop The critical time and distance for the motion profile for each axis are captured and displayed in the Controlled Stop section of the tab. This gives the machine designer a guide when determining over-travel limits. These figures are a guide and do not necessarily show the worst possible case. In a runaway situation or if the motion programming is faulty, the axis may hit an over travel limit at a higher speed than those used in this calculation. Similarly, if the real load is greater than that used in this calculation, the stopping time and distance will be greater. The machine designer must perform a risk analysis of such situations. The Drive Capacity (Temp) bar changes color depending on the capacity percentage; for 80%, the bar is yellow, and for 100% the bar is red. Click Details to view the Controlled Stop Details dialog box. The Deceleration Distance on both the motor and load sides, Deceleration Time, Amplifier Utilization, and Energy Absorbed starting and ending values are displayed for each profile segment. 250 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

251 Understanding Your System Solution Chapter 3 Figure Controlled Stop Details Dialog Box Table Controlled Stop Details Properties (refer to Figure 196) Parameters Decel Distance Decel Time Amplifier Utilization Energy Absorbed This is the critical deceleration distance. It is common to find that the mechanical design does not allow enough distance to stop, if a fault occurs at the end of normal travel. This display helps to predict the required distances on both the motor side and the load side. The time required to come to a complete stop. This mimics the internal drive protection algorithm. In the event that 100% is exceeded, the drive faults and the motor coasts to a stop. This is an indication of the energy that must be handled during a controlled stop and may help to size dump resistors. IMPORTANT Amplifier utilization is critical because it may indicate that a bigger drive is necessary to achieve the required stopping time and/or distance. Rockwell Automation Publication MOTION-UM004B-EN-P - October

252 Chapter 3 Understanding Your System Solution Resistive Brake Module Check Resistive Brake Module to enable selection and analysis of resistive brake modules (RBM). RBM modules provide controlled motor braking by connecting resistors across the windings. An RBM module does not stop the motor if the axis has a thrust, an external force, or a gravity force as a result of being inclined. The RBM module only produces motor torque if the motor is moving and may act as a speed limiter. When this happens, it is essential to use a fail-safe brake. The motor brake may not be sufficient to stop the system and should not be applied when it is in motion. The stopping behavior depends on the initial velocity, inertia, contactor delay, and the value of resistance in the RBM module. This tab enables you to select the optimum resistive brake module. Table Resistive Brake Module Properties (refer to Figure 195) Parameters Resistive Brake Modules Start Speed Plot Time Select the Max. Appl. Speed option if you are sure this value cannot be exceeded. Select the Max. Motor Speed option for a high level of security. This is generally the worst case scenario. This sets the time scale for the distance calculation and graphical display. To zoom in on the left-hand end of the graph, decrease the Plot Time. Increase the Plot Time if the system has not stopped, to evaluate longer stopping times, and to view the ultimate speed when not stopping Load Data Table Load Data Properties (refer to Figure 195) Parameters Load Data Mechanism Data User Defined Select this option to use the External Torque and Load Inertia values from the system data that has been entered in previous tabs. This is the torque on the motor produced by any external torque or force. Select this option to manually enter External Torque and Load Inertia values. In some cases, the maximum inertia/thrust may not coincide with the maximum speed. When this happens, the default (maximum speed and inertia/thrust) may produce an over-cautious solution. Advanced users may want to enter their own value for the inertia and thrust torque (with reference to the motor) for the maximum speed condition. 252 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

253 Understanding Your System Solution Chapter RBM Selection Figure Available Resistive Brake Module Dialog Box Table RBM Selection Properties (refer to Figure 195) Parameters RBM Selection Select RBM Click to produce a list of compatible resistive brake modules, with their associated distances travelled in the Plot Time. You may adjust the Plot Time by entering a new value and clicking Re-Plot. Click each resistive brake module to view the associated Speed versus Time graph. Click Apply when you determine the optimum unit (refer to Figure 197). Details Click to open the Resistive Brake Module Data dialog box (refer to Figure 198). Rockwell Automation Publication MOTION-UM004B-EN-P - October

254 Chapter 3 Understanding Your System Solution Click the Speed-Time, Torque-Time, and Distance-Time tabs to view graphs for the selected resistive brake module. You may also view parameters for a custom resistive brake module. Figure Resistive Brake Module Data Click Product Catalog to view product specifications. Figure RBM Module Product Specifications 254 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

255 Understanding Your System Solution Chapter Apply RBM Selection The initial period (70 ms) allows for the contactor change-over. The speed may stay the same or increase if there an external load during this time and torque will be zero. The peak torque depends upon the speed and may peak at a medium speed, being less at higher and lower speeds. Check for distance continuing to increase over a long period of time, which indicates a non-stopping condition. Figure Axis May Not Stop Message This error message indicates that the axis speed has not fallen close to zero in the allotted time. This may apply to all resistive brake modules or only some of them. Increase the allotted time to analyze further. There are several possible outcomes: Axis may stop with a longer time. Axis speed may reduce but not stop. Be careful to note if the axis speed has really become zero and not a low speed make sure that the position graph is not increasing. Axis speed may increase to a sustained higher level. Axis may run-away; the speed may continue to increase. Rockwell Automation Publication MOTION-UM004B-EN-P - October

256 Chapter 3 Understanding Your System Solution 3.4. Life Estimate The Life Estimate tab provides information on the life and bearing load utilizations for electric cylinders. Figure Life Estimate Dialog Box Table Life Estimate Properties Parameters Operating Conditions (label 1 in Figure 201) Normal Forces and Moments (label 2 in Figure 201) Life Estimate (label 3 in Figure 201) Bearing Load Utilization (label 4 in Figure 201) Lubrication Schedule (refer to Figure 202) Strip Seal Life Estimate (refer to Figure 203) The Hours per Day, Days per Week, and Weeks per Year assumptions are listed here. You can adjust these values by clicking Change Operating Conditions. To calculate the cylinder bearing load utilization, it is necessary to specify the mechanical forces and moments applied to the moving part of the cylinder. All loads must be separately guided and supported. Loads should align along the line of thrust throughout the complete stroke of the cylinders. If residual radial or torsional loading cannot always be eliminated, enter these expected values here to help determine if the loading exceeds the recommended limits of the cylinder. If so, counter measures such as a rod-guide accessory and/or an adjustment to loading and mechanical connections may be necessary. These values are not entered if a rod guide is used. Normal Forces These forces are applied at right angles both horizontally and vertically to the end of the cylinder as shown in the diagram. Normal Distances These distances are from the end of the cylinder where each normal force is applied. Moments These moments are applied to the cylinder in the three planes. They are in addition to any normal forces. The roller screw or ball screw life estimate (depending on the linear actuator type) is listed here. This information is available for Bulletin MPAI and MPAR linear actuators. The normal force and moment utilization (Fz, Fy, Mz, My) and moment utilization (Mx) are displayed here as percentages. Applies to Bulletin MPAI electric cylinders. Applies to Bulletin MPAS linear stages. The Slide Bearing Life Estimate and Strip Seal and Cable Track life estimate is also listed. 256 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

257 Understanding Your System Solution Chapter 3 Figure Lubrication Schedule (Bulletin MPAI actuators only) Figure Strip Seal Life Estimate (Bulletin MPAS linear actuators only) Rockwell Automation Publication MOTION-UM004B-EN-P - October

258 Chapter 3 Understanding Your System Solution 3.5. Configure Axis BOM You can complete the Bill of Materials (BOM) for each axis after fully sizing the application by clicking on the Configure Axis BOM tab. You can configure the motor encoder, and choose connectors, cables, and drive accessories here. Many options are already configured in Motion Analyzer software, as these are required for sizing and cannot be changed in the BOM. These options include, for example, brake, cover, rod guide, or blower. Throughout the steps, use More Info or the Product Details links for more information or refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001, to access the relevant product specifications. Figure Configure Axis BOM Dialog Box 258 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

259 Understanding Your System Solution Chapter 3 Table Configure Axis BOM Parameters Step 1 Motor/Actuator (refer to Figure 204) Step 2 Accessories Step 3 Axis Module/Drive/IAM Step 4 Motor/actuator power cable Step 5 Motor/actuator feedback cable Step 6 Motor/actuator brake cable Step 7 Resistive brake module Step 8 Resistive brake module cables Select the options required. Options that are not available are dimmed. Standard options are shown by default. Encoder Options From the Encoder Options pull-down menu, choose the encoder type for your motor. Brake and Key Mounting Flange Miscellaneous Options The brake is chosen during sizing on the Motor tab. The shaft key will be selected if it is available. Some motors have different mounting options. Different motors and actuators have various options that can be selected. Some options such as blowers and covers, for example, affect sizing and have been selected in the sizing process. Select motor and actuator accessories. The rod guide for electric cylinders was selected during sizing. Check for connector kit. Check non-flex or continuous-flex cable and cable length options. The length selected for the power cable is used for the other cables, unless the lengths are individually changed. Check non-flex or continuous-flex cable, cable length, and flying-lead or connector at drive-end options. Check non-flex or continuous-flex cable and cable length options. For most motors, separate brake cable is not required because brake wires are included in the power cable. Resistive Brake Module for the application is selected in the Axis Stop tab on page 250 and cannot be changed here. Specify cable AWG size and cable length options. Rockwell Automation Publication MOTION-UM004B-EN-P - October

260 Chapter 3 Understanding Your System Solution 3.6. Super Review Click the Super Review tab to review the overall application parameters that were entered or calculated in the previous tabs. There are two options for viewing the Super Review dialog box. Table Super Review Tab Options Parameters Page Summary View Provides summary data and plot profile for the application. 260 Details View Provides segment data in table form from all review locations Summary View The summary view displays data and the plot profile of your choice. Figure Summary View Dialog Box Table Summary View Properties Parameters Review Location Summary Data Plot From the Review Location pull-down menu, choose the point in the system where you would like to review the data. These parameters are listed for the chosen Review Location: Maximum Velocity Total Time Maximum Inertia Maximum Acceleration Total Distance RMS (root mean squared) Torque Select the graph type to display: Profile/Load-Time Graph on page 261. Show Force-Speed Graph on page 263. Show Power-Speed Graph on page Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

261 Understanding Your System Solution Chapter Profile/Load-Time Graph The Profile/Load-Time graph is divided into two sub-windows. In the explanation that follows, the Show Profile/Load-Time graph is used in the example. The Plot Parameters sub-window appears to the left of the Main Profile Plot window. Click the arrows, left of the Main Profile Plot window, to open it. Click the arrows again to close the window. Clicking the motion curves (for example, Distance or Velocity) toggles them on and off. From the motion curve pull-down menu, you can change the color for the curve in both the Main Profile Plot window and the Segment Plot window. Figure Plot Parameters In addition, as you hover over the Main Profile Plot window with the mouse pointer, the Plot Parameters sub-window provides a display of the numeric values of the time (x-axis), and active motion curves (y-axis) associated with the mouse pointer position. Figure Main Profile Plot X and Y-axis Values Rockwell Automation Publication MOTION-UM004B-EN-P - October

262 Chapter 3 Understanding Your System Solution The Profile Zoom Plot sub-window appears below the Main Profile Plot window. Click the arrows, below the Main Profile Plot window, to open it. Click the arrows again to close the window. The Profile Zoom Plot window contains a slider that you can move along the motion profile by clicking and dragging it. As the slider moves, the Main Profile Plot window displays a magnified view of the portion of the plot that is selected by the slider. You can resize the slider by clicking and dragging from either edge. Figure Profile Zoom Plot Window Right-click the Profile Zoom Plot sub-window to display these options. Figure Profile Zoom Plot Options Table Profile Zoom Plot Options Parameters Grid Color Select Normal, Fine, or Remove grid. Adjust the background, curve, and grid colors. 262 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

263 Understanding Your System Solution Chapter Show Force-Speed Graph The force versus speed curve is displayed below. Table Show Force-Speed Graph Options Parameters Force-Speed Options RMS Force Plot Force Curve Select how to view the data: Summary, All Segments, or Elementwise. Check to include the RMS (root mean squared) force on the plot. Check to display the Force Curve Show Power-Speed Graph The power versus speed curve is displayed below. Table Show Power-Speed Graph Options Parameters Power-Speed Options Plot Power Speed Curve Select how to view the data: Summary, All Segments, or Elementwise. Check to display the Power Speed Curve. Right-click one of the plots to choose any of the following options. Rockwell Automation Publication MOTION-UM004B-EN-P - October

264 Chapter 3 Understanding Your System Solution Figure Segment Plot Dialog Box Table Graph Options Parameters Reset Zoom Resets the zoom to 1x. Zoom Lets you zoom in 1x, 2x, 6x or 8x. Grid Select Normal, Fine, or Remove grid. Color Adjust the background, curve and grid colors. Show Curve Select which curves you would like to display on the plot (for example, Distance or Velocity). Show Y Axis Toggle the Y-axis labels on and off when more than one curve is shown. This option is only available on the Profile Plot. 264 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

265 Understanding Your System Solution Chapter Details View The Details view of the Super Review tab provides a table that contains position, time, velocity, acceleration, inertia, and various torque values for each Review Location (Load, Motor, and Drive, for example) and for individual profile segments. Figure Details View Dialog Box Table Details View Options Parameters Select Segment Export Data From the pull-down menu, choose All Segments or a specific profile segment to view in the table. You can view the segment data for each Review Location by clicking + to expand the Review Location. Click the Export Data link to save the Super Review data as a CSV (Comma Separated Variable) file. Rockwell Automation Publication MOTION-UM004B-EN-P - October

266 Chapter 3 Understanding Your System Solution Notes: 266 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

267 Chapter 4 Just Quote Topic Page Axis View 268 IPIM Power Supply/ Accessories View 272 Power Supply and Accessories 273 Rockwell Automation Publication MOTION-UM004B-EN-P - October

268 Chapter 4 Just Quote 4.1. Axis View For each axis, enter the required drive family, motion type, and motor/actuator series and associated optional components by clicking BOM Configuration. Figure Axis View Dialog Box Table Drive and Motor/Actuator a Families Parameter Product Family (step 1 in Figure 212) Motion Type (step 2 in Figure 212) Motor/Actuator Series (step 3 in Figure 212) From the pull-down menu, choose the drive family for your motion application. Rotary Motion includes, for example, low-inertia servo motors and direct-drive motors Linear Motion includes, for example, linear motors, linear stages, and electric cylinders MP-Series includes: Bulletin MPL, MPM, MPF, MPS rotary motors Bulletin MPAS and MPMA linear stages Bulletin MPAR and MPAI electric cylinders TL-Series includes: Bulletin TL and TLY rotary motors Bulletin TLAR electric cylinders Integrated Drive-Motor include Bulletin MDF rotary drive-motor units 268 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

269 Just Quote Chapter 4 Figure Axis View (continued) Table Motor/Actuator Options Parameter Options Cat. No. From the pull-down menus choose the options available for your rotary or linear motion product. Scroll to select from the valid catalog numbers for your rotary or linear motion product. Figure Axis View (continued) Table Axis Module Options Parameter Cat. No. Connector Kits Scroll to select from the valid servo drive catalog numbers. Check to indicate the connector kit for your IAM (converter and inverter) or AM (inverter only) modules. Rockwell Automation Publication MOTION-UM004B-EN-P - October

270 Chapter 4 Just Quote Figure Axis View (continued) Table Motor Power Cable Options Parameter Motor Power Cable (standard) Motor Power Cable (continuous-flex) Check and from the pull-down menu, choose the length for your drive and motor/actuator (standard) power cable. Check and from the pull-down menu, choose the length for your drive and motor/actuator (continuous-flex) power cable. Figure Axis View (continued) Table Motor Feedback Cable Options Parameter Motor Feedback Cable (standard) Motor Feedback Cable (standard) Motor Feedback Cable (continuous-flex) Check and from the pull-down menu, choose the length for your drive and motor/actuator (standard) feedback cable with premolded connector on the drive end. Check and from the pull-down menu, choose the length for your drive and motor/actuator (standard) feedback cable with flying-leads on the drive end. Check and from the pull-down menu, choose the length for your drive and motor/actuator (continuous-flex) feedback cable. 270 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

271 Just Quote Chapter 4 Figure Axis View (continued) Table Motor Brake Cable Options Parameter Motor Feedback Cable (standard) Motor Feedback Cable (continuous-flex) Check and from the pull-down menu, choose the length for your drive and motor/actuator (standard) brake cable. Check and from the pull-down menu, choose the length for your drive and motor/actuator (continuous-flex) brake cable. Figure Axis View (continued) Table Resistive Brake Module (RBM) Cable Options Parameter Resistive Brake Module Resistive Brake Module Cable Select none, or the catalog number for your motion application. Check and from the pull-down menu, choose the length for your drive and motor/actuator (standard) RBM cable. When finished click System View, or use the Axis View pull-down menu to configure the next axis. Rockwell Automation Publication MOTION-UM004B-EN-P - October

272 Chapter 4 Just Quote 4.2. IPIM Power Supply/ Accessories View Power Supply Accessories view of an IPIM module helps you select options for hybrid and network lengths, hybrid coupler cables, and bulkhead adapters. Figure IPIM Module Selection Table Configure IPIM Module BOM Tab s Options Step 1 (Figure 219) IPIM module IPIM module selected on the IPIM Module tab is displayed here. Step 2 (Figure 219) Hybrid cables Hybrid cable lengths selected on the Cable Lengths tab are displayed here. Step 3 (Figure 219) Network cables Network cables can be routed with the hybrid cables, so network cable lengths should be the same as the hybrid cable. The IPIM-to-IDM1 cable must have a straight connector to the IPIM module. Step 4 (Figure 219) Hybrid coupler The hybrid coupler connects between two hybrid cables, to bypass an IDM unit. Step 5 (Figure 220) Network bulkhead adapter Figure Configure IPIM Module BOM Tab Use the network bulkhead adapter for securing network cables as they pass through the cabinet. 272 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

273 Just Quote Chapter Power Supply and Accessories Click Power Supply/Accessories to select all the power supply components. This includes any back plane, fuse, contactor, LIM module, or Shunt module. Some filtering of suitable units is arranged according to the other components selected. The power rail field populates based on the number of slots required. Rockwell Automation Publication MOTION-UM004B-EN-P - October

274 Chapter 4 Just Quote Notes: 274 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

275 Index A AC sharing configuration 56 acceleration 168 actuator tab 225 additional parts tab 39 additional resources 5 advanced templates 104 allocate 16 analysis tab 33 application template 96 advanced four bar linkage 114 inertia calculator 105 winder/unwinder 112 applied force 83 automatic profile 171 selection 207 autotune 246 axis histograms 30, 47 of rotation 91 options 269 stop 250 controlled stop 250 load data 252 resistive brake module 252, 253 summary image 25 B backlash 234 ball screw life 62 bearing life 62 belt drive 180 BOM tab 40, 76 C carriage cut off 100 center driven 113 chain and sprocket 182 coefficient of friction 83 comments window 154 complex rotary load template 90 crank 93 unbalanced load 91 user defined 90 compliance 235 compute transmission data using inertia and ratio 193 number of teeth 195 pitch circle diameter 194 configuration summary tab 37 configure axis BOM 258 IPIM BOM tab 45 power supply BOM tab 35 control loop diagram 245 gains 246 controlled stop 250 conventions 5 counterbalance 84 force 85 mass 85 coupling type backlash 234 compliance 235 rigid coupling 234 crank 93 cruise/dwell 170 cut length analysis 221 cutter knife drive 102 D damping ratio 235 data analysis toolbar 218 cut length analysis 221 dynamic simulation 230 efficiency analysis 227 energy tab 229 power tab 228 ratio analysis 220 ratio/design analysis 219 segment data 249 tolerance/design analysis 222 torque tab 227 DC sharing configuration 52 deceleration 168 define your profile 139 less options profile editor 140 more options profile editor mode 142 derived parameters 153 details view 265 download Motion Analyzer 5 dwell time 140 dynamic simulation 230 control loop gains 246 simulation analysis 239 simulation inputs 231 E efficiency analysis 227 electric cylinders 186 selection 199 empty diameter 113 inertia 113 end effector 82 energy tab 34, 229 Rockwell Automation Publication MOTION-UM004B-EN-P - October

276 Index error list window 155 explorer view 78 export/import tab 65 axis mapping 67 export mapping 67 export options 66 RSLogix external force 147 F feedforward 248 file tab 15 force counterbalance 85 four bar linkage 114 from SolidWorks 120 G gearbox data 196 graph tab 226 view 28 graphical view 17 group view 22 H help tab 76 home tab 16 axis summary image 25 graph view 28 graphical view 17 power interface module (IPIM) view 20 power rail view 18 group view 22 multiple profile view 26 top band fields 27 power rail image 24 power supply/accessories view analysis tab 33 configure IPIM BOM tab 45 configure power supply BOM tab 35 energy tab 34 IAM control power tab 32 IAM/shunt tab 31 IDM cable length tab 43 IDM control power tab 44 IDM power data tab 41 IPIM selection tab 42 multi-axis drives 29 power data tab 30 single-axis analysis tab 48 single-axis config PS BOM tab 50 single-axis drive systems 46 single-axis energy tab 49 single-axis power tab 47 single-axis shunt tab 47 system BOM view 36 system bill of materials view additional parts tab 39 BOM tab 40 configuration summary tab 37 software and accessories tab 38 I IAM control power tab 32 IAM/shunt tab 31 IDM cable length tab 43 control power tab 44 power data tab 41 inclination 83 independent axis workflow 122 index advance 173 profile 171 type 140 inertia calculator 105 less options inertia mode 106 more options inertia mode 107 SolidWorks import 109 inter-dependent axis workflow 131 IPIM selection 272 selection tab 42 J jerk 169, 177 just quote 13 accessories view IPIM selection 272 axis view axis options 269 motor brake cable options 271 motor feedback cable options 270 motor power cable options 270 motor/actuator options 269 product family 268 RBM cable options 271 power supply accessories view 273 just quote mode 22 L lead screw 181 less options inertia mode 106 less options profile editor 140 life estimate 256 operating conditions 62 limits 248 linear load 83 counterbalance 84 motors 184 stages 187 thrusters 189 load data 252 Motion Analyzer Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

277 Index load type tab 82, 224 application template 96 advanced 104 carriage cut off 100 cutter knife drive 102 power/speed 118 press roll feed 97 from SolidWorks 120 linear load 83 rotary complex load 87 rotary load 86 Logix elements 174 M MAM profile 176 manual selection 208 mass counterbalance 85 mechanism type 178 belt drive 180 chain and sprocket 182 electric cylinders 186 lead screw 181 linear motors 184 stages 187 thrusters 189 rack and pinion 183 menu bar 14 BOM tab 76 explorer view 78 export/import tab 65 file tab 15 help tab 76 home tab 16 preferences tab 62 mode just quote 22 less options inertia 106 less options profile editor 140 more options inertia 107 more options profile editor 142 select and size 22 more options profile editor 142 comments window 154 derived parameters 153 error list window 155 profile grid 152 profile plot 149 profile toolbar 145 segment load window 147 segment parameters window 167 segment plot window 148 Motion Analyzer download 5 existing 13 just quote 13 new 13 motion axis move (MAM) 176 motor brake cable options 271 feedback cable options 270 power cable options 270 selection 196 motor/actuator options 269 motoring 30, 47 move distance 140 move time 140 multiple profile view 26 N natural frequency 235 P payload animation 147 mass 147 power data tab 30 tab 228 power interface module (IPIM) view view 20 power rail image 24 view 18 power sharing configuration 51 power supply accessories view 273 power/speed template 118 preface additional resources 5 conventions 5 preferences tab 62 preferred product 210 preferred product status 210 press roll feed 97 profile automatic 171 grid 152 MAM 176 mirror 113 plot 149 tab 223 toolbar 145 trapezoidal 171 triangular 171 ProposalWorks application 210 Q quick access toolbar 14 R rack and pinion 183 ratio analysis 220 ratio/design analysis 219 RBM cable options 271 Rockwell Automation Publication MOTION-UM004B-EN-P - October

278 Index regenerating 30, 47 reported application inertia 212 reported motor inertia 212 resistive brake module 252 selection 253 rigid coupling 234 roller screw life 62 rotary complex load 87 rotary load 86 S S-curve 113 segment data 249 load window 147 parameters window acceleration/deceleration 168 cruise/dwell 170 index advance 173 index profile 171 Logix elements 174 motion axis move (MAM) 176 start condition 168 plot window 148 select and size mode 22 selection 206 automatic 207 manual 208 servo drive selection 201 simulation analysis 239 control loop diagram 245 simulation data 243 simulation plots 240 data 243 inputs 231 Motion Analyzer load 233 SolidWorks load 236 plots 240 single-axis analysis tab 48 config PS BOM tab 50 drive systems 46 energy tab 49 power tab 47 shunt tab 47 sizing and selection 206 sizing your system axis stop 250 configure axis BOM 258 define your profile 139 electric cylinders selection 199 life estimate 256 load type tab 82 mechanism type 178 motor selection 196 selection 206 servo drive selection 201 solution 208 torque/speed curve 211 super review 260 transmission 191 smoothness 140 software and accessories tab 38 software requirements 5 SolidWorks software import 109 independent axis workflow 122 inter-dependent axis workflow 131 load 236 solution 208 data analysis toolbar 218 start condition 168 stiffness 235 strip seal life 62 summary view 260 super review 260 details view 265 summary view 260 surface driven 113 system BOM view 36 T templates 90 tolerance/design analysis 222 actuator tab 225 graph tab 226 load type tab 224 profile tab 223 torque tab 227 torque/speed curve 211 transmission 191 compute using inertia and ratio 193 number of teeth 195 pitch circle diameter 194 trapezoidal profile 171 triangular profile 171 U unallocate 16 unbalanced load 91 unwind 113 user defined 90 W web speed 113 tension 113 wind 113 winder/unwinder 112 zoom 140 Z 278 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

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280 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at for FAQs, technical information, support chat and forums, software updates, and to sign up for product notification updates. For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnect SM support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit Installation Assistance If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running. United States or Canada Outside United States or Canada Use the Worldwide Locator at or contact your local Rockwell Automation representative. New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures. United States Outside United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process. Please contact your local Rockwell Automation representative for the return procedure. Documentation Feedback Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002, available at Publication MOTION-UM004B-EN-P - October 2012 Supersedes MOTION-UM004A-EN-P - May 2012 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.