Application Notes for ASDA Series Servo Drive

Application Notes for ASDA Series Servo Drive
Application Notes for ASDA Series Servo Drive
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Asia
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*We reserve the right to change the information in this catalogue without prior notice.
Application Notes for
ASDA Series Servo Drive
DELTA_IA-ASD_ASDA-Series_AN_EN_20150324
www.deltaww.com
Preface
About this application notes
This notes provide basic application examples and settings that apply to ASDA-A2 servo drive.
The content includes:
Note:

PR Operation

E-Cam Operation

Application Examples

Application Techniques
1.
Please refer to ASDA series user manual for detailed description of parameters.
2.
Please refer to ASDA series user manual for detailed description of system
framework and motion control mode.
3.
Please refer to ASDA-Soft user manual for detailed
description about using the ASDA-Soft.
Personnel
This document is for personnel who have already purchased ASDA series servo drive or
engineers and technicians who use ASDA series servo drive to configure the product.
If you have any enquiry, please contact the distributors or DELTA customer
service center.
[email protected]
Important Notice

Different device has different features and operational ways. Technical personnel who is in
charge of operating the software shall implement appropriate measures and follow the
instructions of the user guide.

This manual mainly focuses on settings of ASDA-A2 servo drive when it is applied to
different types of machine. Please follow the instructions and notices of the machine which
is applied. Delta shall not be liable for the indirect, derivative, subsidiary, or related loss
caused by inappropriate operation of machine.

Delta will not take responsibility for the results of unauthorized modifications of this product.
Delta shall not be liable for any damages or troubles resulting from unauthorized
modification.

The drawings, figures, values and content presented in this application notes are typical
examples and are only used for functional description. However, there must be different
demands and variations in practical operation and settings. Configurations shall be
changed in accordance with the real applications. It is not suggested to use the same
setting values in the example of this notes. Delta will not take responsibility for the direct or
indirect loss caused by the system configuration of different applications.

No patent liability is assumed with respect to the use of the information contained herein.

No part of this work may be reproduced in any form (by photocopying, microfilm or any
other method) without the written permission of Delta.

Technical changes which improve the performance of the device may be made. Delta has
the right to change the definition and contents of this application notes.
Safety Precautions
To your safety, please pay special attention to the following safety precautions
before using this application notes.
The symbol of danger, warning and stop represent:
It indicates the potential hazards. It is possible to cause severe injury or fatal harm if not
follow the instructions.
It indicates the potential hazards. It is possible to cause minor injury or lead to serious
damage of the product or even malfunction if not follow the instructions.
It indicates the absolute prohibited activity. It is possible to damage the product or
cannot be used due to malfunction if not follow the instructions.
System Operation

Please follow the instruction when using servo drive and servo motor, or it is
possible to cause fire or malfunction. For instructions and safety precautions of
ASDA-A2 servo drive, please refer to its user manual. To use the relevant
parameter settings, please refer to the important notice of ASDA-Soft User Guide.

To avoid danger, please refer to the selection of wiring rod when wiring.
Wiring
Operation


Before start the machine, please set the relevant parameters properly. Failing to
set to correct value might cause malfunction of the mechanism.
Before start the machine, please check if the emergency stop can be used
anytime.
Table of Contents
Introduction of PR Operation
1.1
System Information ····················································································· 1-2
1.2
Introduction of ASDA-A2 PR Function ······························································ 1-10
1.3
Motion Control ···························································································· 1-29
1.4
Presentation of PR ······················································································ 1-39
1.5
How is PR Arranged?··················································································· 1-42
1.6
PR Setting Examples ··················································································· 1-44
Introduction of E-Cam Operation
2.1
Introduction of E-Cam ·················································································· 2-2
2.2
Source of the Master Axis ············································································· 2-5
2.3
The Clutch ································································································· 2-7
2.4
The E-gear of the Master Axis ········································································ 2-13
2.5
E-Cam Curve ····························································································· 2-14
2.6
E-gear Ratio and Scaling of E-Cam Curve ························································ 2-40
2.7
E-Cam Setting Example ··············································································· 2-42
2.8
Simultaneously Using E-Cam Function and PR Command ··································· 2-46
2.9
Troubleshooting when E-Cam is not Working Properly ········································ 2-48
Applications Examples
March, 2015
3.1
How to Use CAPTURE Function to Create an E-Cam Curve ······························· 3-4
3.2
Application to Wrapping Machine ··································································· 3-20
3.3
Application to Labeling Machine ····································································· 3-39
3.4
Printing Machine Application with Synchronization of Multiple Axes ························ 3-57
3.5
Application to Gantry···················································································· 3-64
3.6
Application Example of Packing Machine ························································· 3-83
3.7
Application of Precision Positioning via Mark Reading ········································· 3-95
3.8
Application Example of Packing Machine with Phase Alignment Function ················ 3-101
I Application Techniques
II
4.1
DO Output with Fixed Distance ····································································· 4-2
4.2
How to Use E-Cam Function to Compensate Tolerance on Ball Screw ···················· 4-8
4.3
PT Command Transferred from Analog Voltage ················································· 4-17
4.4
Speed Change during the Execution of PR Position Command ····························· 4-22
4.5
Macro for E-Cam Application ········································································· 4-26
March, 2015
Introduction of PR
Operation
1.1 System Information ............................................................................................... 1-2
1.1.1 What is System Parameter and How is it Used? .......................................... 1-2
1.1.2 Mapping Parameter ....................................................................................... 1-5
1.1.4 Data Array.................................................................................................... 1-10
1.2 Introduction of ASDA-A2 PR Function ........................................................... 1-10
1.2.1 Shared Setting List for PR ........................................................................... 1-13
1.2.2 Introduction of PR Homing .......................................................................... 1-14
1.2.2.1 Reference to Limit .............................................................................. 1-14
1.2.2.3 Reference to Z Pulse ......................................................................... 1-17
1.2.2.4 Reference to the Falling-Edge Signal on Home Sensor .................... 1-18
1.2.2.5 Reference to Current Position ........................................................... 1-20
1.2.3 PR Speed Command .................................................................................. 1-22
1.2.4 PR Position Command ................................................................................ 1-23
1.2.5 Jump Command .......................................................................................... 1-25
1.2.6 PR Write-in Command ................................................................................ 1-25
1.2.7 PR Triggering Methods................................................................................ 1-26
1.2.7.1 Trigger by DI.CTRG / POS0 ~ POS5 / STOP .................................... 1-26
1.2.7.2 Parameter P5-07 ............................................................................... 1-26
1.2.7.3 DI.SHOM............................................................................................ 1-27
1.2.7.4 Event Trigger...................................................................................... 1-27
1.2.7.5 Others CAPTURE Completed / COMPARE Completed / E-CAM
Disengaged ...................................................................................................... 1-29
1.3 Motion Control .................................................................................................... 1-29
1.3.1 Monitoring Variables Related to PR ............................................................ 1-29
1.3.3 Overlap of Commands ................................................................................ 1-34
1.3.4 Interrupt of Command ................................................................................. 1-35
1.4 Presentation of PR.............................................................................................. 1-39
1.5 How is PR arranged?.......................................................................................... 1-42
1.6 PR Setting Examples .......................................................................................... 1-44
March, 2015
1-1
Introduction of PR Operation
ASDA Series Application Note
This Chapter introduces the basic system and setup information about the ASDA-A2, providing
the background information for using the PR function. The Delta PR function in the ASDA-A2
servo drive is defined as “Program Register” or parameterized setup of sequence and built-in
motion functionality. In the last part, operation examples of PR commands will be presented to
demonstrate and prove its motion command performance.
1.1
1.1.1
System Information
What is System Parameter and How is it Used?
The purpose of system parameter is allow for configuration of functions and commands of the
servo drive, serving as a mode reference, data display, or operation conditions during operation.
On ASDA-A2 servo system, users may have a comprehensive control over the servo by reading
and writing parameters. System parameter is presented in the format of Px-xx. The first
character after the start code P is the group character and the second character is the parameter
character. See the parameter groups below:
Group 0: Monitoring parameters
Group 1: Basic parameters
Group 2: Extension parameters
Group 3: Communication parameters
Group 4: Diagnosis parameters
Group 5: Motion control parameters
Group 6: PR parameters
Group 7: PR parameters
16-bit and 32-bit parameters are included in ASDA-A2 system. Users may read and write
parameters with the following methods.
1. Panel of the servo drive: using buttons on the panel to read or write parameters.
Please refer to A2 user manual for setting detail.
Panel Display
Mode Key
Shift Key
MODE
▲
SHIFT
Set Key
Power Indicator
CHARGE
▼
SET
Down Key
Up Key
Figure 1.1 Display Panel of the Servo Drive
1-2
March, 2015
ASDA Series Application Note
Introduction of PR Operation
2. USB: Connect to a computer via USB and use ASDA-Soft (software for ASDA series
servo drive) to read or write parameters.
ASDA-Soft provides Parameter Editor for users to read or write parameters. Please refer to
ASDA-Soft User Guide for operation detail.
Figure 1.2 Parameter Editor
3. CANopen: Use CANopen fieldbus to connect to a host controller and
read/write parameters with the controller.
4. RS485/RS232: Use RS485 or RS232 to connect to a host controller and
read/write parameters with the controller.
Regarding reading and writing parameters with CANopen and RS485/RS232, it is for
editing the value for the communication address that corresponds to each parameter.
Please refer to Chapter 9 of ASDA-A2 user manual for communication protocol and
settings and Chapter 8 for communication address of each parameter which shown at the
right corner of each parameter table.
Figure 1.3 Communication Address of Parameter
March, 2015
1-3
Introduction of PR Operation
ASDA Series Application Note
5. PR: Edit parameters by triggering PR event.
Use write-in function of PR to pre-set the parameter and value that required editing.
Once this PR is triggered, parameter settings can be modified. The related setting and
triggering methods will be explained in Section 1.2.7.
Figure 1.4 Use PR Write-in Function to Edit Parameter Setting
In this example, if system parameter value is shown in hexadecimal format, the bit code
will be presented by 0xDCBAUZYX.
1-4
March, 2015
ASDA Series Application Note
1.1.2
Introduction of PR Operation
Mapping Parameter
Advantages about using mapping parameters are listed below:
1. Quickly read and write: It allows users to consecutively read and write communication
addresses of different parameter groups that are not jointed.
2. Read any parameters from PC scope: PC scope channel can read mapping parameters; it can
read any parameters via mapping parameters.
3. Enable the function of reading parameter value after password is set: users may access the
parameter that is going to be monitored via mapping parameter. Then, users may still read its
value via mapping parameter when a parameter is set with password.
ASDA-A2 can map any of the parameters to the specified address. In ASDA-A2 system, 8
groups of mapping parameters are available: P0-35 ~ P0-42 is the index group, the parameter
value specified by the index group will be mapped to P0-25 ~ P0-32 respectively. See Figure 1.5,
the input value of P0-35 ~ P0-42 is in hexadecimal format.
Index
Content
P0-35
P0-25
P0-36
P0-26
P0-37
P0-27
P0-38
P0-28
P0-39
P0-29
P0-40
P0-30
P0-41
P0-31
P0-42
P0-32
Figure 1.5 Mapping Parameters
Besides parameter setting, mapping parameter can also be set via Status Monitor in ASDA-Soft,
which shown in Figure 1.6.
8 groups of mapping parameter are organized together in Status Monitor. Steps to setup are
shown below:
1. Select the mapping parameter that is going to be used.
2. Use the drop-down list to select the parameter to be mapped.
3. If “32-bit” is selected, the high-word item will be blocked to insure the doubleword is mapped
correctly, and all bits of the mapping parameters are used to display in the same parameter.
March, 2015
1-5
Introduction of PR Operation
ASDA Series Application Note
Click Change to change the setting.
Figure 1.6 Using Status Monitor to Configure Mapping Parameter
The size of mapping index and mapping content is 32-bit. A mapping parameter can map to two
16-bit parameters. The parameter content specified by the low-word will be mapped to the
low-word of the mapped content. The parameter content specified by the high-word will be
mapped to the high-word of the mapped content. For example, P1-06 and P1-36 are both
parameters of 16-bit; In P0-37, when 0x0106 is written into the low-word and 0x0124 is written
into the high-word, the low-word of P0-27 will show the content of P1-06 and the high-word will
show the content of P1-36. See Figure 1.7.
Mapping Parameter
Index of Mapping Parameter
P0-27
P0-37
16- bit
0x0124 0x0106
0x5678 0x0123
Parameters
P1-06
0x0123
0x5678
P1-36
Format of Data: 0GAB
G: Parameter Group
AB: Parameter # in Hex.
Figure 1.7 Example of Mapping a 16-bit Parameter
1-6
March, 2015
ASDA Series Application Note
Introduction of PR Operation
If the size of mapping content is 32-bit, a mapping parameter can map one parameter which has
the size of 32-bit. For example, P1-09 is a 32-bit parameter. Enter 0x0109 in both high-word and
low-word of P0-35, the content of P1-09 will all be mapped to P0-25.
Index of Mapping Parameter
Mapping Parameter
P0-35
P0-25
32-bit
0x0109 0x0109
0x0001 0x1234
Parameters
P1-09 H-Word
0x0001 0x1234
P1-09 L-Word
Figure 1.8 Example of Mapping a 32-bit Parameter
If respectively specifying a 32-bit parameter in low-word and high-word of the mapping index, the
mapping content will only show the low-word part of each 32-bit parameter. For example, P1-09
and P1-10 are both 32-bit; writing 0x0109 into low-word of P0-38, low-word part of P1-09 will be
mapped into the low-word part of P0-28. Writing 0x010A into high-word of P0-38, the low-word
part of P1-10 will be mapped into the high-word part of P0-28. See Figure 1.9.
Index of Mapping Parameter
P0-38
32-bit
0x010A 0x0109 Parameters
Mapping Parameter
P0-28
0x3214 0x1203
P1-09 L-Word
0x0001 0x1203
0x0002 0x3214
P1-10 L-Word
Figure 1.9 Example of Mapping Two Sets of 32-bit Parameter
Mapped parameter groups 1~4 can be observed via PC scope. This can be done by selecting
the items from the drop-down list of each channel on PC scope.
March, 2015
1-7
Introduction of PR Operation
ASDA Series Application Note
Figure 1.10 Using PC Scope to monitor Mapping Parameters
1.1.3
Monitoring Parameter
Monitoring Parameter can be used to observe the prompt change inside the servo drive. Types
of monitoring parameter and their codes provided by ASDA-A2 can be found in Chapter 7 of
ASDA-A2 User Manual. To read monitoring variables from the drive panel, users can set the
variables to be monitored in P0-02 and the panel will display the content based on the setting of
P0-02. Pressing Up and Down keys can change the displayed content. To read monitoring
variables via communication, users may set the codes of the variables to be monitored in
P0-17~P0-21 and the set variables will be displayed in P0-09 ~ P0-13 respectively. Figure 1.11
shows the setting example; the index can specify codes of the monitoring variables and the read
values that codes represent will be displayed in the content of the monitoring variables.
Monitoring
Parameters
P0-09 1231
P0-10 232682
P0-11
303
P0-12
0
P0-13 12345
Specified
Monitoring
Parameters
P0-17
P0-18
P0-19
P0-20
P0-21
02d
03d
07d
026d
019d
Examples
02: Position Deviation
03: Feedback Position
07: Motor Speed
26: Status Monitor #4
19: Mapping Parameter #1
Figure 1.11 The Setting Example of Monitoring Variables
1-8
March, 2015
ASDA Series Application Note
Introduction of PR Operation
Monitoring variables can be set via Status Monitor in ASDA-Soft. The Status Monitor window has
organized 5 groups of monitoring variables in the same section. The setting steps are shown
below.
1. Select the monitoring variables to be set.
2. Use the drop-down list to select the monitoring variables user wishes to observe.
3. Click on Change to modify the setting.
Figure 1.12 Use Status Monitor to Configure Monitoring Variables
Monitoring groups from #1 to #4 can be observed via PC scope. This can be done by selecting
the items from the drop-down list of each channel. See Figure 1.13.
Figure 1.13 Use PC Scope to Observe Monitoring Variables
March, 2015
1-9
Introduction of PR Operation
ASDA Series Application Note
1.1.4 Data Array
Data Array in ASDA-A2 servo drive is a continuous block of memory; it is used to save the
captured data, compared value and E-CAM tables. Data array is capable to save 800 data in
total. As size and saving destination of these data is not specified in the system, users have to
define the saving address of each datum properly so as to avoid data overlap and causing
problems of overwriting. Detail about data array is explained in Chapter 2 E-CAM of this
application note; details about how to read and write data array can also be found in ASDA-A2
user manual and ASDA-Soft user manual.
1.2
Introduction of ASDA-A2 PR Function
There are several ways to set the attributes and value settings for each of the PR’s (such as
setting P6-02 and P6-03 for PR#1). The most intuitive way is to use the PR wizard in ASDA-Soft
software tool, as it uses dropdown selection boxes and pop-up wizard windows to explain each
entry choice. Another way is to simply set the parameter values directly from the parameter
editor in the ASDA-Soft software tool. A third way is to set the parameter values by
communication port from a host controller or HMI by setting/resetting PR functions for static or
dynamic use.
In PR mode, motion commands are generated in the servo drive and used to control the motor.
Commands are generated based on parameters settings and are composed of one or more
profiles. Thus, commands generated by PR can be changed by editing their corresponding
values. Including Homing mode, ASDA-A2 provides 64 profiles.
PR#0: Homing mode
PR#1 ~ PR#63 can be set as: Position Command- Position Control
Speed Command- Speed Control
Write Command- Edit Parameter Setting or Data Array
Jump Command- Edit PR Executing Procedure
ASDA-A2 also provides various types of PR triggering methods, which allow users to select
based on different applications.
Each definition and its corresponding data of PR are defined by parameter settings. Parameters
related to PR mode are included in Chapter 7, mainly in Group 6 and Group 7, in ASDA-A2 user
manual. If selecting a PR path to be edited in ASDA-Soft, the corresponding parameter of this
PR will be shown at top of the window. See Figure 1.14 for example, when selecting PR#1 to edit,
value of P6-02 and P6-03 will be displayed at top of the window. P6-02 is for defining the
attribute of PR#1, which is for determine the type of PR command and to determine if this PR is
going to execute interrupt command or to execute the next PR procedure automatically. On the
other hand, P6-03 is the value setting for the PR#1, and definition of what the setting is for
depends on the attribute setting of P6-02. For instance, if P6-02 is a speed command, P6-03 will
be defining the target speed; when P6-02 is a Jump command, P6-03 determines the jumping
1-10
March, 2015
ASDA Series Application Note
Introduction of PR Operation
target of PR command. Parameters defining PR#2 are P6-04 and P6-05; the definition of P6-04
has to be identical to that of P6-02 and definition of P6-05 has to be identical to definition of
P6-03, and so on. If users need to change the setting of individual PR command, directly
changing the parameter that corresponds to this PR will change the definition or value of this PR
command. For example, if regarding PR#1 as speed control, changing the target speed of PR#1
can be done easily by using communication, panel, or using other PR to edit the setting of P6-03.
If directly changing the setting of P6-02, PR#1 will have a different command definition.
Figure 1.14 PR Parameters
Below are the parameters that correspond to PR setting. P6-02 and P6-03 are presented as
examples.
P6-02 PDEF1 PATH#1 Definition
Operational
Panel / Software
Interface:
Communication
Address: 0604H
0605H
Related Section:
7.10
Default: 0
Control
PR
Mode:
Unit: Range: 0x00000000 ~ 0xFFFFFFFF
Data Size: 32-bit
Format: HEX
Settings: Properties of PATH# 1:
P6-02
P6-03
March, 2015
.31 ~
28
-
.27 ~
24
-
.23 ~
20
DLY
.19 ~ .15 ~ 11 ~
16
12
8
DATA (32-bit)
7~4
OPT
3~0
TYPE
1-11
Introduction of PR Operation
ASDA Series Application Note

TYPE, OPT:
OPT
7
6
5
4 BIT
-
UNIT
22AUTO
INS
CMD






P6-03
TYPE
OVLP
2INS
-
-
-
INS
-
-
AUTO
INS
3 ~ 0 BIT
1: SPEED, Speed setting control
2: SINGLE, Positioning control. It will load in
the next path when finished.
3: AUTO positioning control. It will load in the
next path when finished.
7: JUMP to the specified path
8: Write the specified parameter to the
specified path
TYPE: 1 ~ 3 accept DO.STP stop and software limit.
INS: When executing this PR, it interrupts the previous one.
OVLP: Allow the overlap of the next path. The overlap is not allowed
in speed mode. When overlap happens in position mode, DLY has no
function.
AUTO: When PR procedure completes, the next
procedure will be
loaded in automatically.
CMD: Refer to Chapter 7 for PR command description.
DLY: 0 ~ F, delay time number (4 BIT). The delay after executing this
PR. The external INS is invalid.
24DLY (4) Index P5-40 ~ P5-55
PDAT1 PATH# 1 Data
Operational
Panel / Software
Interface:
Communication
Address: 0606H
0607H
Related Section:
7.10
Default: 0
Control
PR
Mode:
Unit: Range: -2147483648 ~ +2147483647
Data Size: 32-bit
Format: DEC
Settings: PATH# 1 Data
.31 ~
28
.27 ~
24
.23
~20
.19 ~
16
.15 ~
12
11 ~ 8
7~4
3~0
DATA (32-bit)
Property of P6-02; P6-03 corresponds to the target position of P6-02 or
jump to PATH_NO.
Note: PATH (procedure)
The unit of position data in PR mode is PUU. PUU is the position unit that encoder’s original
pulse number being converted with E-gear ratio through the servo drive. For example, the
resolution of ASDA-A2 is 1280000 pulse/rev, if E-gear ratio is 128:10 (P1-44=128 / P1-45=10),
the PUU for an ASDA-A2 motor to make one full rotation is 1280000*(10/128) = 100000 PUU.
The best thing about using this method is that the unit of commands, errors, and feedback are
the same, which means no conversion is needed here and it is easy to be read and compared.
1-12
March, 2015
ASDA Series Application Note
Introduction of PR Operation
PULSE
PUU
Cmd_O
Err_PUU
Fb_PUU
V001
P1-44
P1-45
V004
V002
V000
V005
P1-45
P1-44
Servo
drive
Motor
V003
Figure 1.15 Definition of PUU
1.2.1
Shared Setting List for PR
ASDA-A2 provides 16 sets of acceleration/deceleration time (P5-20~P5-35),16 sets of delay
time (P5-40~P5-55), and 16 sets of target speed (P5-60~P5-75) in the setting list; these are
available when configuring PR profiles. If multiple sets of PR use the same setting in the
meantime, when value of this set is changed, all PRs that use this set will also be changed. In
other words, there is no need to change each PR setting respectively and that is why it is easy
and convenient to be used. For instance, if multiple PR commands all specify P5-62 as target
speed, when their values are changed, the target speed of PR motion command that define
P5-62 will thus be changed. Users can easily complete the setting through the built-in wizard
interface of ASDA-Soft. See figure 1.16.
Selection
of the
shared list
Shared setting list
Settings of each PR
Corresponding
parameters
Figure 1.16 Shared Data of PR
March, 2015
1-13
Introduction of PR Operation
1.2.2
ASDA Series Application Note
Introduction of PR Homing
ASDA-A2 provides 9 homing methods in PR mode, such as using home sensor or limit as the
origin. If including the sub-selection such as taking Z pulse and limit as triggering reference, over
30 choices are available. Homing method is defined by P6-00 and value of origin is specified by
P6-01.
Main homing methods supported in PR mode on ASDA-A2 are listed below.
1.2.2.1
Reference to Limit (P5-04.X=0: Move forward to look for positive limit;
P5-04.X=1: Move backward to look for negative limit)
This homing method is to take positive limit or negative limit as the origin. After the limit is
detected, users may consider whether to regard Z pulse as the origin. See Figure 1.17.
Figure 1.17 Regarding Limit Signal as Origin
If the setting of homing is identical, the origin being found will be exactly the same regardless of
the starting position. See Figure 1.18 for homing path and its codes.
S1: starting position
S2: starting position is at the limit
E: end position
H: motor operating at high speed
L: motor operating at low speed
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
H
Y=0, Return to Z
S1
E
L
H
L
Y=1, Ahead to Z
S1
E
L
S2
E
L
H
Y=2, Do not search
for Z
E
S1
L
Z Pulse
high
PL Signal
low
Figure 1.18 Homing Path when Reference to Limit Signal
In Figure 1.18, take Y=1 and look for Z for example, no matter the starting position is S1 or S2, it
will stop at position E after homing is completed. When starting position is S1, the motor will
operate at higher speed until reaching the rising signal of positive limit (PL) and then turn to lower
speed to look for Z pulse. When Z pulse is found, the motor will decelerate to stop. When starting
position is S2, as the PL is triggered, ASDA-A2 servo drive will have sensed that the current
position has gone beyond the PL signal; motor will return and look for the rising signal of PL at
low speed; upon finding, motor moves backward to look for Z pulse and then stop.
March, 2015
1-15
Introduction of PR Operation
1.2.2.2
ASDA Series Application Note
Reference to Rising-Edge Signal on Home Sensor (P5-04.X=2: move
forward to look for rising signal on home sensor; P5-04.X=3: move backward
to look for rising signal on home sensor)
This homing method is to take home sensor as reference, regarding rising signal on the home
sensor as homing origin. When home sensor detects the signal, Z pulse can also be set as
reference origin.
look for
look for
Figure 1.19 Reference to Rising-edge Signal of Home Sensor
In Figure 1.19. Y=0, the motor will return in the opposite direction to look for the Z pulse if the
limit signal is encountered before the Z pulse is found. When homing command is issued, the
sensor board is at S1 and has not passed through the home sensor. The motor will operate at
high speed to look for the rising edge signal of ORG, which is the generated signal when the
sensor board triggering home sensor. Then, the motor will return to look for Z signal at low speed.
After finding Z signal, it will decelerate to stop at position E.
When staring at position S2, the motor’s position has gone beyond ORG sensor; this means
when homing command is issued, sensor board has also encountered the home sensor. Sensor
board will firstly encounter the limit signal and meanwhile motor can be set to automatically move
backward or stop and display errors; this is an example of motor moving backward automatically.
After operating in reverse direction and encountering ORG triggering signal at the first time,
motor will switch to low speed because it has encountered the limit signal and moved backward.
As ASDA-A2 acknowledges that this ORG signal is not the origin signal, it will keep running until
encountering the OFF signal of ORG and then starts to look for Z signal. Upon finding Z signal, it
will decelerate to stop at position E.
When the starting position is at S3, the sensor board happens to be at the position of home
sensor. Meanwhile, ASDA-A2 receives the signal of ORG ON, the motor will start looking for Z
signal at the moment it returns and looks for ORG OFF signal. When finding Z signal, the motor
will decelerate to stop at position E.
When executing homing, different starting positions will not influence the result of finding the
1-16
March, 2015
ASDA Series Application Note
Introduction of PR Operation
origin. No matter the starting position is S1, S2, or S3, the origin is at position E.
H
H
E
Y=0, Return to Z
S3
S2
S1
L
L
H
ERR
H
H
L
Y=1, Ahead to Z
L
S1
S3
E
S2
ERR
H
H
Y=2,
Do not look for Z
H
E
S1
S3
S2
L
L
ERR
H
Z Pulse
PL Signal
ORG Signal
Figure 1.20 Homing Path when Taking Rising Edge Signal as Reference
1.2.2.3
Reference to Z Pulse (P5-04.X=4: move forward directly to look for Z pulse;
P5-04.X=5: move backward directly to look for Z pulse)
Directly regard Z pulse as reference homing position. There is always a Z pulse whenever motor
runs a cycle. This method is applicable when the motor operating distance is within one cycle.
P5-04.Y does not need to be set here.
Figure 1.21 Regard Z Pulse as Original Point
When homing, users can choose whether to let motor look for Z pulse either by moving forward
or backward. When encountering the limit signal, choices of making motor automatically operate
in reverse direction or showing errors are available. In Figure 1.22, after homing, different
starting position (S1 and S2) will lead to different stop positions. However, the origin will be at
position of Z pulse. No matter starting position is S1 or S2, the generated coordinates system
March, 2015
1-17
Introduction of PR Operation
ASDA Series Application Note
after homing will be identical.
L
Ignore Y
L
E
S1
E
ERR
S2
L
Z Pulse
PL Signal
Figure 1.22 Homing Path when Taking Z Pulse as Reference
1.2.2.4
Reference to the Falling-Edge Signal on Home Sensor (P5-04.X=6: move
forward to look for the falling edge signal of home sensor; P5-04.X=7: move
backward to look for the falling edge signal of home sensor)
This homing method is to take the falling edge signal of home sensor as reference. After home
sensor has detected the signal, Z pulse can be also regarded as homing origin.
Limit
Stop or
Go back
ORG
ON -> OFF
Go backward to
look for Z
Ignore Z
Go forward to
look for Z
Figure 1.23 Taking the Falling-edge Signal of Home Sensor as Origin Signal
See the example in Figure 1.24. The motor returns and looks for Z. When homing command is
issued, the motor’s position is at S1 and the sensor board has not passed through the home
sensor. At this stage, motor will operate at high speed first; as soon as it encounters the rising
edge signal of ORG sensor, motor will then switch to low speed. When encountering the failing
edge signal of ORG sensor, motor will keep operating at low speed to look for Z pulse; it then
slows down and stops at position E upon finding Z signal.
1-18
March, 2015
ASDA Series Application Note
Introduction of PR Operation
When starting from position S2, it means when issuing the homing command, the sensor board
has passed through the sensor. The sensor board will encounter limit signal first; meanwhile,
motor can be selected to automatically reverse or to stop and display errors. In this example,
motor encounters the limit signal and then reverse automatically. Before encountering the ON
signal of ORG sensor, motor would operate at high speed. After ORG signal is triggered, motor
will then switch to low speed and reverse to find the falling edge signal of ORG sensor. Next, it
will return and look for Z pulse and stop at position E upon finding Z signal.
S3: While homing command is issued, the sensor board happens to be at the position of the
ORG sensor. As it is a falling edge trigger, motor would operate at low speed to look for the
falling edge signal of ORG. Upon finding the falling signal, motor will return to look for Z pulse
and then it slows down to stop at position E after finding Z pulse.
Whether starting position is at S1, S2, or S3, the position of origin is at E.
H
H
L
Y=0, Return to Z
ERR
E
S1
S3
S2
L
H
Y=1, Ahead to Z
H
H
L
ERR
S1
S2
S3
H
H
H
L
Y=2,
Do not look for Z
E
ERR
S1
S3
E S2
H
Z Pulse
PL Signal
ORG Signal
Figure 1.24 Homing Path when Taking Falling-edge Signal of Home Sensor as Reference
March, 2015
1-19
Introduction of PR Operation
1.2.2.5
ASDA Series Application Note
Reference to Current Position (P5-04.X=8)
This homing mode regards motor’s current position as reference origin. Coordinates positioning
can be done by triggering homing signal without operating the motor.
Figure 1.25 Regarding Current Position as Home Position
There is one thing worth noticing when homing in PR mode. When finding the reference point,
motor will decelerate to stop at somewhere close to the reference point because of the inertia.
ASDA-A2 will not request the motor to move to the exact reference origin automatically. Users
may use another PR command to request the motor to move to the origin or to any position in the
coordinate system. Now, the coordinate system has been built, no matter where the motor stops,
the servo will know its stop position on the coordinates. In this case, whether motor stops at the
origin or not, part of the operation such as issuing absolute commands will not be influenced. On
the other hand, when it comes to relative commands or E-CAM applications, the motor has to be
moved to a fixed reference position such as 0 on the coordinates because this type of command
will directly regard motor’s stop position as start position.
Please refer to Figure 1.26, if 0 is the homing origin, when motor finds the origin and stops, it will
stop at coordinate position -523. If motor needs to move back to the absolute 0 on the
coordinates, calling PR#1 after homing is required and its absolute position has to be 0.
If motor has to move to any position after homing, this method can be used. For example, motor
has to move to position 44356, users may use the setting of calling one PR path after homing
and regard 44356 as the target position.
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
PR#1
-2000
Coordinate after -3000
-1000 0 1000
homing.
-523
The position where motor
stops after homing.
H
Y=0,
Searching Z
E
S1
L
Z Pulse
PL Signal
Figure 1.26 Positions of Motor and Homing Origin
PR homing mode of ASDA-A2 can regard any value in the coordinate system as homing origin;
position 0 does not necessary to be the homing origin. By confirming the homing reference origin,
the coordinate system can be established. Take Figure 1.27 for example, the origin reference is
2000 (P6-01=2000) and motor stops at 1477 on the coordinates. As the coordinate system has
been built and acknowledge where 0 is, the next step is to issue PR motion commands. Then,
ASDA-A2 is able to figure out the path of target position.
Coordinate after homing -1000
The position where motor
stops after homing.
0
2000
1000
4000
3000 5000
1477
H
Y=0,Search for Z
S1
E
L
Z Pulse
PL Signal
Figure 1.27 Defined Value of Homing Reference Origin
March, 2015
1-21
Introduction of PR Operation
ASDA Series Application Note
1.2.3 PR Speed Command
Users may use PR mode to configure the speed command, including acceleration/deceleration
time, target speed, and delay time. The speed command here refers to the speed command in
PR mode (P1-01=0), which is different from command in speed mode (P1-01=2)
Delay time refers to the interval after previous command is completed and before carrying out
the next command. The setting of delay time is defined by the servo drive, which means the
servo drive will not start counting the delay time until the motor has reached the target speed.
Delay time is not defined by motor’s feedback signal because the feedback setting time varies
with different system performance.
If the trigger setting of PR is defined as a speed command, motor will operate according to the
acceleration/deceleration setting until reaching the target speed. Then it keeps operating till
other command interrupts this PR command.
Speed
Delay
Target
Speed
Feedback Speed
Command
Time
Acc. Time
Speed
Feedback Speed
Command
Target
Speed
Delay
Dec. Time
Time
Figure 1.28 PR Speed Command
1-22
March, 2015
ASDA Series Application Note
1.2.4
Introduction of PR Operation
PR Position Command
When using PR mode to configure position commands, other than target position, users have to
decide how motor reaches the target position. That is, the acceleration/ deceleration and target
speed of the motor has to be specified. Besides, delay time will start to be counted after motor
reaches the target position.
4 Types of Command
Speed
Target
Speed
DLY
Distance
Time
Distance
Figure 1.29 Setting of Position Command
PR position control of ASDA-A2 provides four types of position commands:
1. Absolute command:
The value of position command is the absolute position on the coordinates, which is the
target position.
2. Relative command:
Value of motor’s current position + Value of position command = Target position
3. Incremental command:
Value of previous target position + Value of current position command = Target position
4. Capture command :
Value captured by Capture function + Value of position command = Target position
See the example in Figure 1.30. Target position of previous command is 30000 PUU, when
motor reaches position 20000 PUU, the following commands will interrupt the current motion.
1. Absolute command 60000 PUU:
Target position is the new position command, 60000 PUU.
2. Relative command 60000 PUU:
Target position (80000 PUU) = motor’s current position (20000 PUU) + new position
command (60000 PUU)
March, 2015
1-23
Introduction of PR Operation
ASDA Series Application Note
3. Incremental command 60000 PUU:
Target position (90000 PUU) = Previous target position (30000 PUU) + New position
command (60000 PUU)
4. Capture command 60000 PUU:
If the last value captured is 10000 PUU, target position will be 10000 PUU + 60000 PUU =
70000 PUU
Current
position
of motor
FB_PUU
Absolute
command
60000
Absolute command 60000
0
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Current
position
of motor
FB_PUU
Relative
command
60000
60000
Relative command 60000
0
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Current
position
of motor
FB_PUU
Incremental command 60000
0
Cap. Relative command 60000
0
The target
position of
current
command
Cmd_E
Incremental
command
60000
60000
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
The
position
latched by
capture
function
60000
Current
position
of motor
FB_PUU
Capture
command
60000
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Figure 1.30 Types of Position Command
Regarding position command, two types of setting are available. Type 2 (Single positioning
control, Motor stops when positioning is complete), the PR procedure stops when this PR
command is completed. Type 3 (Auto positioning control, Motor goes to the next path when
positioning is complete), automatically carry out the next PR command after the current one is
completed. To carry on to the next path or to stop is the only difference between these two types;
other settings are identical.
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March, 2015
ASDA Series Application Note
1.2.5
Introduction of PR Operation
Jump Command
Users may use Jump command to call any PR. It serves as functions like subroutines and is able
to turn PR paths into a loop. See Figure 1.31.
Figure 1.31 Example of PR Jump Command
1.2.6
PR Write-in Command
(Write the specified parameter to the specified path)
Write-in command can modify the writable parameter settings or values saved by data array in
the servo drive. Users can edit the time of modifying parameter values by using the PR
command executing time. Source of write-in data can be constants, value of system parameter,
value in data array, or value presented by monitoring variables. See the following table.
Data Source
Constant (Input constant)
System Parameter ( Specified system
parameter)
Data Array ( Specified address of data array)
Monitoring Variables ( Specified monitoring
variables)
Target
System Parameter ( Specified system
parameter)
Data Array ( Specified the address of data
array)
Figure 1.32 PR Write-in Function
March, 2015
1-25
Introduction of PR Operation
1.2.7
ASDA Series Application Note
PR Triggering Methods
Multiple types of PR triggering methods are available on ASDA-A2. Users may choose the most
suitable method based on the application.
1.2.7.1
Trigger by DI.CTRG / POS0 ~ POS5 / STOP
To use this trigger method, users have to use DI to select the PR to be carried out. Firstly, use
DI.POS0~5 (setting value: 0x11, 0x12, 0x13, 0x1A, 0x1B, 0x1C) to select PR position command.
After selecting, use DI.CTRG (0x08) to carry out this PR. Users may use DI.STOP (0x46) to stop
this PR. When using DI.STOP to cease the PR operation, the part that has not yet been
executed in this PR command will not be eliminated. See Figure 1.33.
POS1~5
select PR.
PR# 5
The remaining
command is still kept
inside the servo.
PR# 5
Being executed PR
CTRG
STOP
Figure 1.33 Method of Triggering PR by DI
If users would like to carry out the PR command that has not been completed after using
DI.STOP and it is an absolute command (ABS), users may carry out the same PR command or
call another incremental (INC) command of which position value is 0. On the other hand, if this is
not an absolute command (ABS), the only way to complete it is to call another incremental
command (INC) of which position value is 0. To clear the uncompleted PR command after using
DI.STOP, it needs to carry out a relative command (REL) of position value is 0.
1.2.7.2
Parameter P5-07
Users may use software, HMI, host controller, or panel to write the PR to be executed in P5-07.
When the read value equals the entered command value plus 10000, it means the PR command
is completely issued. When the displayed value equals the entered command value plus 2000, it
means PR command has been completely carried out. As shown in Figure 1.34, when the next
PR path to be executed is PR#20, the displayed value of P5-07 will be 20. As PR command has
been sent completely but motor is not in place, P5-07 will display 10020. After finishing carrying
out the PR, P5-07 will display 20020.
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
ASDA
Soft
P5-07
20
HMI
Host
Controller
PR#20
20, PR is being executed.
10020, command sent and final
destination does not yet reach.
20020, PR is executed.
Button
Figure 1.34 Triggering PR by Parameter
To observe the PR procedure, check the item ADR in PC scope channel and then enter
0x20002507. By doing so, users may monitor the change of P5-07. Regarding the entered value,
0X20002 is a fixed value; 5 stands for the parameter group of P5-07; 07 represents the
hexadecimal value of the parameter number.
20003
Figure 1.35 Observe PR Procedure by PC Scope
1.2.7.3
DI.SHOM
Use DI.SHOM (0x27) to trigger PR#0 (Homing mode). This DI triggers PR#0 only.
1.2.7.4
Event Trigger
Using event trigger requires settings of relevant DI and parameters. Regarding DI, four sets are
available, Event 1 (EV1, 0x39), Event 2 (EV2, 0x3A), Event 3 (EV3, 0x3B), and Event 4 (EV4,
0x3C). Every DI has one rising edge and one falling edge to trigger different PRs respectively. If
four sets of DI are all used, they can trigger eight PRs in total. Four sets of rising edge that can
trigger PRs shall be set in P5-98; the other four sets of falling edge that can trigger PRs shall be
set in P5-99. Setting values of P5-98 and P5-99 and their corresponding PRs are shown in table
of Figure 1.36.
March, 2015
1-27
Introduction of PR Operation
ASDA Series Application Note
1
2
1
EV4
DI=0x39(EV1),
0x3A(EV2),
0x3B(EV3), or
0x3C(EV4).
Setting
PR#
1
2
P5-98 Rising-edge events to PRs
2
EV3
4
EV1
P5-99 Falling-edge events to PRs
EV4
3
EV2
5
6
7
8
EV3
9
EV2
A
EV1
B
C
D
51 52 53 54 55 56 57 58 59 60 61 62 63
P5-98 = 0x0602
P5-99 = 0x0903
EV1=
PR#52
EV1=
PR#53
EV3=
PR#56
EV3=
PR#59
Figure 1.36 Trigger PR by Event
For example, when P5-98 = 05D2 and P5-99 = 790A: (The way that Delta usually use when
describing parameters: P5-98=0xUZYX)
1. EV1: Because P5-98.X = 2, the rising edge signal of EV1 will trigger PR#52. Because
P5-99.X = A, the falling edge of EV1 will trigger PR#60.
2. EV2: Because P5-98.Y = D, the rising edge signal of EV2 will trigger PR#63. Because
P5-99.Y=0, the falling edge signal of EV2 will not trigger any PR command.
3. EV3: Because P5-98.Z = 5, the rising edge signal of EV3 will trigger PR#55. Because
P5-99.Z=9, the falling edge signal of EV3 will trigger PR#59.
4. EV4: Because P5-98.U = 0, the rising edge signal of EV4 will not trigger any PR.
Because P5-99.U = 7, the falling edge signal of EV4 will trigger PR#57.
1-28
March, 2015
ASDA Series Application Note
1.2.7.5
Introduction of PR Operation
Others CAPTURE Completed / COMPARE Completed / E-CAM
Disengaged
If Bit 3 of P5-39 has been set, after Capture command (P5-38 = 0) is completed, the servo will
automatically call PR#45. If P5-88.BA has been set, when E-Cam is disengaged, the system will
regard the setting of P5-88.BA as PR path to be carried out and then automatically carry out this
PR.
E-Cam disengaged
Disengaging
conditions.
P5-88.U= 2,4, or 6
Call any PR set by
P5-88.BA.
Capture function
finished
P5-38 =
P5-38 - 1
True
P5-38= =0
Bit 3 of
P5-39.X
==1
True
PR#50
DI7
Figure 1.37 Other Methods of Triggering PR
1.3
Motion Control
1.3.1
Monitoring Variables Related to PR
Regarding the operation of PR, four parameters are available to be used to observe commands
and feedback.
1.
Cmd_O: Command operation, the motion command in operation which represents the
absolute coordinates of the current output command. It also includes the setting of
acceleration/deceleration and target speed when operating. (monitoring variable 001)
2.
Cmd_E: command end, the target position; when command is issued to the servo, the
servo drive will figure out the final target position and promptly update Cmd_E (variable
064).
3.
Fb_PUU: feedback PUU, motor’s current position (monitoring variable 000).
4.
Err_PUU: error PUU, the deviation between command and the current position during
motor’s operation (monitoring variable 002).
Users can use PC scope of ASDA-Soft to observe PR’s monitoring variables. As shown in Figure
1.38, user can select feedback position or monitoring variable 000(00h) to monitor Fb_PUU,
select position command or monitoring variable 001(01h) to monitor Cmd_O, or select position
deviation or monitoring variable 002(02h) to see Err_PUU, and then observe Cmd_E by setting
up monitoring variable 064(40h). To observe monitoring variables in PC scope, check the item
ADR and enter 0x10000064 to see the change of Cmd_E. In regards to the input value,
0x100000 is a fixed value and the value 64 represents the 64-bit monitoring variable of target
position.
March, 2015
1-29
Introduction of PR Operation
ASDA Series Application Note
Figure 1.38 PC Scope of PR Monitoring Variables (32-bit)
Except that Err_PUU is 16-bit, other three parameters are 32-bit. To see the whole picture of
Cmd_O, Cmd_E, and Fb_PUU, users have to select the item of 32-bit display; however, only two
variables can be monitored at the same time in this case. See Figure 1.39.
Figure 1.39 Monitoring Variables on PC Scope (32-bit)
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
As feedback value has to be identical to the command value, Cmd_O = Fb_PUU + Err_PUU.
Shown in Figure 1.40, after the servo issues the command, which is an internal one, the servo
will immediately know its target destination, which is Cmd_E in this case. However, motor has to
operate according to the motion command (acceleration/deceleration and target speed) until
reaching the target. Cmd_O command requests the motor to move forward step by step as
specified. The current position sent by motor is Fb_PUU; Err_PUU is the actual amount that the
motor falls behind Cmd_O.
Err_PUU
Fb_PUU
Cmd_O
Cmd_E
Before
command
accepted
Err_PUU
Fb_PUU
Cmd_O
Cmd_E
After
command
accepted
Cmd_E
Command
being
executed
Err_PUU
Fb_PUU
Cmd_O
Err_PUU
Fb_PUU
Cmd_O
Cmd_E
Err_PUU
Fb_PUU
Cmd_O
Cmd_E
Command
finished
Positioning
completely
Figure 1.40 Example of Position Command
In PR mode, after command is completely issued and motor is in place, DO.MC_OK will be On.
Demonstrated in Figure 1.41, DO.CMD_OK will be ON when the command is completed
(including delay time) and motor is in place. If delay time is long, when motor has reached the
target position but the command has not been completed, DO. MC_OK will not be On; it will wait
for the conditions to be fulfilled, it will wait until DO.TPOS and DO.CMD_OK are both on.
DI.CTRG
DO.CMD_OK
DLY
COMMAND
DO.TPOS
Target
position
reached
DO.MC_OK
(TPOS ) AND
(CMD_OK)
Figure 1.41 Example of Monitor Signal MC_OK
March, 2015
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Introduction of PR Operation
ASDA Series Application Note
Another exception is homing command. The difference between homing and position command
is that Cmd_E does not know where the target position is when homing. Only when reference
origin is found and coordinate system is built can Cmd_E’s position be known. That is, after
homing command is issued and before origin found and coordinate system built, Cmd_E =
Cmd_O. See Figure 1.42.
Err_PUU
Fb_PUU
Cmd_O
Cmd_E
Before
command
accepted
Err_PUU
Fb_PUU
Cmd_O
Cmd_E
After
command
accepted
Err_PUU
Fb_PUU
Cmd_O
Cmd_E
Cmd_E = Origin
Cmd_E = Origin
Command
being
executed
Err_PUU
Fb_PUU
Cmd_O
Cmd_E
Err_PUU
Fb_PUU
Cmd_O
Cmd_E
Command
finished
Positioning
completely
Figure 1.42 Example of Homing
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
1.3.2 Sequence Command
PR can also specify motion commands including position control and speed control. Sequence
command is a motion command that does not have overlaps (OVLP) or interrupts (INS). It is
executed in sequence. After previous command is executed and delay time is over, the next
command can be carried out. In terms of command of position control, counting of delay time
starts after motion command. Regarding speed command, counting of delay time will start after
the command reaches the target speed. See Figure 1.43.
SPEED
INS
OVLP
DLY
INS
OVLP
DLY
TIME
P_Command
1 (Type 3)
SPEED
DLY 1
AUTO
INS
OVLP
DLY
P_Command 2
(Type 2)
INS
OVLP
DLY
DLY 1
TIME
V_Command 1
(Type 1)
P_Command 2
(Type 2)
Figure 1.43 Sequence Command
March, 2015
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Introduction of PR Operation
1.3.3
ASDA Series Application Note
Overlap of Commands
When using the overlap function, delay time is still effective in the system. To smoothly carry out
commands one after another, please set the delay time to 0 in the previous part when using the
overlap function. In this case, the next command will start operating when previous command is
in deceleration zone. By doing so, two motion commands can be smoothly connected and
vibration can thus be reduced. See figure 1.44. As delay time will influence the time sequence of
overlap, delay time is suggested to be set 0 in this application. Please note that when overlap is
enabled, previous command’s delay time count will begin from the moment that command starts.
Overlap is set in the previous command; that is to say, the deceleration zone of previous
command overlaps the acceleration zone of the next command.
SPEED
INS
OVLP
DLY
INS
OVLP
DLY
TIME
P_Command
1 (Type 3)
DLY 1
P_Command 2
(Type 2)
SPEED
INS
OVLP
DLY
INS
OVLP
DLY
TIME
P_Command
1 (Type 3)
P_Command 2
(Type 2)
Figure 1.44 Overlap of Command
To have the overlap function perform well, users need to set up as follows:
Absolute value of deceleration curve slope from previous command = absolute value of
acceleration curve slope from next command
As shown in Figure 1.45, when previous command enters the deceleration zone, it will be able to
change to the speed specified by the next command smoothly, reducing the vibration caused by
speed changing.
Figure 1.45 Settings of Overlap Command
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
See Figure 1.46 for example, the meshed part is the overlapped area. When speed of the two
position commands is identical and the absolute value of deceleration curve slope of previous
command equals acceleration curve slope of the next command, the measure of meshed area
can compensate the area with slanting lines, allowing motor to keep the same speed when
switching from the first command to the second one and keep the total operation procedure the
same.
Speed
Time
Position Command 1 Position Command 2
(Type 3)
(Type2)
Figure 1.46 Overlap Command with Consistent Slopes
In Figure 1.47, the absolute value of deceleration curve slope does not equal to that of the
acceleration curve slope. Since the overall procedure cannot be changed, which means the sum
of two position command’s measurement of the speed curve should be identical. When the
meshed area can only compensate part of the area with slanting lines, it will cause speed
changing when connecting to position commands and the two commands cannot connect
smoothly during the process.
Speed
Time
Position Command 1
(Type3)
Position Command 2
(Type2)
Figure 1.47 Overlap Command with Inconsistent Slope
1.3.4
Interrupt of Command
Interrupt command, a command that is being executed and being replaced or combined with the
other command before it is completed. The final result of command varies with the command
types. The function of interrupt is to replace the previous command with the latter command.
Interrupting method can be categorized into two types: internal and external. Description is as
follows.
March, 2015
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Introduction of PR Operation
ASDA Series Application Note
Internal Interrupt:
In a series of PR profiles, when PR has enabled function of automatically move to the next
command, the system will read the next command first after reading the current PR.(If delay time
is set, the next command will be read after delay time is over.); the system reads the next
command before the current one is completed. If the next command has set the interrupt function,
as it has higher priority, the system will promptly deal with the interrupt command, replacing or
combining previous command with the latter one. In the following example, PR#1 and PR#2 both
automatically call the next command to be executed. However, interrupt is only set in PR#2. After
the system finishes reading PR#1, it will read PR#2 immediately. While interrupt function is set in
PR#2 and no delay time is set in PR#1, PR#1 will not be carried out and be replaced with PR#2.
Next, the system will then continue to read PR#3. As PR#3 has not set interrupt, the system will
start carrying out PR#2. PR#3 is the reserved command, which will be carried out after PR#2 is
completed.
PR
#1
Position(3)
D=0, S =20.0 rpm
200000PUU, INC
PR
#2
(I)
Position(3)
D=0, S=100.0 rpm
300000PUU, INC
With interrupt
PR
#3
Position(2)
D=0, S=200.0 rpm
100000PUU, INC
Without interrupt
Figure 1.48 Example of Internal Interrupt in PR Profile
Delay time is effective to internal interrupt. With interrupt function, count of delay time of previous
command begins when previous command starts. If the delay time of previous command is set to
0 and the next command is set with interrupt, previous command will not be executed and next
command will be carried out directly. If previous command has set delay time, the next command
will be executed after the delay time is over.
When next PR command is an absolute one and with interrupt, no matter what next PR is, the
final destination will be the target position, CMD_E from next PR command. When next PR
command is incremental or relative and with interrupt, the destination will be the previous
command’s CMD_E plus next PR command’s CMD_E.
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
INS
OVLP
DLY
SPEED
INS
OVLP
DLY
Absolute: Cmd_E = command
P_Command
1 (Type 3)
TIME
AUTO
INS
OVLP
DLY
INS
OVLP
DLY
The final destination:
Absolute: Cmd_E = command
V_Command 1
(Type 1)
DLY 1
If 0, this command
will be omitted.
Relative, Incremental:
Cmd_E = last Cmd_E +
command
P_Command 2
(Type 2)
DLY 1
If 0, this command
will be omitted.
SPEED
The final destination:
TIME
Relative, Incremental:
Cmd_E = last Cmd_E +
command
P_Command 2
(Type 2)
Figure 1.49 Internal Interrupt
External Interrupt:
In a PR profile, any type of trigger method is used to force carrying out the other PR command.
(Please refer to Section 1.2.7 for PR trigger method.) When the next PR command with interrupt
function comes in, the command that is being executed will be changed. Delay time will not be
effective to the external interrupt. That is, when command with external interrupt comes in, the
next command will definitely be executed no matter what type of previous command is. See
Figure 1.50, PR profile A is carrying out PR#2. Meanwhile, if any type of PR trigger method is
used to trigger PR profile B (Triggering PR#30, with interrupt), the motion command of PR#2
being executed will be combined with that of PR#30. Therefore, the system will not carry out the
rest of the motion command of PR#2; instead, it will carry on to PR profile B.
PR Profile A
PR
#1
Position (3)
D=0, S =20.0 rpm
200000PUU, INC
PR
#2
(I)
Position (3)
D=0, S=100.0 rpm
300000PUU, INC
PR
#3
Position (2)
D=0, S=200.0 rpm
100000PUU, INC
When PR#2 is being executed, PR#30 is
triggered by any type of PR trigger method.
PR Profile B
PR Position(3)
#30 D=0, S = 2000rpm
(I ) 500000PUU, INC
PR Position (3)
#31 D=0, S= 600.0 rpm
(I) 400000PUU, INC
PR Position(2)
#32 D=0, S=200.0 rpm
300000PUU, INC
With interrupt
Figure 1.50 External Interrupt of PR Profile
March, 2015
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Introduction of PR Operation
ASDA Series Application Note
If the next PR command is an absolute one with interrupt, no matter what previous PR command
is, the final destination will be the target position CMD_E of the next PR command. If the next PR
command is an incremental one and with interrupt, the final destination will be previous PR
command’s CMD_E plus the next command’s CMD_E. If the next PR command is relative and
with interrupt, when interrupt occurs, the final destination is the motor’s current position Fb_PUU
of previous PR plus the next PR’s CMD_E.
SPEED
INS
OVLP
DLY
INS
OVLP
DLY
The final destination:
Absolute: Cmd_E = command
Relative: Cmd_E = Fb_PUU + command
Incremental: Cmd_E = last Cmd_E + command
Capture: Data captured + Command
P_Command 1
(Type 2 or 3)
DLY
P_Command 2
(Type 2 or 3)
SPEED
AUTO
INS
OVLP
DLY
TIME
INS
OVLP
DLY
V_Command 1
(Type 1)
DLY
The final destination:
Absolute: Cmd_E = command
Relative: Cmd_E = Fb_PUU + command
Incremental: Cmd_E = last Cmd_E + command
Capture: Data captured + Command
P_Command 2
TIME
(Type 2)
Figure 1.51 External Interrupt
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March, 2015
ASDA Series Application Note
1.4
Introduction of PR Operation
Presentation of PR
This section explains how PR functions are presented. With the presentation format shown here,
the whole PR procedure can be understood more easily. In this document, this format will
continue be used to illustrate the PR profile. See Figure 1.52, PR profile can be presented with
following ways.
1. If this PR command is completed and the PR profile is then completed without moving
to the next PR (without Auto), information of this PR is presented with a rectangle frame.
If the PR is with Auto function, which means it will be carrying out the next PR, this PR
will be presented in an arrow-shaped frame, pointing to the next PR. This format is
adapted to all presentation of PR functions. However, Jump function can only be
presented in an arrow-shaped frame because the PR specified in the Jump command
will definitely be executed.
2. The presentation is consisted of 5 parts. See Figure 1.52 for the description of each
part.
Part (1) The number of PR.
Part (2) This part shows whether this PR command has interrupt function. If yes, label
(I) is presented here; If not, this part will be blank.
Part (3) This part shows functions of this PR command, which are mainly homing
(Home), speed control (Speed), position control (Position), write-in (Write), and
jump (Jump).
Part (4) Information in this part varies with PR functions. Details will be explained based
on each mode in the following content.
Part (5) Information in this part varies with PR functions. Details will be explained based
on each mode in the following content.
Figure 1.52 Presentation of PR
3. Homing mode: As shown in Figure 1.53, interrupt function is not available in this mode.
Thus, label shown in Part (2) mentioned in Figure 1.52 is not required here. In this
mode, “Home” is shown in Part (3); Part (4) is for specifying offset value on the
coordinates, which is the value set by P6-01. Part (5) shows the PR command that
being automatically called after homing is completed. If it stops after homing is
completed and without moving to the next PR automatically, PR#0 is marked here.
March, 2015
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Introduction of PR Operation
ASDA Series Application Note
Default
Homing
Command
PR
#0
Home
Offset
=0 0
Offset=
PR#1
Go to PR#1
after homing
PR
#0
Coordinate offset
set in P6-01
Home
Home
Offset
Offset
==100
PR#0
PR#0
Stay in PR#0 after
homing
Figure 1.53 Homing Command
4. Speed command: See Figure 1.54, Part (3) mentioned in Figure 1.52 shows “Speed”;
Part (4) is the delay time; Part (5) presents the target speed of this PR.
With interrupt
Speed
Command
Without interrupt
PR Speed
#51 DLY = 100
(I) 20.0 rpm
With Auto to
next.
PR Speed
#51 DLY = 2000
300.0 rpm
Without
Auto to next.
PR Speed
#51 DLY = 100
(I) 200.0 rpm
Figure 1.54 Speed Command
5. Jump Command: See Figure 1.55. Part (3) mentioned in Figure 1.52 shows “Jump”
here; Part (4) shows the delay time; Part (5) presents the target PR of this Jump
command.
Jump
Command
PR Jump
#51 DLY = 0
(I) PR#1
PR Jump
#51 DLY = 0
PR#1
Figure 1.55 Jump Command
6. Write-in Command: See Figure 1.56. Part (3) mentioned in Figure 1.52 shows “Write”
here; Part (4) shows the delay time; Part (5) is the written target and value. For
example, P5-18=20 means writing 20 to P5-18 when this PR command is being
executed.
Write 20 to P5-18.
Write-in
Command
PR Write
#51 DLY = 0
(I) P5-18= 20
PR Write
#51 DLY = 0
P5-18 = 20
PR Write
#51 DLY = 0
(I) P5-18 = 20
Figure 1.56 Write Command
7. Position command: See Figure 1.57. Part (3) mentioned in Figure 1.52 shows “Position
(2)” here; this means to stop after the command is completed. If “Position (3)” is shown,
it means to automatically carry out the next PR command after this command is
completed. Part (4) here shows the delay time and target speed; Part (5) shows the
type and required operating distance of the position command. Regarding the
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
command type, ABS stands for an absolute command, REL for relative command, INC
for incremental command, and CAP for capture command.
Type 2 position command
PR#51 with
interrupt
Target speed
Type 2, finish
and stop.
PR Position (2)
#51 D = 0, S = 10.0 rpm
(I) 90 PUU, ABS
Absolute
command to
90 PUU.
Delay = 0
PR Position (2)
#51 D = 0, S = 10.0 rpm
(I) 90 PUU, REL
Relative
command to
90 PUU.
PR#51 without
interrupt
PR Position (2)
#51 D = 0, S = 10.0 rpm
90 PUU, INC
Incremental
command to
90 PUU.
PR Position (2)
#51 D = 0, S = 10.0 rpm
(I) 90 PUU, CAP
Cap. relative
command to
90 PUU.
Type 3 position command
PR#51 with
interrupt
Type 3, finish and
Call next PR
PR Position (3)
#51 D = 0, S = 10.0 rpm
(I) 900 PUU, ABS
PR
#51
(I)
PR#51 without
interrupt
Position (3)
D = 0, S = 10.0 rpm
900 PUU, REL
PR Position (3)
#51 D = 0, S = 10.0 rpm
900 PUU, INC
PR Position (3)
#51 D = 0, S = 10.0 rpm
(I) 900 PUU, CAP
Figure 1.57 Position Command
When the system continuously carries out a series of PR paths, they are regarded as a PR group.
The first PR command in the group is called the Head PR, which is externally triggered. Jump
function or Auto function (automatically move to the next PR path) can be set in the Head PR to
continue carrying out other PR commands. See Figure 1.58.
externally
triggered
Head PR
PR
#5
(I)
PR
#6
(I)
PR
#7
(I)
PR
#8
(I)
A PR group (PR#5, PR#6, PR#7, PR#8)
externally
triggered
Head PR
PR
#10
(I)
PR
#39
(I)
PR
#40
(I)
PR
#41
(I)
A PR group (PR#10, PR#40, PR#41)
Figure 1.58 PR Group
March, 2015
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Introduction of PR Operation
1.5
ASDA Series Application Note
How is PR arranged?
ASDA-A2 will update the command status every 1 ms; Figure 1.59 shows how PR profile is
arranged in ASDA-A2 and illustrating how it deals with PR commands.
High
Priority
Low
CTRG
PR Queue
STP
P5-07
SHOM
EV1~4(↓)
EV1~4(↑)
PR Queue (first in first out)
Every 1 ms, it will issue a Head PR command if any Head PR is
waiting in the PR queue.
The new Head PR issued by PR Queue will terminate the PR group
being executed in the PR Executor.
PR Executor
PR Executor
Motion
Command
Generator
1. The PR Executor will dispatch every single PR in the PR group to the next level if it is a
PR with motion function (Type 1 Constant Speed Control, Type 2 Position, and Type 3
Position to Next).
2. The Type 7 Jump and Type 8 Write-in Parameter will be finished in PR Executor.
3. Eight consecutive PRs with INS set can be guaranteed to be executed within 1 ms in
PR Executor.
Sequence / Interrupt / Overlap
Motion Command Generator
1. The motion command will be generated here.
2. It could be sequence, interrupt, or overlap.
Output
Motion Profile
SPEED
TIME
Figure 1.59 Arrangement Procedure of PR
PR Trigger Mechanism
When PR command is triggered with different methods at the same time, the executing order is
CTRG > STP > P5-07 > SHOM > EV1~4 (rising-edge trigger) > EV1~4 (falling-edge trigger).
PR Queue
Once all PR commands are triggered, they will enter the PR Queue and wait. Triggered PR
command is the Head PR. Thus, its PR group will then enter and wait in the PR Queue. As long
as there is a PR command waiting in the Queue, the system will send the Head PR every 1 ms
and its PR group to the PR executor in order; the command that enters first will be sent first.
Whether there is a PR command being executed, the Queue will include every triggered PR and
make sure it enters the Queue.
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
PR Executor
The newly-received Head PR and its PR group in the PR executor will immediately replace the
PR group being executed. If the PR group contains motion commands, which includes speed
command and position command, no matter this PR group is completed or not, the executor will
distribute those PR with motion commands to the motion command generator. In addition, PR
with write-in command or Jump command will be completed at the moment PR executor is read;
they will not enter the motion command generator. In PR executor, 8 commands with interrupt
and without delay time, as well as being continuously carried out will be completed within 1 ms. If
there is a PR command that hasn’t been completed within 1 ms and a new PR command group
has been sent to the PR executor by the Queue, new PR command group will then replace the
previous one. In other words, instead of carrying out the group that hasn’t been executed, the
executor will start carrying out new ones.
Motion Command Generator
Motion command generator has a buffer zone for temporarily reserving the next command. All
motion commands are integrated here. Commands that are being carried out can also be
interrupted here. If a PR command contains speed or position orders, PR executor will
automatically send this command to the motion generator. As long as motion commands enter
the generator, they will be carried out right away. If other command (with interrupt) also enters
the generator, it will be integrated with the current command in the generator and the integration
is based on its setting. The setting of each PR determines whether multiple motion commands
can overlap, interrupt the previous command or being executed in sequence.
March, 2015
1-43
Introduction of PR Operation
1.6
ASDA Series Application Note
PR Setting Examples
Five similar PR examples are listed here. The difference among them is whether interrupt/delay
time is set in each PR. Below is the PR operating procedure.
Example 1:
PR
#1
Position (3)
D=0, S=20.0 rpm
200000PUU, INC
PR
#2
(I)
Jump
DLY=0
PR#10
PR Write
#10 DLY=0
(I) P5-55=10
PR Position (3)
#11 D=0, S=100.0 rpm
300000PUU, INC
(A ) 1ms
(B ) 1ms
Command Group
Note: Each command group
is read within 1 ms
PR Write
#12 DLY=0
(I) P5-55=12
Command Group
Command group (A) and (B) have motion commands thus
both of them need motion command generator. However,
as PR#11 has no interrupt, group (B) will not be executed
until PR#1 is completed.
Figure 1.60 Example 1
PR Settings:
In the toolbar of ASDA-Soft, select PR Mode Setup to open PR Mode Editor.
Figure 1.61 Open PR Mode Editor
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March, 2015
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Introduction of PR Operation
Please follow the steps to edit the related settings in PR Mode Editor:
1. PR#1:
ⓑ
ⓒ
ⓐ
ⓓ
ⓔ
ⓕ
Figure 1.62 Settings of PR#1
a. Select path PR#01.
b. Select Type [3] in section TYPE settings.
c. Select item INC Incremental Position as the command type.
d. Set Target Speed Index to 20.0 rpm. Settings of related
acceleration/deceleration shall be appropriate.
e. No delay time; set 0 here.
f.
March, 2015
Set Position CMD DATA to 200000 PUU.
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Introduction of PR Operation
ASDA Series Application Note
2. PR#2:
PR
Jump
#2
DLY = 0
( I)
PR # 10
Figure 1.63 Settings of PR#2
a. Select path PR#2.
b. Select Type [7] Jump to the specified path in Type Settings.
c.
Enable interrupt function; select When this PR is executing, it interrupts the
previous one (1: YES).
d. No delay time; set 0 here.
e. Select PR#10 as the Jump to the specified PR Number.
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ASDA Series Application Note
Introduction of PR Operation
3. PR#10:
PR
# 10
( I)
Write
DLY =0
P 5 - 55 = 10
Figure 1.64 Settings of PR#10
a. Select Path PR#10.
b. Select Type [8] Write the specified parameter to the specified path in Type
Settings.
c. Enable interrupt function; select When this PR is executing, it interrupts the
previous one (1: YES).
d. As this PR is presented in an arrow-shaped frame, please select Auto move to
the next PR when completed (1: YES).
e. No delay time; Set 0 here.
f.
Select 0: Parameter and P5-55 as the target.
g. Select 0: Constant and enter 10 at section Data.
March, 2015
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Introduction of PR Operation
ASDA Series Application Note
4. PR#11:
PR
#11
Position (3)
D=0, S =100 .0 rpm
300000 PUU , INC
Figure 1.65 Settings of PR#11
a. Select path PR#11.
b. Select Type [3] in the TYPE settings.
c. Select INC Incremental Position as the command type.
d. Set Target speed index to 100.0 rpm. Related settings of
acceleration/deceleration have to be appropriate.
e. No delay time; Set 0 here.
f.
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Set Position CMD DATA to 300000 PUU
March, 2015
ASDA Series Application Note
Introduction of PR Operation
5. PR#12:
PR
Write
# 12
DLY =0
( I)
P 5 - 55 = 12
ⓑ
ⓒ
ⓓ
ⓔ
ⓕ
ⓐ
ⓖ
Figure 1.66 Settings of PR#12
a. Select path PR#12.
b. Select [8]: Write the specified parameter to the specified path at Type Settings.
c. Enable interrupt function; select When this PR is executing, it interrupts the
previous one as (1: YES).
d. As this PR is presented in a squared frame, please select No here and it will not
automatically move to the next PR when completed.
e. Select 0: Parameter and P5-55 as the target.
f.
No delay time; set 0 here.
g. Select 0: Constant and enter 12 at section DATA.
PR Motion Analysis:
With the feature that the servo updating commands every 1 ms, when reading a series of PR
commands of different types, the first step is to arrange a series of PR commands into PR
groups. The key to it is to look for the PR command without interrupt function in the group. In
Figure 1.60, PR#1 and PR#11 have no interrupt, and PR#2 and PR#10 that following PR#1 have
the interrupt function; the following PR#12 have interrupt function as well. In this case, PR#1,
PR#2, and PR#10 in the executor will be the command group and executed in the first 1 ms;
PR#11 and PR#12 will be the command group in the next 1 ms. Because PR#1 is a motion
command, the second PR group (PR#11 and PR#12) will not be executed until the motion
command from PR#1 is completed.
PR#1 / PR#2 / PR#10: After entering PR executor, jump command PR#2 and write-in command
PR#10 will be completed here; meanwhile P5-55 is set to 10. As PR#1 is a motion command, it
will be distributed to the motion command generator to generate motion commands.
March, 2015
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Introduction of PR Operation
ASDA Series Application Note
PR#11 / PR#12: Because PR#11 has no interrupt, it does not exist with PR#1, PR#2, and PR#10
in the PR executor at the same time (it is not categorized into the same PR group with PR#1,
PR#2 and PR#10); it will not enter the executor until the first PR group enters it after 1 ms.
PR#11 will not have any influence on the motion command of PR#1; on the other hand, it waits
for PR#1’s motion commands to be completed and then carry on. PR#12 and PR#11 will enter
the executor together and start to execute the command after PR#1 is completed. After this PR is
completed, 12 will be written to P5-55.
Result:
Figure1.67 shows the final result of PR procedure in Example 1.
PR Position (3)
#1 D= 0, S= 20.0 rpm
200000PUU, INC
PR
#2
(I)
Jump
DLY=0
PR#10
PR Write
#10 DLY=0
(I) P5-55=10
PR Position (3)
# 11 D=0,S= 100.0 rpm
300000PUU, INC
PR Write
#12 DLY=0
(I) P5-55=12
(A ) 1ms
(B ) 1ms
Command Group
Command Group
Note: Each command
group is read within 1 ms
Command Group (A) and (B) have motion commands thus both of them
need motion command generator. However, as PR#11 has no interrupt
function, group (B) will not be executed until PR#1 is completed.
660542
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10
10
Figure 1.67 Output of PR Example 1
T: Operating start time of PR command
t = T ~ t = 4+T: Carry out PR#1, PR#2 and PR#10. Motor operates 200000 PUU at speed of 20
rpm; meanwhile, P5-55 is set to 10.
t = 4+T ~ t = 5.2+T: Carry out PR#11 and PR#12. Motor operates 300000 PUU at speed of 100
rpm; meawhile, P5-55 is set to 12.
1-50
March, 2015
ASDA Series Application Note
Introduction of PR Operation
Example 2:
PR
#1
Position (3)
D=0, S=20.0 rpm
200000PUU, INC
PR
#2
(I)
Jump
DLY=0
PR#10
PR Write
#10 DLY=0
(I) P5-55=10
PR Position(3)
#11 D=0,S=100.0 rpm
(I) 300000PUU , INC
PR Write
#12 DLY=0
(I) P5-55=12
1ms
命令群Group
Command
Figure 1.68 Example 2
PR Motion Analysis:
In Figure 1.68, only PR#1 has no interrupt; however, as it is the Head PR, these 5 PR commands
will enter PR executor together and be completely executed within 1 ms.
After entering PR executor, motion commands generated by PR#11 will interrupt the motion
commands of PR#1. Thus, only motion commands from PR#11 will enter the motion command
generator. PR#2, PR#10, and PR#12 will be completed in the executor. When carrying out
PR#10, P5-55 will be set to 10. After PR#12 is executed, P5-55 will be set to 12. Because they
are both carried out within the same 1 ms, the result of PR#10 will be replaced by PR#12 right
away. On the other hand, as there is still time difference between executing PR#10 and PR#12,
the value of P5-55 will be 10 in a very short time.
March, 2015
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Introduction of PR Operation
ASDA Series Application Note
Result:
Figure 1.69 shows the result after PR Group is executed in Example 2.
PR
#1
Position (3)
D=0, S=20.0 rpm
200000PUU, INC
PR Jump
#2 DLY=0
(I) PR#10
PR Write
#10 DLY=0
(I) P5-55=10
PR Position (3)
#11 D=0,S=100.0 rpm
(I) 300000PUU , INC
PR Write
#12 DLY=0
(I) P5-55=12
1ms
Command
Group
命令群
660542
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660542
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10
10
Figure 1.69 Output of PR Example 2
In this example, the first position command (PR#1) is interrupted by the second position
command (PR#11). The first position command is hardly executed; therefore, only the output of
the second command is read by the motion command generator. The command executing time
is 1.2 sec. with the speed of 100 rpm, and moves from 0 to 300000 PUU. Regarding P5-55,
when PR#10 is carried out, P5-55=10. However, it will be immediately replaced by PR#12 as
P5-55 = 12. Figure 1.69 shows that from PR#10 to PR#12, it only takes 0.25 ms to carry out.
1-52
March, 2015
ASDA Series Application Note
Introduction of PR Operation
Example 3:
PR
#1
Position(3)
D=0 , S=20.0 rpm
200000PUU , INC
PR
#2
Jump
DLY= 0
PR#10
PR Write
#10 DLY= 0
(I) P5-55=10
(A ) 1ms
PR Position(3)
#11 D=0, S= 100.0 rpm
(I) 300000PUU, INC
PR Write
#12 DLY=0
(I) P5-55=12
(B ) 1ms
Command group
Command group
When command group (A) is completed, command group (B) will be executed.
Figure 1.70 Example 3
PR Motion Analysis:
In Figure 1.70, as PR#1 and PR#2 have no interrupt; PR#1 will enter PR executor first. After 1ms,
PR#1 takes other PR commands into the executor.
After PR#1 is completed in the executor, as it is a motion command, it will be distributed to
motion command generator to generate motion command.
Other PR commands that enter the executor have to wait to be executed until PR#10 is
completed. When PR#10 is completed and P5-55 = 10, PR#12 will interrupt immediately. Same
as Example 2, result of P5-55 = 10 only lasts shortly and will be replaced by the result of P5-55 =
12. Since PR#2 has no interrupt, motion command generated by PR#11 will not interrupt motion
command from PR#1. In this case, the servo system will continue to carry out the motion
command of PR#11after that of PR#1.
Result:
Figure 1.71 is the result after carrying out PR groups in Example 3.
Regarding motor’s operation, the result is the same in Example 1. Motion commands from PR#1
and PR#11 will both be executed. And the second position command is carried out after the first
position command is over (after 4 sec.).
In terms of P5-55, as it cannot be carried out until position command of PR#1 is fulfilled, when t =
T ~ 4+T, P5-55 has not been set up. In this period, P5-55 will display the previous reserved value,
which is not referential. When t = 4, PR#2 ~ PR#12 start to be carried out and meanwhile the
value of P5-55 will be 10 first for a very short time, then change to 12, which is identical to
Example 2.
PR
#1
Position(3)
D=0 , S=20.0 rpm
200000PUU , INC
(A ) 1ms
Command Group
PR
#2
Jump
DLY= 0
PR#10
PR Write
#10 DLY= 0
(I) P5-55=10
PR Position(3)
#11 D=0, S= 100.0 rpm
(I) 300000PUU, INC
PR Write
#12 DLY=0
(I) P5-55=12
(B ) 1ms
Command Group
When command group (A) is completed, command group (B) will be executed.
March, 2015
1-53
Introduction of PR Operation
ASDA Series Application Note
660542
21.2
660542
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10
10
Figure 1.71 Output of PR Example 3
Example 4:
Command Group
Command Group
Figure 1.72 Example 4
PR Motion Analysis:
In Figure 1.72, only PR#1 has no interrupt but it has 10 ms delay time. Thus, PR#2 will enter the
executor after PR#1 starts to be carried out for 10 ms.
During the 10 ms delay time, PR#1 is completed in the executor and has entered motion
command generator to make the motor run. After 10 ms, other PR commands will enter the
executor one after another and be completed. The motion command generated by PR#11 will
enter motion command generator and replace the motion command from PR#1 because of its
interrupt setting. However, as PR#11 is incremental, the motor’s total traveling distance should
be: distance generated by PR# + distance generated by PR#11, which is 500000PUU. After 10
ms, the motor will operate at the speed specified by PR#11.
1-54
March, 2015
ASDA Series Application Note
Introduction of PR Operation
Result:
Figure 1.73 shows the result after PR group is executed in Example 4.
Command Group
Command Group
660542
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660542
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10
10
Figure 1.73 Output of PR Example 4
From t = Ts to t = T+10 ms, motor will operate based on the position command generated by
PR#1. After 10 ms, the command of PR#1 will be interrupted by PR#11. Thus, motor will operate
based on the motion profile generated by PR#11 after 10 ms. Regarding P5-55, it is the same as
example 2 and 3. As PR#10 is interrupted by PR#12, when PR#10 is executed, P5-55 = 10.
However, this will be replaced by PR#12 right away and then P5-55 = 12.
March, 2015
1-55
Introduction of PR Operation
ASDA Series Application Note
Example 5:
PR
#1
Position(3)
D=0, S=20.0 rpm
200000PUU , INC
PR
#2
(I)
Jump
DLY=0
PR#10
PR Write
#10 DLY=5000
(I) P5-55=10
(A )1ms
PR Position (3)
#11 D=0,S=100.0 rpm
(I) 300000PUU , INC
PR Write
#12 DLY=0
(I) P5-55=12
(B ) 1ms
Command Group
Command Group
Figure 1.74 Example 5
PR Motion Analysis:
In figure 1.74, only PR#1 has no interrupt; as PR#1 is the Head PR, PR#1, PR#2, and PR#10 will
enter PR executor at the same 1 ms. However, since PR#10 has set delay time of 5000 ms,
PR#11 and PR#12 will enter the executor after 5000 ms.
In PR executor, PR#1, PR#2, and PR#10 are consecutively carried out. The motion command
from PR#1 will enter the motion command generator to make the motor run when this PR
command is completed. After PR editor has completed PR#10, it waits for 5 seconds and then
carries out the next PR command. And motion command from PR#1 will be completed within 5
seconds.
After 5 seconds, PR editor will go on to carry out PR#11 and PR#12. The motion command from
PR#11 will enter motion command generator to make the motor run. Therefore, motion
commands from PR#1 and PR#11 will both be carried out. Besides, PR#12 will interrupt PR#11
so P5-55 = 12 after 5 seconds.
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March, 2015
ASDA Series Application Note
Introduction of PR Operation
Result:
Figure 1.75 shows the result after PR group is carried out in Example 5.
PR
#1
Position(3)
D=0, S=20.0 rpm
200000PUU , INC
PR
#2
(I)
Jump
DLY=0
PR#10
PR Write
#10 DLY= 5000
(I) P5- 55 = 10
PR Position (3)
#11 D=0,S=100.0 rpm
(I) 300000 PUU, INC
(A )1ms
PR Write
#12 DLY = 0
(I) P5-55=12
(B ) 1ms
Command Group
Command Group
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660542
21.2
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10
10
Figure 1.75 Output of PR Example 5 PR
See Figure 1.75, from t = T to t = 4+T sec, motor operates according to PR#1’s command.
Because PR#10 has set delay time of 5 sec., PR#11’s command will be executed after
t = 5+T sec.. From t = T to 5+T sec., P5-55 = 10. After 5+T second, P5-55 = 12.
March, 2015
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Introduction of PR Operation
ASDA Series Application Note
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1-58
March, 2015
Introduction of E-Cam
Operation
111111010111111111111111111111111111111 1111111
1
2.1 Introduction of E-Cam ......................................................................................... 2-2
2.2 Source of the Master Axis ..................................................................................... 2-5
2.3 The Clutch ............................................................................................................ 2-7
2.3.1 Settings for Engaging E-Cam ........................................................................ 2-7
2.4 The E-Gear of the Master Axis ........................................................................... 2-13
2.5 E-Cam Curve ...................................................................................................... 2-14
2.5.1 Create an E-Cam Curve by Software.......................................................... 2-16
2.5.2 Using Macro to Create an E-Cam Curve .................................................... 2-32
2.6 E-gear Ratio and Scaling of E-Cam Curve ......................................................... 2-40
2.7 E-Cam Setting Example ..................................................................................... 2-42
2.7.1 Creating an E-Cam Curve ........................................................................... 2-42
2.7.2 Relevant Parameter Settings and Enabling E-Cam Function ..................... 2-44
2.8 Simultaneously Using E-Cam Function and PR command ................................ 2-46
2.9 Troubleshooting when E-Cam is not Working Properly ...................................... 2-48
March, 2015
2-1
Introduction of E-Cam Operation
2.1
ASDA Series Application Note
Introduction of E-Cam
E-Cam, a virtual cam implemented by software that simulates a machine cam. E-Cam curve is
built by software to achieve the relative motion between Master axis and Slave axis like real
cams. If the output of E-cam is the same as that of the machine cams, replacing machine cams
with E-Cam system becomes feasible. Unlike the machine cam, E-Cam can be applied without
the limitation on modifying cam shapes. As long as it is a Master-Slave application and the
Master-Slave relation can be translated into equations, E-Cam can be applied.
What are the advantages when machine cam is replaced by E-Cams?
1. Higher energy efficiency: Eliminating the frictions between mechanical parts such as
cam discs, energy can thus be saved.
2. Modifying cam shape becomes easy: Cam shape can be modified any time to make
different motion.
3. Low mechanical consumption: E-Cam is simulated by software, eliminating concerns on
mechanical consumption.
4. Wide range of application: E-Cam function can be applied to any applications that can be
achieved by the equation; a machine cam is not necessarily required.
5. Flexibility: One master axis can command multiple slave axes, which is rather complex
in the machine cam.
6. Positioning system for physical goods: In application of machine cam system such as
packaging machine, when its cutting shear tries to aim at the target position, the system
is not able to modify the error occurs during printing, thus errors are accumulated
permanently.
What are the disadvantages when replacing machine cam with E-cams?
1. Real time: Signal processing takes time; the synchronization of E-Cam is generally
inferior to mechanical ones. However, this problem can be overcome by firmware.
2. Accuracy: If signal communication is interfered and causing pulse loss, users have to
use other methods to conduct positioning.
2-2
March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
Mechanical Power
Pulse Command
Input of Master Axis
Output
of Cam
Cam
If both of the axes work in the same manner, the Servo
system can be used to replace the machine Cam.
Figure 2.1 E-Cam and the Machine Cam
In E-Cam system, the cam makes the motion based on the E-Cam curve. The position of master
and slave is a one-to-one function relation, which is the E-Cam curve function. The function of
master axis is to send pulses to the slave axis. The slave axis will move according to the
received pulses and the corresponding E-Cam curve.
PUU,
Position
The
(Slave)
corresponding
position of
slave axis.
Position of the master
axis corresponds to
position of the slave axis.
The pulse train
from master.
Pulse
(Master)
Figure 2.2 An E-Cam Curve
March, 2015
2-3
Introduction of E-Cam Operation
ASDA Series Application Note
Figure 2.3 illustrates parameter settings of E-Cam with the concept of using machine cams. The
required parameters of using E-Cam are shown below.
Master Axis:
Sources of master
axis
P5-88.Y
Clutch:
Control the timing that
the slave axis starts to
follow the master axis.
P5-88.UZ, P5-87, P5-89
Master E-Gear:
The scaling of
command pulse.
P5-83, P5-84
E-Cam Curve:
The E-Cam function
defines the relationship of
master and slave.
P5-81, P5-82, P5-85
Slave E-Gear:
The scaling of E-Cam
curve to output.
P1-44, P1-45, P5-19
Output of
E-Cam
Figure 2.3 Using Parameters to Simulate the Machine Cams
2-4
March, 2015
ASDA Series Application Note
2.2
Introduction of E-Cam Operation
Source of the Master Axis
P5-88
High Word
Parameter settings
of E-Cam
Low Word
S
0
BA
0~2
-
00~3F
U
Z
Y
X
0~8 0~2 0~5
0~6 0~3
Figure 2.4 P5-88.Y: Settings for Source of the Master Axis
Source of the master axis can be specified by P5-88.Y. Any pulses that conform to the hardware
specifications of ASDA-A2 can be the source of master axis, such as encoder, PLC, or a servo
drive. 7 sources are available on ASDA-A2:
P5-88.Y = 0: CAP axis (Capture axis); use the source of capture function (P5-39.Y) as the source
of master axis.
P5.88.Y = 1: AUX ENC (Auxiliary encoder); source signal of master axis is input via CN5
connected to an external encoder.
P5.88.Y = 2: Pulse Cmd (Pulse Command); pulse signal of the master axis is input from CN1.
P5.88.Y = 3: PR command; it is a virtual axis that acquires the internal signal. The PR specifies
the motion command and when this PR is carried out, the signal generated will be
regarded as the source of master axis.
P5.88.Y = 4: Time axis; the system generates signals every 1 ms and send them directly to the
master axis.
P5.88.Y = 5: Synchronous capture axis; signals from this axis have been adjusted. This is mainly
applied in the application of flying shears. This mechanism is to regard the
captured source signal that being corrected as the source signal for slave axis. In
the application of flying shears, if using mark-tracking function to correct its cutting
position, synchronous capture axis shall be specified as the source for the master
axis.
Servo
Drive
Marking Sensor
DI7
Correcting
Machanism
CN1 or
CN5
P5-78
P5-79
P5-80
Master source, P5-37,
set by Capture
parameter P5-39.Y.
(Y=1 or 2)
E-Cam
Curve
Output
Synchronous
Cap. axis
P5-77
Figure 2.5 Synchronous Capture Axis
P5.88.X = 6: Analog channel 1; it is a virtual axis, which captures the analog voltage (via speed
channel by analog command) and regard it as the source of master axis. The unit
is the output frequency 1 M pulse/s corresponded by every 10 V.
March, 2015
2-5
Introduction of E-Cam Operation
ASDA Series Application Note
Pulse By-pass Function
On ASDA-A2, the by-pass function allows one master axis to drive multiple slave axes. With this
function, a servo can send the received signals to the next slave axis (servo). Signals passing
through the servo will not be attenuated because ASDA-A2 acts like an amplifier, boosting the
signal and maintain its origin intensity before output. For example, the input signal of 4.5 V will be
amplified to 5 V when output. However, signal attenuation during transmission via cables shall be
taken into consideration (because of the resistor in the cable). If the signal is attenuated to an
extent that cannot be identified by the input terminal, strengthening or shortening the cable is
required. Please be aware of this issue when wiring two servo drives; shielded twisted-pair is
suggested in this case. Regardless the signal delay, the signal transmission time of every
ASDA-A2 servo drive is only 50n second. That is, when 10 ASDA-A2 servos are serial
connected and transmit pulses with by-pass function, the input lag between the first servo drive
and the tenth is 0.5u second.
Although the only pin for pulse input on ASDA-A2 is OA, /OA, OB, /OB of CN1, pulses can also
be input via CN1 or CN5. The source of input signal can be specified by P1-74.B. Thus, when
using by-pass function and to use CN1 as the pulse input channel (shown in Figure 2.6), P1-74.B
is set to 2 for each slave axis (servo) so the servo will output the signal received from CN1.
Master Slave 1 Slave 1 Slave 2 Slave 2 Slave 3 Slave 3
CN1
CN1
CN1
CN1
CN1
CN1
CN1
Pulse, OA,
OA,
Pulse , OA,
Pulse , OA,
/Pulse, /OA,
/OA,
/Pulse, /OA,
/Pulse, /OA,
Sign,
OB,
OB,
OB,
OB,
Sign,
Sign,
/Sign
/OB
/OB
/OB
/OB
/Sign
/Sign
P1-74. B = 2
P1-74. B = 2
P1-74. B = 2
Figure 2.6 Pulse By-pass Function: CN1 IN / CN1 OUT
When wiring, users may use CN5 as the input channel. See Figure 2.7, P1-74.B is set to 1 on
every slave axis (servo); these servos will output signals received from CN5.
2-6
March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
Master Slave 1 Slave 1
CN5
CN1
CN1
Opt A, OA,
OA,
/Opt A, /OA,
/OA,
Opt B, OB,
OB,
/Opt B
/OB
/OB
P1-74. B = 1
Slave 2 Slave 2 Slave 3 Slave 3
CN1
CN5
CN1
CN5
OA,
OptA,
Opt A, OA,
/Opt A, /OA,
/Opt A, /OA,
OB,
Opt B,
Opt B, OB,
/OB
/Opt B
/OB
/ Opt B
P1-74. B = 1
P1-74. B = 1
Figure 2.7 Pulse By-pass: CN5 IN / CN1 OUT
2.3
The Clutch
The function of clutch is controlling the timing for engaging and disengaging of E-Cam. When
E-Cam is enabled, whether the slave axis will operate according to the master axis signal is
subject to the status of clutch. Only when cams are engaged are they able to operate based on
the pulses from the master axis. While cams are disengaged, slave axis is unable to operate
even when pulses from the master axis are received. The conditions for engaging and
disengaging are described below.
2.3.1
Settings for Engaging E-Cam
P5-88.Z
Engaged
Cam
Figure 2.8 Engaging of E-Cam
Shown in Figure 2.8, when E-Cam is engaged, the master axis will drive the slave axis via the
clutch and make it operate.
March, 2015
2-7
Introduction of E-Cam Operation
ASDA Series Application Note
High Word
P5-88
Parameter Setting
of E-Cam
Low Word
S
0
BA
U
0~2
-
00~3 F
Z
Y
X
0~8 0~2 0~
0~6 0~
0~3
Figure 2.9 P5-88.Z: Settings for the Engaging Timing
The engaging timing is specified by P5-88.Z:

Engage immediately: When P5-88 = 1, it means E-Cam will be engaged immediately
when E-Cam function is enabled. This setting is applicable when slave axis has to keep
operating unless E-Cam is disabled. P5-88.Z has to be set 0 when using this setting.

DI enabled: E-Cam engages when DI (0x36) is ON (high level), and meanwhile
P5-88.Z = 1. If DI remains ON after E-Cam is enabled, the cam will remain engaged.

Use Capture function: When P5-88.Z = 2 and the first data is captured, E-Cam is
engaged. When capture function is enabled, then the signal will be input via DI7 after
the sensor is triggered. If using this function to engage E-cam, the engaging timing will
be the moment that sensor is triggered and signal be input via DI7. Unlike the previous
method that uses the signal of sensor to trigger DI 0x36, carrying out capture function
allows the time sequence of the system become more accurate because DI7 inputs
with high speed in capture function, which action time is only 5 us.
2.3.2
Settings for Disengaging E-Cam
P5-88.U
Disengaged
Cam
Figure 2.10 Disengaging of E-Cam
Compare with the engaging time of E-Cam, its disengaging time is rather complicated. After
disengaging, the slave axis will remain still regardless the action of master axis. It is because the
master axis is unable to use clutch to control the salve axis. See Figure 2.10.
2-8
March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
High Word
P5-88
E-Cam Settings
S
0
0~2
-
BA
Low Word
U
Z
Y
X
00~3F 0~8 0~2 0~
0~6 0~
0~3
Figure 2.11 P5-88.U: Settings for Disengaging Time
Disengaging timing is specified by P5-88.U:

P5-88.U = 0: Remain engaged unless E-Cam function is disabled.

P5-88.U = 1: DI disabled. When disabled, set DI (0x36) to OFF (low level). If this DI
remains OFF, E-Cam will remain disengaged.

P5-88.U = 2: When E-Cam reaches the moving distance specified by P5-89 after
engaging, the motor will stop right away after disengaging.
PUU, Position
(Slave)
P5-88.U = 2
The Servo will
stop at this
position
exactly when it
disengages.
Pulse
(Master)
The pulse number set in
P5-89 for disengaging.
Figure 2.12 P5-88.U = 2 Disengaging Timing

P5-88.U = 6: When E-Cam reaches the moving distance set by P5-89 after engaging,
the motor will decelerate to stop with smooth speed. However, the position will go
beyond the stop position commanded by the master axis.
PUU, Position
(Slave)
The Servo will
decelerate to
stop around
this position
with smooth
speed
P5-88.U = 6
Pulse
(Master)
The pulse number set in
P5-89 for disengaging.
Figure 2.13 P5-88.U = 6 Disengaging Timing

P5-88.U = 4: When E-Cam reaches the moving distance set by P5-89 after engaging, it
will disengage and operate in a cyclic manner. When the lead pulse amount is reached,
it automatically engages again. After starting operating in a cyclic manner, the lead
pulse is specified by P5-92.
March, 2015
2-9
Introduction of E-Cam Operation
ASDA Series Application Note
P5-88.U = 4
PUU, Position
(Slave)
The pulse number
set in P5-89 for
disengaging.
P5-92 for
Lead
pulse
The pulse number
set in P5-89 for
disengaging.
Pulse
(Master)
Figure 2.14 P5-88.U = 4 Operation of E-Cam
In Figure 2.14, the lead pulse number specified by P5-92 is the one before the cycle starts; this
lead pulse is effective only when P5-88.U = 4 and E-Cam starts to work in a cyclic manner. No
matter what engaged/disengaged condition it is, as long as E-Cam is going to engage again after
disengaging, the lead pulse is still determined by P5-87. After E-Cam starts to operate in a cyclic
manner, the lead pulse is determined by P5-92.
PUU, Position
(Slave)
Engaging
Condition
fulfilled
Pulse
Master
)
(
Reaches the lead pulse amount
Engaged
P5-87
Figure 2.15 Initial Lead Pulse Amount
In addition to settings mentioned above, there are other settings available. For example, setting
P5-88.U to 8 will disable E-Cam after disengaging, which is identical to the setting of P5-88.X = 0.
Disengaging E-Cam is different from disabling E-Cam. When E-Cam is disabled, this function is
completely unusable. On the other hand, while E-Cam is disengaged, E-Cam system remains
working although motor is stopped. Meanwhile, the slave axis is still monitoring the pulses sent
from the master axis. Disabling E-Cam is like switching off a car engine (P5-88.X= 0).
Disengaging E-Cam is like the car is in neutral and the engine remains on (P5-88.X =1).
Therefore, the function of P5-88.X is similar to the key for starting a car. Function of P5-88.UZ
can be regarded as the gear for controlling a car, which determines whether to engage or
disengage E-Cam. The setting of P5-88.U = 8 cannot be used individually; it has to set with the
disengaging timing, which can be set by Bit-OR for multiple selection. Except P5-88.U = 2, 4, and
6 that cannot be set simultaneously, disengaging timing can also be set by Bit-OR for multiple
disengaging timing. See table below.
2-10
March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
P5-88.U
Function
Disengaged Condition
0
0
Remain engaged
1
1
DI(0x36) OFF: CAM OFF
2
2
After Disengaged
-
After master axis receives the pulse amount which is set by
P5-89, the motor stops immediately after disengaging.
Enter Stop Status
P5-88.U = 1 or P5-88.U = 2:
3
1+2
E-Cam disengaged when disengaged condition fulfilled.
After master axis receives the pulse amount which is set by
P5-89, E-Cam will be disengaged and operate in a cyclic
4
Pre-engage
4
manner, waiting for the lead pulse and then engage
automatically again.
5
Returns to
Status, which is
set by P5-92
E-cam keeps operating in a cyclic manner until (P5-88.U = 1)
Pre-engage or
disengaged condition is fulfilled and then E-Cam disengages.
stop status
1+4
After master axis receives the pulse amount which is set by
P5-89, the motor will decelerate to stop with smooth speed after
6
6
disengaging. However, it will go beyond the stop position
Enter Stop Status
commanded by the master axis.
P5-88.U = 1 or P5-88.U = 6: E-Cam is disengaged after
7
1+6
disengaged condition fulfilled.
Cannot be
8
set
Disable E-Cam after disengaging.
-
individually
9
1+8
P5-88.U = 1: Disable E-Cam after disengaged condition fulfilled.
A
2+8
P5-88.U = 2: Disable E-Cam after disengaged condition fulfilled. E-Cam disabled
B
1+2+8
P5-88.U = 1or P5-88.U = 2: Disable E-Cam after disengaged
(P5-88.X = 0)
condition fulfilled.
C
4+8
Special function, which can reduce the vibration caused by
Returns to
speed changing when returning to pre-engage status. It is
Pre-engage
usually applied to the condition of P5-92 = 0, P5-89 = P5-84.
Status
If P5-88.U = 1, E-Cam disengages when disengaged condition
Pre-engage or
D
1+4+8
is fulfilled. Or it will operate according to the setting of P5-88.U =
Stop status
C.
IP5-88.U = 6: Disable E-Cam after disengaged condition
E
6+8
fulfilled.
P5-88.U = 1 or P5-88.U = 6: Disable E-Cam after disengaged
F
E-Cam disabled
(P5-88.X = 0)
1+6+8
condition fulfilled.
March, 2015
2-11
Introduction of E-Cam Operation
ASDA Series Application Note
Monitoring E-Cam Status
P5-88,
E-Cam Settings
High Word
Low Word
S
0
BA
U
Z
Y
X
0~2
-
00~3F
0~8
0~2
0~5
0~1
P5-88.U = 1, 2, 6
P5-88.X = 0
S0
Stop
S1
Engaged
P5-88.U = 4.
The lead pulse
number is set
by P5-92.
P5-88.X = 0
The condition set by P5-88.Z satisfied.
The lead pulse number is set by P5-87.
Initial lead pulse is set by P5-87;
Pre-engaged time of each cycle
is set by P5-92. (Can be read
from monitoring variable 061)
S2
Lead
Pulse
Figure 2.16 E-Cam Status
The status of E-Cam can be monitored via P5-88.S. When E-Cam is enabled (P5-88.X =1), the
system will update its status in P5-88.S.
P5-88.S = 0: Disengaged status. The system will check if the engaged conditions are fulfilled.
When fulfilled, E-Cam will then move on to S2 Lead Pulse status.
P5-88.S = 2: E-Cam is in Lead Pulse status (S2). In this status, E-Cam will count the received
pulses of the master axis. When received pulse amount reaches the setting value, E-Cam will
engage again (move on to status S1). Lead pulse is the delay pulse which is counted after
engaged conditions are fulfilled.
P5-87 is for specifying the initial lead pulse, which is the lead pulse amount required before the
first engaging. On the other hand, P5-92 is for specifying the lead pulse number before it starts a
cycle; when engaged condition is set to 4 (P5-88.U = 4) and the system is working in a cycle, the
lead pulse number is determined by P5-92. However, the initial lead pulse is still specified by
P5-87 in this condition. If E-Cam is disabled now (P5-88.X = 0), the E-Cam status will return to
Stop status (S0).
P5-88.S = 1: Engaged Status. The system will keep checking on whether disengaged condition
is fulfilled. When fulfilled, E-Cam will switch to status S0 (Stop) or S2 (Lead Pulse) based on the
setting (disengaged condition is specified by P5-88.U).
2-12
March, 2015
ASDA Series Application Note
2.4
Introduction of E-Cam Operation
The E-Gear of the Master Axis
E-gear ratio of the master axis will determine the pulse resolution, which is defined by P5-83 and
P5-84. When the slave axis receives the pulse number P from the master axis specified by P5-84,
E-Cam will rotate M circle specified by P5-83, which is M cycle of the E-Cam table. For example,
when P5-84 = 10000 and P5-83 = 1, it means when slave axis receives 10000 pulses from the
master, E-Cam travels from 0° to 360°, which is one cycle of the E-Cam table.
In Figure 2.17, If the E-gear ratio of the master is taking 10000 as a standard, when this value is
higher (value of P5-84 becomes higher or value of P5-83 becomes lower), the pulse width will
become narrower thus making a higher pulse resolution of the master axis. On the other hand, if
the E-gear ratio value of the master is lower (value of P5-84 becomes lower or value of P5-83
becomes higher), the pulse width will become wider thus making a lower pulse resolution of the
master axis.
PUU, Position
(Slave)
360º
Pulse
(Master)
10000
12500
8000
12500
10000
1
12500
1
10000
1.25
10000
0.8
P5 - 84
P5 - 83
1000000
100
1250000
100
1000000
125
1000000
80
1000000
450 º
1000000
288 º
Figure 2.17 E-Gear Ratio of the Master Axis
March, 2015
2-13
Introduction of E-Cam Operation
2.5
ASDA Series Application Note
E-Cam Curve
When E-Cam is engaged and receiving pulses from the master, the slave axis will operate
according to the setting of E-Cam curve. On ASDA-A2, E-Cam can be applied as long as the
pulse from the master axis and position of the slave axis is a one-to-one relation.
Position (PUU)
Slave
Pulse
0。 45。 90。135。180。225。270。315。360。 Master
Figure 2.18 E-Cam Curve
E-Cam curve can be created by ASDA-Soft or macro parameters. Although E-Cam curve can be
created in several ways, the only way for ASDA-A2 is to store the angle of E-Cam and
corresponding position on slave axis in data array.
ASDA-A2 can save 800 data in total; a single curve can have 721 data at maximum (720
divisions). Therefore, as long as the total data is below 800, multiple E-Cam curve data can be
saved. Data amount of E-Cam is stored in P5-82. And the data of the first E-Cam curve that
saved in data array is specified by P5-81. When data array has saved multiple data of E-Cam
curve that can be specified by P5-81 and P5-82.
See Figure 2.19 for example. To replace a machine cam with E-Cam curve, the first step is to
equally divide the cam. In this example, the real cam is divided into 8 equal parts thus the angle
of each part is 360/8 =45°. The second step is to figure out distances between center of the cam
and its edge. Then, put these values into data array. In this case, this data presents the position
of the slave axis. The start position (0°) and destination (360°) shall be the same, and both data
shall be put in data array so as to present a complete cycle of a cam. Therefore, there are 8+1 =
9 points in data array. When P5-81 = 50 and P5-82 = 8 (8 divisions), E-Cam curve (position of
the slave axis) will be stored at the address from 50 to 58. When using this curve, the system will
access E-Cam’s position and its corresponding angle based on the setting of P5-81 and P5-82.
Users may use E-Cam editor of ASDA-Soft to manually create a table and write the data to data
array.
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March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
Data Array
8
P5-81 = 50
7
1
6
starting
address
2
5
30000
20000
40000
45000
30000
20000
20000
50000
30000
3
4
Position ( PUU )
(Slave)
40000
50
51
52
53
54
55
56
57
58
P5-82 + 1 = 8 + 1 = 9
50000
45000
30000
20000
30000
20000
1 2
3 4
5
30000
20000
6 7 8
1
0。 45。 90。135。180。225。270。315。360。
Pulse
(Master)
Figure 2.19 E-Cam Curve and Machine Cam
DO.0x118, DO.0x11A or monitoring variable 062(3Eh) can be used to monitor the operating
speed of E-Cam.
Position, PUU
(Slave)
Pulse
(Master)
0。
DO.0x118
DO.0x114A
Monitoring
variable 062
45。
90。
。
135
。
180
。
225
P5-90 = 180
P2-78 = 90
。
270
。
315
360。
P5-91 = 280
P2-79 = 225
Pulse
number
specified
by P5-83 and P5-84
P5-83
與 P5所定義的脈波數
Figure 2.20 Monitoring the Operating Speed of E-Cam
As shown in Figure 2.20, if DO.0x118 is ON, it means position of E-Cam is within the setting
range. P5-90 is for specifying the starting angle of DO output when DO is ON; P5-91 is for
specifying the ending angle of DO output when DO is ON.
DO.0x11A and DO.0x118 have the same function. When using DO.0x11A, P2-78 is for specifying
the starting angle of DO output; P5-79 is for specifying the ending angle of DO output.
March, 2015
2-15
Introduction of E-Cam Operation
ASDA Series Application Note
Monitoring variable 062 will display the current pulse number being received so users may
acquire the E-Cam’s position. For example, if the master axis outputs 3600 pulses (P5-84 =
3600), E-Cam rotates one circle (P5-83 = 1), this means it moves from 0° to 360°. When E-Cam
moves to 180°, and monitoring variable 062 will read 1800 pulses.
How to Create an E-Cam Curve?
2.5.1 Create an E-Cam Curve by Software
Users may use ASDA-Soft to create E-Cam curves. By clicking on E-Cam Editor on the tool bar,
a window of E-Cam editor will pop up. At the starting page, users may select the way to create an
E-Cam table. See Figure 2.21. There are 7 ways available:
Manually create a table, Speed Fitting Creation, Rotary Shear-W/O Sealing Zone, Rotary
Shear-W/T Sealing Zone, Rotary Shear-Adjustable Sealing Zone, Cubic Curve Creation, Rotary
Shear- Printer Machine, and Cubic Curve Creation.
Figure 2.21 Ways to Create E-Cam Table in ASDA-Soft

Manually Create a Table
From the perspective of using the machine cam, Figure 2.19 is an example of manually creating
an E-Cam table. It is to use the distances between cam center and its edge and their
corresponding angles to create an E-Cam curve, which is to present the relationship between
angle and position of the slave axis. This method is applicable when each corresponding angle
of the slave axis is known.
Figure 2.22 displays the screen of Manually create a table:
1. The first step is to setup the area number (P5-82). Despite the type of E-Cam, it can be
divided into 720 equal parts (721 points) at maximum. To a cycle of 360°, it means the
minimum degree of each part in one cycle is 0.5°; every 0.5° will correspond to a position
of the axis. More setting points means higher curve resolution and more detail about the
curve can be presented. However, it will occupy more space in data array. Users need to
find a balance between resolution and resource allocation of data array and put
2-16
March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
appropriate area number of E-Cam in data array. Data array is able to store max 800
data. Users need to pay special attention to the setting limit if desire to store multiple
E-Cam curves.
2. After setting up the area number, click on Create Table. Then the software will equally
divide 360 degree equally and put the values into the table according to the area number
set by the user. When E-Cam area number is n, n+ 1 divisions will be shown in the table.
3. Every divided angle that corresponding to a position is put in the table in the unit of PUU.
4. The right down corner of the window will display a complete E-Cam curve. X-axis shows
the angle of E-Cam, from 0° to 360°. Regarding Y-axis, users may select whether to
show position (PUU), speed (PUU/s), or acceleration of the slave axis.
5. When manually creating an E-Cam table, change of position setting should be
reasonable; otherwise, motor overload may occur due to the abrupt speed change or
overcurrent.
Figure 2.22 Manually Create a Table

Speed Fitting Creation
If operating speed becomes users’ first priority when using E-Cam, using Speed Fitting
Creation to create E-Cam curve is recommended.
Figure 2.23 shows the settings of Speed Fitting Creation:
1. Arrange areas according to their proportion in one cycle of E-Cam curve, which includes
waiting area, acceleration area, deceleration area, and stop area.
2. Destination (L) is the total distance the slave axis travels. Its unit is PUU.
3. S-Curve No. is for specifying the smooth level when the position curve transits. The
higher the number the value is, the smoother of motor operation will be during
acceleration and deceleration. Point number of Stop Area is suggested to be set to the
same number as the S-Curve No.
March, 2015
2-17
Introduction of E-Cam Operation
ASDA Series Application Note
4. Although this method is to use the speed relation to create an E-Cam curve, the system
is actually making a curve by using cam angles and their corresponding position on the
slave axis that are saved in the table.
Position
Curve
Speed
Curve
速度
Acceleration
Curve
Smooth level of
the curve
Accel. area
Constant
Speed area
Decel. area
Waiting
area
Stop area
Figure 2.23 Speed Fitting Creation

Rotary Shear- without Sealing Zone
Rotary Shear- with Zone
Rotary Shear- Adjustable Sealing Zone
Three types of rotary shear curve are available in ASDA-Soft, Rotary Shear-W/O Sealing
Zone, Rotary Shear- W/T Zone, and Rotary Shear- Adjustable Sealing Zone. When using
Rotary Shear-W/O Sealing Zone, the curve created does not have a sealing zone. While
using Rotary Shear-W/T Sealing Zone, a rotary shear curve with fixed 51° in the sealing
zone can be created. When using Rotary Shear-Adjustable Sealing Zone, the width of
constant speed area on the rotary shear curve can be specified by software.
These three ways of creating the table is specifically designed for rotary shear application.
The main difference among them is the setting of constant speed area. In general, a curve
without constant speed area is applied to sharp cutter applications; a curve with constant
speed area is suitable for flat cutter applications. Figure 2.24 presents the basic mechanism
of rotary shear. The master axis is the material feeding axis and the slave axis is the cutter
axis. The key point of rotary shear curve is that the material feeding axis (Master) and the
cutter axis (Slave) must operate at the same speed during the cutting process (when cutter
meets the material) so that the material will not be stocked in front of the cutter or be pulled
by the cutter. See Figure 2.25.
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March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
Master Axis
Slave Axis
Figure 2.24 Rotary Shear
Material being sent too fast
Material being sent too slow
Figure 2.25 Speed of Master Axis does not Synchronize with the Slave Axis
E-Cam curve with a constant speed area is mainly applied to mechanism with flat cutters,
which is generally used for package with sealing zones. See Figure 2.26.
Sealing
Zone
Sealing
Zone
Sealing
Zone
Figure 2.26 Application of Flat Cutter
An E-Cam curve with constant speed area will ensure a smooth cutting process without
damaging the material. Figure 2.27 can explain why flat cutters need a constant speed area.
The key is that the master axis and the cutter axis must operate at the same speed during
cutting time. Therefore, as long as the cutting moment is within the constant speed area, a
March, 2015
2-19
Introduction of E-Cam Operation
ASDA Series Application Note
curve with wider constant speed area can be applied to narrower cutters. However, when
using a E-Cam curve which constant speed area is too narrow or doesn’t have enough
constant speed area to a flatter cutter, material might be damaged due to the inconsistent
speed of the master and slave axis when cutting.
Figure 2.27 Relationship between E-Cam curve and the Rotary Shear
The table below elaborates the difference between having a constant speed area and without a
constant speed area. Similarly, when cutting action takes place, speed of cutter axis and the
master axis must be the same. This table may help users understand that the proportion of
cutting circumferences and cutting lengths will determine how the cutter axis works.
Curves without sealing zone:
for sharp cutter applications
Cutter circumference >
Cutting length:
U-shaped speed curve;
the slave axis speed
slows down for cutting
action.
Cutter circumference
<Cutting length:
Inverted U-shaped
speed curve; the slave
axis speeds up for
cutting action.
Speed
Curve
Curves with sealing zone:
for flat cutter applications
Position
Curve
Position
Curve
Speed
Curve
Master Speed
Master Speed
Master
Speed
Maser Speed
Speed
Curve
Position
Curve
Position
Curve
Speed
Curve
1. Cutter circumference > Cutting length: During cutting, two axes run at the same speed.
Other than that, the speed of slave axis is faster than master axis. The faster the
slave axis operates, the shorter the cutting length will be.
2. Cutter circumference =Cutting length: Speed of cutter axis = Speed of the master
axis.
3. Cutter circumference < Cutting length: During cutting, two axes run at the same speed.
Other than that, the speed of slave axis is slower than master axis.
Basically, the speed of cutter axis can be used to adjust the cutting length. However, the
wider the constant speed zone, the less adjusting flexibility for cutting length. See Figure
2.28. Let’s compare the curve with wider constant speed area and the curve with the
2-20
March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
narrower constant speed area. If the required operating distance of the cutter axis is the
same (integral value of the speed curve is the same), curve with wider constant speed
area will accelerate/decelerate faster during the non-constant speed area thus reaching
the operating limit (max. torque limit). So, compare with the curve with narrower constant
speed area, when cutting length becomes shorter, curve with wider constant speed area
will have less flexibility for adjusting the cutting length.
Max. motor
speed
Higher speed
with the same
circumference.
Wider
cutter for
wider
constant
speed area.
Slave speed
Master speed
V dt = Distance
The moving distance of slave.
(circumference of the cutter)
The moving distance of master axis.
(cutting length)
The extra traveling distance of the
slave axis.
Figure 2.28 How does Width of Constant Speed Area Change Motor Speed and Current
If the cutting length cannot be shortened because of the speed or the maximum current
limitation on the slave axis, without changing other conditions, adding more cutters will
shorten the traveling distance of the slave axis among each cutting. In addition, this will slow
down the slave axis as well as the current output; chances of motor reaching its operating
limit will be less.
Half
circumference
(two cutters)
Circumference
(one cutter)
Slave
speed
Master
speed
Master
speed
Slave
speed
Figure 2.29 How Adding Cutters Change the Speed of the Cutter Axis
March, 2015
2-21
Introduction of E-Cam Operation
ASDA Series Application Note
The definition of constant speed area is determined by the proportion of required constant speed
during material feeding, not the constant speed area generated when cutter is operating.
Different material requires different constant speed area. Thus, to generate different E-Cam
curve is required. That is, the constant speed area is determined by the material.
Constant Speed Area
Constant
?º Speed Area
360
o
(One Cycle of Curve)
Figure 2.30 Definition of Constant Speed Area
When using software to create an E-Cam curve, the first step is to know the specifications of the
mechanism. Figure 2.31 shows the specifications that users need to know before creating the
curve.
Gear Box
Tooth #A
(to motor)
Tooth #B
(to cutter)
Encoder pulse
number per
revolution
The
number
of cutter
Diameter
d2
Cutting
Length L
Diameter
d1
Figure 2.31 The Mechanism of a Rotary Shear
No matter it is Rotary Shear-W/O Sealing Zone, Rotary Shear- W/T Sealing Zone, or Rotary
Shear- Adjustable Sealing Zone, mechanical specifications is required when creating a curve
via the software. See Figure 2.32.
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March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
Figure 2.32 Enter Values of Rotary Shear Specifications

Gear Ratio: Directly enter the number of gear and the system will figure out the gear
ratio automatically.

Cutter number (Knife No.) and diameter (Knife Diameter d1): The cutter number can be
changed according to the application and should be equally allocated on the cutter
axis.“Cutter radius” is the distance from cam center to cutter tip, cutter radius times two
is “Cutter diameter”. Therefore, regardless the cutter number, cutter diameter is always
the same. See Figure 2.33. ASDA-Soft will figure out the cutter circumference from the
cutter diameter.
Figure 2.33 The Relationship between Cutter Number and Cutter Diameter

Encoder diameter (d2) and pulse number (Encoder Pulse): Encoder pulse is the pulse
number being sent when encoder rotates one cycle. As encoder diameter and pulse
number are known, the resolution of the command of the master axis can be figured
out, which is the value of P5-84 (when P5-38 = 1). In this case, if pulse number of the
master axis (P5-84) is known, there is no need to enter encoder diameter and encoder
pulse number. Users can directly enter the value of P5-84.

Motor PUU No. per rev.: It is the required PUU when the motor operates one cycle and
converted from E-gear ratio.

Cut length (L): the cutting length of the material, which can be changed by users.
When using the software to create a rotary shear curve, to avoid creating an inappropriate
curve, the software will automatically generate a creatable range based on the ratio of
cutting range and cutter circumference. For example, if cutting length A is much shorter than
March, 2015
2-23
Introduction of E-Cam Operation
ASDA Series Application Note
the moving distance a of slave axis when cutting, it will be unable to increase the speed of
slave axis to satisfy the demand of short cutting length. If the value of R is too small, it might
need to modify the mechanism to conquer the problem.
Please refer to Figure 2.34 for the limit of curve creation.
A: Cutting length
a: The moving distance of the slave axis when cutting
Figure 2.34 Range Limit for Creating the Curve by Software

Speed Compensation:
In some applications, the speed of the master axis and the slave axis is not consistent when
cutting. In this case, parameters of speed compensation can be used to modify the relative
speed between them. When speed compensation is set to a positive value, the slave axis will
operate faster than the master in constant speed area. When the speed compensation is set
to a negative value, the slave axis will operate slower than the master in constant speed
area.
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March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
Figure 2.35 Speed Compensation
When creating a rotary shear curve by Rotary Shear-W/T Sealing Zone, no additional
parameter is required because the constant speed area is fixed to 51°; there is no need to
set up the constant speed area.
However, to use the software to adjust the constant speed area, other than entering the
mechanical specifications, users have to specify the proportion among each area (constant
speed area, S area, acceleration/deceleration area, and stop area) See Figure 2.36.
Acceleration area
Constant speed area
S-Curve
Figure 2.36 Proportion of Constant Area can be Adjusted

Cubic Curve Creation
Knowing the position and speed, this function is rather practical. If the position and its
corresponding angles are known, simply by filling in the position (0°~ 360°) of the master
axis and the slave axis, this function can automatically connect and optimize the curve. In
some applications, users might need a linear line or curve to complete point-to-point motion
when applying the method of Manually Create a Table. On the other hand, modifying curves
March, 2015
2-25
Introduction of E-Cam Operation
ASDA Series Application Note
can be easily done by Cubic Curve Creation.
When using this method, the connection between two points can be a straight line, a curve,
or an S-curve.
1. Straight line: starting angle (the angle when departing from the start point) and ending
angle (the angle when arriving the target point) cannot be adjusted.
2. Curve: A monotonically increasing or decreasing curve, which can be regarded as
acceleration/deceleration curve. The starting angle is adjustable.
3. S-Curve: The starting angle and the ending angle are adjustable. The angle will
determine the speed when departing the start point or reaching the target point.
Inappropriate setting will result in abrupt change of speed and makes the system
unstable. To have smooth operating speed, testing on the departing and arriving angle is
essential when creating an E-Cam curve.
11
Straight
Line
22
Monotonically
Increasing/
Decreasing curve
33
S-Curve
Figure 2.37 Types of Connection between Two Points
Figure 2.38 shows the screen of Cubic Curve Creation. Section (1) includes the angle of
each point (0°~360°), Position (unit: PUU), Curve Type (constant line, constant acceleration,
and cubic curve), N1 Theta Out (arriving angle), and N2 Theta In (departing angle). To
modify the corresponding data of each point, users may drag the point in section (2) or by
directly selecting or entering the value in section (1).
When dragging the point in section (2), the content in section (1) will be promptly changed.
When directly entering or selecting the required content in section (1), the graph will be
updated after clicking on Create Cubic Table. From section (3), the simulated E-Cam curve
can be observed. Section (4) shows the current position and speed curve. Please make sure
the curve size setting is appropriate.
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March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
Figure 2.38 Screen of Cubic Curve Creation
When editing the curve by dragging points in section (2), points can be inserted or deleted by
right clicking the mouse button. Users may change the point number to modify the cam
shape so as to satisfy the demand of different applications.
Figure 2.39 Adjusting Points
After E-Cam curve is created by using Cubic Curve Creation, the system will figure out
E-Cam area number (P5-82) based on the sampling angle (360/sampling angle). Then, the
corresponding curve position of each angle will be put in the table. The data downloaded to
data array is the data of this table.
March, 2015
2-27
Introduction of E-Cam Operation
ASDA Series Application Note
Figure 2.40 E-Cam Table of Cubic Curve Creation
To create a curve with higher precision, sampling angle can be set to 1 so that the E-Cam area
number can be increased to 360.However, as the default setting (P-19: E-CAM Curve Scaling =
1) will round off the value of Position Y thus causing speed trembling. To solve this problem,
users can select the value with more decimal digits and then use P5-19 to magnify the scaling.
See Figure 2.41. When selecting a smaller scaling value, values in the table will be magnified
based on the scale. For example, if value of P5-19 is changed from 1 to 0.0001, after clicking on
Convert to E-Cam Table, the position data in the table will be magnified and become 10000 times
of the original value. With this method, values with more decimals can be accessed by the
system and a curve with higher precision can be made. The scale of entire curve will remain the
same and the curve will become smoother.
Figure 2.41 Scaling Function of Cubic Curve Creation
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March, 2015
ASDA Series Application Note

Introduction of E-Cam Operation
Rotary Shear- Printer Machine
Here come the operational principles:
The relation between printing axis and material feeding axis is shown in Figure 2.42. Each
printing axis does not connect to ball-screw but operates individually. Due to the printing
length limit, it cannot do full printing. The printing axis operates at constant speed and toward
the same direction. When the printing plate reaches the paper (graph A), the speed of paper
and printing plate is the same and both are in the same direction (graph B). When printing is
complete, paper and printing plate separate (graph C). Then, paper decelerates to stop and
operate towards the opposite direction for a short distance (graph D). When it starts printing
again, paper operates at the same speed and same direction as the printing cylinder. So that
the printing plate always synchronizes with the paper when printing. If the printing axis and
paper separate, paper is retrieved. Both axes still synchronize with one another. With this
pattern, the adjacent printing pattern is closely arranged with one another and it therefore
saves the use of paper. This application is very common in intermittent printing machine.
A
The rotating direction of
printing axis
Printing plate
B
Printing
axis
Material
feeding
axis
Printing
axis
Direction of the paper
Material
feeding
axis
Material
feeding
axis
Material
feeding
axis
The rotating direction of
material feeding direction
D
C
Printing
axis
Printing
axis
Material
feeding
axis
Material
feeding
axis
Material
feeding
axis
Material
feeding
axis
Figure 2.42 Motion Analysis on Intermittent Printing
See Figure 2.43. ASDA-Soft provides servo setting wizard for intermittent motion control.
Users could plan it according to the required print area and blank area and manually adjust
the angle in synchronous area and waiting area. Complete the setting of material feeding
axis by following the steps below.
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Introduction of E-Cam Operation
ASDA Series Application Note
Figure 2.43 Setting Wizard for Intermittent Motion Control
When using this method to create an E-Cam curve for rotary shear printing machine,
mechanical specifications have to be filled in the table. See Figure 2.44.
Propeller shaft
Printing range
Blank range
Mechanical gear ratio
= PL + BL : Pitch
S-pulse
Pulse number per
revolution (PUU/rev)
Figure 2.44 Mechanical Specification Settings for Rotary Shear-Printing Machine
Users have to learn the relation of each unit of length in advance.
L (Circumference of printing cylinder) = π x d2
(Pitch of materials) = PL + BL
R=L/
2-30
(equals to the “cutting length” in Rotary shear. In printing application, most cases
March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
are R>1.)
Take the initial parameter in software as the example:
L (Circumference of printing cylinder) = π x 100 = 314.15 mm
(Pitch of materials) = PL + BL = 200+20=220 mm
R=L/
= 314.15 / 220 = 1.428 (R>1, reasonable range)
In addition, L (Circumference of printing cylinder) has to be larger than
(Pitch of materials).
The purpose of intermittent motion is to save the use of space and reduce the cost without
idling and wasting the materials.
See Figure 2.44. Users only have to fill in the value according to the setting mechanical
parameters. Please note that the setting of pulse number of encoder and diameter of the
printing axis (d2) should be appropriate. Printing axis is the master axis of printing machine.
Pulse number from the encoder represents the one sent by printing roller per cycle. If master
axis connects to the printing roller, its setting value is (P1-46)*4. If the printing roller is
equipped with decelerator, then the factor needs to be taken into consideration. For instance,
if the decelerator is 1:5, then the setting value should be (P1-46)*4*5.
d2: Diameter of printing cylinder includes the length of printing plate. See Figure 2.45.
Figure 2.45 Definition of Printing Cylinder Diameter (d2)
Next, description about how to determine the width of synchronous area is shown is as follows.
See Figure 2.46.
deg_sync (Degree of synchronous area) = PL / L x 360°. This formula can help to calculate the
degree of synchronous area.
Take the initial parameter in software as the example:
deg_sync (Degree of synchronous area) = PL / L x 360° = 200 / 314.15 × 360 = 229.190°
Please note that the setting of degree of waiting area and S-curve cannot exceed 360°.
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Introduction of E-Cam Operation
ASDA Series Application Note
Synchronous area
The moving direction of
PL
the product
Printing range
Figure 2.46 Synchronous Area Setting of E-Cam Curve for Rotary Shear- Printer Machine
If the curve needs to be fine adjusted, users can adjust the degree of Waiting Angle, S-Curve
Angle, and Syn. Extra Angle in Advanced Setting section of the software.
Figure 2.47 Setup the Degree of E-Cam Curve for Rotary Shear-Printer Machine
To have a stable printing quality, users can extend the range of synchronous speed area.
deg_sync (Angle of synchronous area) = PL / L x 360° + SyncAdd (increase the angle of
synchronous area)
The default setting of waiting area is 0. It is because the acceleration/deceleration curve is
smoother than no one in this status. The bigger value in waiting area, the shorter distance motor
can run in reverse direction and the speed change is greater. It is easier to cause current
overload. When waiting area is set to 0°, if the motor is still overload due to the acceleration or
deceleration, this problem can be solved by reducing the operating speed of master axis or
changing to a more powerful motor.
2.5.2
Using Macro to Create an E-Cam Curve
PR mode on ASDA-A2 provides two ways to create E-Cam curve for rotary shear by macro:
Using Macro 6 to create E-Cam curve for rotary shear with a fixed 51° sealing zone; Using Macro
7 to create E-Cam curve for rotary shear with adjustable sealing zone.
The E-Cam curve created by macro command is the same as that created by ASDA-Soft. The
best thing about using macro command to create E-Cam curve is that the cutting length can be
easily modified by changing parameter setting with HMI or PLC. For those who need to modify
the cutting length, this method can be very useful.

Macro 6 (Rotary shear curve with a fixed 51° sealing zone): If material is changed,
users only need to re-enter the cutting length and determine whether to apply speed
compensation. Steps to set up are shown below:
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Introduction of E-Cam Operation
Step 1: When using Macro 6, the first step is to store the required relevant parameters in
data array, which includes P5-81 (the start address of E-Cam curve in data array) and P5-85
(engaging time). When using Macro 6, P5-82 is always set to 7, which means the E-Cam
curve has 7+1 divisions only and cannot be changed.
Step 2: Specify the scaling of the E-Cam curve, which includes the E-gear ratio P1-44/P1-45
(E-Cam is part of the system, which will be influenced by E-gear ratio.) and scaling of E-Cam
curve P5-19.
Data Array
1
2
P5-81
The starting
address
P5-85 = 0
P5-82 =7 (7+1 items)
(This number is always 7
when using this macro.)
Position (PUU)
Slave
Slave E-Gear:
The scaling of E-Cam
curve when output.
P1-44, P1-45, P5-19
Master (Pulse)
Figure 2.48 Relevant Parameter Settings of E-Cam Curve when Using Macro 6
Step 3: See Figure 2.49. Figure out the mechanical specifications and enter relevant
parameters, which is the same as the data required when creating E-Cam curve for rotary
shears. Users may use HMI to input the required data and use HMI or PLC to calculate
relevant values and download them to the servo drive.
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Introduction of E-Cam Operation
ASDA Series Application Note
Gear Box
Tooth #A
(to motor)
3
Tooth#B
#B
(to cutter)
Encoder pulse
number per
revolution N
Cutting
L
Length
Number of
切刀的數目
cutter
C
Diameter
編碼器直徑
d2
Diameter
d1
P5- 83 = 1
P5- 84 = N / ( π *d 2 (mm) ) * L (mm) , (Pulse number required for L)
P5- 94 = A * C
P5- 95 = B
P5- 96 = L (mm) / ( π *d 1 (mm) ) * C * Vc * 1000000
Vc = Speed compensation
Vc =1 Do not compensate
Vc = 0.9, Slow down to 90 %, Vc = 1.1 Speed up to 110%
Figure 2.49 Mechanical Settings when Using Macro 6
Step 4: When all relevant parameters are set, write 6 to P5-97 to enable macro 6. After macro is
enabled, read P5-97 again. If its value is 0x1006, it means the table is successfully created by
the macro. If error codes are shown, please correct the parameter value according to the error
message.
Write P5-97 = 6
Modify the parameter
value according to the
error message
Read P5-97
P5-97 = 0x1006 ?
False
True
Success
List of error codes from P5-97 for #6 macro command
F061h: E-Cam engaged. Unable to create a table.
F062h: Value of P5-94 exceeds the range of 1~65535.
F063h: Value of P5-95 exceeds the range of 1~65535.
F064h: Value of P5-96 exceeds the range of 300000~2500
F065h: Inappropriate address. Value of P5-81 exceeds
the range.
F066h: Value of P5-82 must be 7.
F067h: Value of E-gear ratio is too high. Lower the
value but keep the original ratio of P1-44 and
P1-45. (1280:100  128:10)
Figure 2.50 Enable Macro Command 6
After the curve is created successfully, it can be used to enable the E-Cam. When system
setting is complete, most of the mechanical specification will not be changed. The parts that
will be modified might be the setting of cutting length of the material and speed
compensation. If the cutting length has to be changed, the setting can be done by entering
the new value of cutting length and relevant parameters. After enabling the macro (P5-97 =6),
a new E-Cam curve can thus be used. With this method, it is easy to modify relevant
settings.
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
Introduction of E-Cam Operation
Macro 7 (E-Cam curve for rotary shear with adjustable sealing zone.)
When using flat cutters which cutting length is changed, the width of the cutter usually
remains the same. However, different material will change the cutting length and angle in
synchronous zone because this area is determined by material. This is an important reason
why this macro command is created. When using Macro 7 and the material has to be
changed, the setting can be completed by re-specifying the cutting length and specifying
whether speed compensation is needed. Steps to set up are shown below.
Step 1: The first step is to store the required relevant parameters in data array in order to
create an E-cam curve. P5-81 (the start address of saving the E-Cam curve in data array)
and P5-85 (engaging timing) are included. What’s different from Macro 6 is that value of
P5-82 is an adjustable variable, which range is from 30 to 72 when using Macro 7. That is,
the E-Cam can be divided into 30 ~ 72 parts. To obtain the best resolution, set the area
number to 72 is recommended.
Step 2: The second step is to specify the scaling of E-Cam curve, which includes system’s
E-gear ratio P1-44/P1-45 (E-Cam is part of the system thus it might be changed by the
system’s E-gear ratio.) and scaling of E-Cam curve (P5-19).
Data Array
1
2
P5-81
The starting
address
P5-85 = 0
P5-82 = 30~72 (30+1 ~ 72+1 items)
(Highly recommend to set P5-82 to 72.)
Position (PUU)
Slave
Slave E-Gear:
The scaling of E-Cam curve when output.
P1-44, P1-45, P5-19
Master (Pulse)
Figure 2.51 Relevant Parameter Settings for E-Cam Curve when Using Macro 7
Step 3: Specify proportion of each speed areas on E-Cam curve. As the size of constant
speed area on E-Cam curve is adjustable, other areas such as acceleration/deceleration
area, S-curve, and Stop area have to be set manually. The setting proportion of each area
has to be appropriate in order to operate smoothly. The function of S-curve is to smooth the
curve when speed changes. Its setting is level- based, which is from 1 to 4. Others are
specified according to its angle.
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Introduction of E-Cam Operation
ASDA Series Application Note
3
S°
o
o
Y
360 = 2 W +2Acc +2S + Y
o
S =(
=(2
2^S) * 360 / (P5-82)
S
S
o
P5-82=72
2
3
1
10
o
20
o
40
o
80
W
360°
o
P5-93.H (Hex.)
P5-93.L (Hex.)
16 bits (S level, 1~4)
P5-93
P5-94
Acc S°
W Acc
4
16 bits (W ,0~170º)
32 bits (Y, Constant Speed Area, 0~330º, Decimal)
Figure 2.52 Setting Proportion of Each Speed Area of Rotary Shear Curve when Using Macro 7
Since the waiting area is adjustable, there are more limitations when creating E-Cam curve
by Macro 7. See Figure 2.53.
a
a
A
R (Length Ratio)
a
a
A
P5-93.H (Hex.)
P5-93
P5-94
16 bits (S level, 1~4)
A
a
Data Array
P5-93.L (Hex.)
16 bits (W ,0~170º)
P5-82 = 30~72
32 bits (Y, Constant Speed Area, 0~330º, Decimal)
360º = 2W + 2Acc + 2Sº +Y
W’ = 180 + 360/(P5-82) - 360/R + (P5-94)/2
W < W’, Error Code F07A, enlarge waiting zone or
narrow constant speed area.
W = W’, The starting speed of the curve = 0.
W > W’, The starting speed of the curve > 0.
Figure 2.53 Limitations of Creating E-Cam Curve for Rotary Shear by Macro 7
Step 4: See Figure 2.54. Figure out the mechanical specifications and enter relevant
parameters. The required specification data is the same as that needed when creating
E-Cam curve for rotary shear. Users may use HMI to enter the data or use HMI or PLC to
calculate relevant values and download them to the servo drive.
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Introduction of E-Cam Operation
Gear Box
Tooth #A
(to motor)
4
Tooth #B
(to cutter)
Encoder pulse
number per
revolution, N
Diameter
d2
The
number
of cutter,
C
Cutting
Length L
Diameter
d1
P5-83 = 1
P5-84 = N / (π * d2 (mm) ) * L (mm), (pulses required by L)
P5-95.H (Hex.) P5-95.L(Hex.)
P5-95.H (in Hexadecimal) = A * C
16 bits ( A x C)
16 bits ( B)
P5-95
P5-95.L (in Hexadecimal) = B
P5-96 = L (mm) / (π * d1 (mm) ) * C * Vc * 1000000
Vc = Speed compensation, Vc = 1, Do not compensate.
Vc = 0.9, Slow down to 90%, Vc = 1.1, Speed up to 110% .
Figure 2.54 Mechanical Settings when Using Macro 7
Step 5: When all relevant parameters are set, write 7 to P5-97 to enable Macro 7. After it is
enabled, read the same parameter P5-97 again, if the value is 0x1007, it means this table is
created by macro successfully. If any error code occurs, please modify the parameter
List of error codes from P5-97 for #7 macro
Write P5-97 = 7
Modify the parameter
according to the
error message
F071h: E-Cam engaged. Unable to create a table.
F072h: Value of P5-94 exceeds in the range of 0~330.
F073h: Value of P5-93.H (Hex.) exceeds the range of 1~4.
F074h: Value of P5-93.L (Hex.) exceeds the range of 0~170 (Dec.).
Read P5-97
F075h: Value of P5-96 exceeds the range of 50000~5000000.
F076h: Value of P5-82 exceeds the range of 30~72.
F077h: Inappropriate address. Value of P5-81 exceeds the range.
P5-97 = 0x1007 ?
False
True
Success
F078h: E-gear ratio value is too big. Make the value smaller but
keep the original ration of P1-44 and P1-45
(1280:100  128:10)
F079h: Acc zone is too small, narrow W, Y or S.
F07Ah: Waiting zone is too small. Enlarge W or narrow Y.
*Please refer to Chapter 8 of ASDA-A2 User Manual for parameter details.
according to the error message.
Figure 2.55 Enable Macro Command 7
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Introduction of E-Cam Operation
ASDA Series Application Note
Two examples are presented below to help users create E-Cam curves with Macro 7.
Example 1:
When using Macro 7 to create E-Cam curve and R = 1.1 ~ 5 (when R > 1.0, cutting length is
longer than cutter circumference), adopting rules presented in the diagram (Figure 2.56) can
avoid occurrence of error codes.
Step 1: Figure out the length ratio R first. Make sure the value is within the range of 1.1 ~ 5 or
this flow chart is not applicable.
Step 2: Specify the S level. Then, figure out the proportion of constant speed area and
waiting zone to meet the range condition. Enter all the values to the designated parameters.
Step 3:
1) If not applying speed compensation, the setting is done after calculating value of P5-95
and P5-96.
2) If positive speed compensation is used, which means the slave axis speed is faster
than the master axis, users may consider adjusting the size of the constant speed area
or speed up the slave axis.

Taking adjusting the speed of the slave axis as priority: Select the max. possible
positive speed compensation. Then calculate the variation of the constant speed
area based on this compensation value. A new range of the constant speed area
can thus be acquired.

Taking adjusting the size of the constant speed area as priority: If size of the
constant speed area is the priority, select a new constant speed area to re-define
the range and figure out the required compensation value.
Step 4: After setting the compensation value (Vc) and new range of the constant speed area,
revise the setting of constant speed area.
Step 5: Figure out value of P5-95 and P5-96 and the setting is complete.
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Introduction of E-Cam Operation
Start
1
Calculate length
ratio R = A/a
R>5
Change
False
mechanism or
Use other
methods
V first
1.1 ≦ R ≦ 5
Calculate the possible
biggest constant
speed area
Y=360/R - (3+2(s+1))*5
0 ≦ P5-94 ≦ Y
False
Select possible
highest Vc
∆Y = 360/ R*(1-1/ Vc)
Select new constant
speed area
Ynew < Y
∆Y = Y - Ynew
0 ≦ P5-94 ≦ Ynew
Calculate constant
speed area
Ynew = Y-∆Y
0 ≦ P5-94 ≦ Ynew
Calculate Vc
Vc = 360/ (360 - ∆Y*R)
True
Define S smooth level
P5-93.H=S=1~4
Lower S level
Y≧0
True
Calculate the waiting zone
Wd=360 - 360/R - (2(s+1)-1)*5
P5-93.L = W = (Wd /2), convert to
Hex.
True
1
Y first
Speed
compensation
Vc >1
False
Renew the waiting zone
P5-93.L = Wnew
= (Wd+∆Y) /2,
Covert to Hex.
Calculate P5-95 & P5-96.
P5-95.H = A*C, (Hex.)
P5-95.L = B, (Hex.)
P5-96 = 1000000*R*Vc
P5-97 = 7
Finish
Figure 2.56 Diagram of Creating E-Cam Table with Macro 7 (R = 1.1 ~ 5)
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Introduction of E-Cam Operation
ASDA Series Application Note
Example 2:
When using Macro 7 to create an E-Cam curve and R = 0.5 ~ 1.09 (when R < 1.0, cutting length
< cutter circumference), follow the instructions shown in Figure 2.57 to write macro commands
can avoid occurrence of error codes. Table in Figure 2.57 shows the setting range of waiting area
and constant speed area based on the S level.
Marco Command P5-97 = 7 (8)
The table is for the case of R = 0.05~1.09 and P5-82 = 72.
P5-93.H = S = 1 ~ 4;
P5-93.L = W = (Wd/2), (Hex.)
P5-94 = Y; P5-95.H = A*C, (Hex.); P5-95.L = B, (Hex.)
S = 1 Wd = 0º~150º
Wd = 0º~(150º-∆χ)
Wd = 0º~(150º+∆χ)
Y = 0º~150º
Y = 0º~(150º+∆χ)
Y = 0º~(150º-∆χ)
S = 2 Wd = 0º~140º
Y = 0º~150º
Wd = 0º~(140º-∆χ) Y = 0º~(150º+∆χ)
Wd = 0º~(140º+∆χ) Y = 0º~(150º-∆χ)
S = 3 Wd = 0º~110º
Wd = 0º~(110º-∆χ)
Wd = 0º~(110º+∆χ)
Y = 0º~110º
Y = 0º~(110º+∆χ)
Y = 0º~(110º-∆χ)
S = 4 Wd = 0º~50º
Wd = 0º~(50º-∆χ)
Wd = 0º~(50º+∆χ)
Y = 0º~30º
Y = 0º~(30º+∆χ)
Y = 0º~(30º-∆χ)
P5-96 = 1000000 * R * Vc; P5-97 = 7
Figure 2.57 Diagram for Creating E-Cam table with Macro 7 (R = 0.05 ~1.09)
2.6
E-gear Ratio and Scaling of E-Cam Curve
P5-19 and E-gear ratio of the slave axis will change the E-Cam scaling from issuing command to
output. See Figure 2.58.
Position (PUU)
Slaver
E-Cam
Master
P5-19
E-Cam
Curve
Scaling
P1-44
P1-45
Slave
E-Gear
Position (PUU)
Slaver
E-Cam
Master
Figure 2.58 Scaling of E-Cam Curve
The E-gear ratio of E-Cam axis is identical to the system’s which specified by P1-44 and P1-45.
Change of slave axis’ E-gear ratio will change the system’s E-gear ratio; the system’s E-gear
ratio will not be restored even when E-Cam is disengaged. Therefore, it is not suggested to
modify the scaling of E-Cam curve by P1-44 and P1-45 as this will also change the E-gear ratio
of the entire system. When E-cam is disabled, PR command will also refer to this E-gear ratio.
Effect brought by P5-19 is the same as the E-cam’s E-gear ratio but only effective to E-Cam
system instead of the system’s E-gear ratio. In this case, using P5-19 to change the scaling of
E-Cam curve is recommended. In terms of E-Cam’s output, the effect of adjusting value of P5-19
is the same as adjusting the value of P1-44 /P1-45. When P5-19 = 0.5, the output of E-Cam axis
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Introduction of E-Cam Operation
will only output half of the PUU number. If P5-19 is set to a negative value, the output of E-cam
curve will be inverted compared with that is set to a positive value. If using firmware version
earlier than v1.038 sub48, after value of P5-19 is changed, users have to re-engage E-Cam to
make the modification become effective. If Bit 2 of P5-88.X is set, a new E-Cam curve scaling will
be effective immediately when its value is changed.
Position (PUU)
Slave
Position (PUU)
Slave
(Pulse)
(Pulse)
Master
Master
P5-19 =1
P5-19 =0.5
Position (PUU)
Slave
(Pulse)
Master
P5-19 =-1
=
Figure 2.59 Scaling of E-Cam Curve
Changing P5-19 will only change the position of E-Cam. The pulse number from master axis
required for E-Cam to rotate a cycle remains the same. That is, it only changes the value of
Y-axis of the E-Cam curve; scale of X-axis remains the same. Therefore, the moving distance of
the slave axis and operating speed are both changed. To allow the operating speed synchronize
with the moving distance that has been changed, the pulse number of the master axis (ratio of
P5-84/P5-83) shall be adjusted based on the proportional scale. See Figure 2.60.
Position (PUU)
Slave
Distance
20000
PUU
(Pulse)
Master
Distance
10000
PUU
Pulse Number
(Pulse)
Master
3600
Pulse Number
7200
Figure 2.60 Proportional Scaling of E-Cam Curve
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Introduction of E-Cam Operation
2.7
ASDA Series Application Note
E-Cam Setting Example
(This example only illustrates the basic setting of E-Cam, real application example can be found
in Chapter 3 of this application note.)
2.7.1
Creating an E-Cam Curve
In this example, Speed Fitting Creation in ASDA-Soft is used to create a simple E-Cam curve.
For details about ways to create E-Cam curves, please refer to ASDA-Soft user manual.
The first step is to figure out the motion of the slave axis and mechanical specifications. Then,
translate the motion into an E-Cam curve. Please note that the mechanical specifications might
change the scale of the curve. The mechanical motion and specification below is also shown in
Figure 2.61:
The master axis is a material feeding axis that operates with a constant speed. And there is an
encoder equipped on this axis. When material feeding axis moves, it will drive the encoder to
operate. The traveling distance of the material feeding axis is the total rotating distance of the
encoder. Pulses sent by the encoder are directly transmitted to CN1 of the slave axis as the
source of the master axis. The encoder will send 52 pulses every 1 mm and this is the
specification of the encoder.
The slave axis is a ball screw which pitch is 10 mm and total length is slightly longer than 200
mm. After E-Cam is engaged, the position of the slave axis operates from 0 mm to 200 mm. After
reaching the position, E-Cam will disengage. Then, a PR position command will be triggered to
take the slave axis back to position 0. Then, it uses the CAP function triggered by the sensor to
make E-Cam engaged. The E-gear ratio setting of the slave axis is P1-44 = 128 and P1-45 = 10,
which means it takes 100000 PUU for motor of the slave axis to make one full rotation.
Slave Axis
Lead of the carrier: 200 mm
Pitch of the ball screw: 10 mm
Master Axis
Pulse No. of the Encoder: 52 pulse/mm
DI 7
Use capture function
to engage E-Cam
Figure 2.61 Mechanical Specification
From the information above, the required setting value for creating an E-Cam curve can be
known.
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Introduction of E-Cam Operation
1. The moving distance of the carrier is 200 mm and the pitch of the ball screw is 10 mm.
It takes 20 rotations for the moving carrier to reach the entire traveling distance.
2. It takes 100000 PUU for the motor to make one rotation.  It takes 2000000 PUU in total
for the motor to make 20 rotations.
3. It takes 100000 PUU for the motor to make one rotation and its traveling distance is 10
mm per rotation.  It takes 10000 PUU to travel 1 mm.
4. The carrier’s moving distance is 200 mm and the encoder which connects to the master
axis sends 52 pulses every 1 mmWhen the slave axis travels 200 mm, it means the
encoder will send 10,400 (52 x 200) pulses to the slave axis when the slave axis
operates one cycle.
See Figure 2.62 for example of creating E-Cam curve by Speed Fitting Creation.
Figure 2.62 Speed Fitting Creation
1. Set up the E-gear ratio: P1-44 = 128 and P1-45 = 10。
2. Specify the required pulse number when both master and slave axis operate every 1 mm.
The unit of the master axis is pulse; the unit of slave axis is PUU. From Figure 2.61, we
can know that when the master axis operates for 1 mm, the encoder will send 52 pulses;
from calculation above, it takes 10000 PUU for the slave axis to operate every 1 mm.
3. Speed Section. This section allows users to set the proportion of each area, namely
Waiting area, Acceleration Area, Constant Area, Deceleration Area, and Stop Area).
Area proportion will change the speed of the slave axis. The total traveling distance can
be known from the calculation above, which is 2000000 PUU. Total points of this E-Cam
curve can be set in P5-81; P5-82 allows users to specify the address where this E-Cam
March, 2015
2-43
Introduction of E-Cam Operation
ASDA Series Application Note
curve is stored in data array. When only one E-Cam curve is stored, changing settings of
P5-81 and P5-82 is not required.
4. Select Based on lead pulse, calculate P5-84 pulse number. Since the moving distance of
the slave axis cannot be changed, which means the traveling distance is fixed, the
system will work out the value required by P5-84 based on the lead pulse. When the
setting is complete, the constant speed area of the slave axis will be consistent with the
master axis.
5. When the above setting is completed, click on Download Table and Burn Table Data to
data array.
2.7.2
Relevant Parameter Settings and Enabling E-Cam Function
When the creation of E-Cam curve is complete, the next step is to enable E-Cam function in
order to have the system work. It is easy to use PR to setup relevant parameters to control
E-Cam. Figure 2.63 is a reference setting; users may edit it to cater to the application.
Start homing
1
procedure when the
system operates for
the first time
Enable capture
function & E-Cam
and wait for the
start signal
2
Homing
procedure
PR
#0
#0
Home X=?
Offset =0
PR#1
Setup disengaging time Specify Capture address
Back to position 0
PR Position
PR Write
PR Write
PR
##12
1 D=0, S=10.0 rpm
#2
# 3 DLY= 0 ms
#2
#4
# 2 DLY=0ms
DLY= 1ms
#4
( I) 0 PUU, ABS
=0
(I) P5-39
P5-89 =P5-84
=0x
(I) P5- 36=
Set capturing amount
PR
#2
#4
(I)
Write
DLY= 0 ms
P5-97=0
P5-38=1
Stop capture function
PR
#4
#5
(I)
Write
DLY= 1ms
DLY=0ms
P5-39=0x 0020
Stop E-Cam
PR
#36
#
(I)
Write
DLY=1ms
DLY=
0ms
P5-88=0x0250
P5-88=0x 000A2220
Enable capture function Enable E-Cam
PR Write
PR Write
DLY= 0 ms
#7
#8
#4
# 7 DLY=0ms
DLY= 1ms
(I) P5-88=0x000A2221
P5-88=0x0251
(I) P5-39=0x0021
P5-39=0x
Homing after
E-Cam disengaged
3
Move back to 0 after
E-Cam disengaged
PR Position
#12
# 10 D=0, S=100
S=
.0 rpm
(I)
(I)
0 PUU, ABS
Back to the origin and wait for the next
captured data to engage E-Cam
PR
#12
#11
Jump
DLY=0
PR# 4
Figure 2.63 Using PR command to control E-Cam
PR#0: Homing procedure. Users can specify the homing method according to the mechanism.
Take the mechanism in Figure 2.61 for example. The origin is on the far left. For this type
of mechanism, it has to return to the origin first before taking the next step when system is
started so as to avoid danger.
PR#1: Make sure the slave axis stops at absolute position 0.
PR#2: Specify the disengaging time. Set P5-89 to the same value of P5-84. Then, the slave axis’
operating distance per cycle = the traveling distance per cycle of the E-Cam curve. In this
example, P5-84 = 11555, which is figured out based on slave axis’ lead pulse number by
the ASDA-Soft software tool.
2-44
March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
PR#3: Specify the place where the captured data is saved in data array. In this example, the
E-Cam’s engaging time is controlled by the capture signal. Therefore, parameters
relevant to the capture function have to be set. The captured data can be stored anywhere
in data array. However, please note that since some data of E-Cam curves have been
saved in data array, it is necessary to avoid the area that is in use to ensure no safety
issue arises.
PR#4: Specify the amount of the captured data. Only one datum is required. The capture
function here is only for making E-Cam engaged. The captured value does not mean
anything.
PR#5: Initialize the capture function. Specify CN1 pulse input (P5-39.Y = 2) as the source for the
master axis of the capture function.
PR#6: Initialize E-Cam function. Specify CN1 pulse input (P5-88.Y = 2) as the master source;
Set the engaging time when capture function is enabled (P5-88.Z = 2); Set the
disengaging time when the moving distance has reached the setting value of P5-89
(P5-88.U = 2).When E-Cam disengaged, the system will call PR#10 (P5-88.BA = A)
automatically. To ensure PR#5 and PR#6 are carried out, set delay time to 1 ms in this
PR.
PR#7: Enable Capture function. Set P5-39.X to 1 in order to enable the capture function.
PR#8: Enable E-Cam function. Set P5-88.X to 1 in order to enable E-Cam function.
PR#10: After E-Cam disengaged, the system will call this PR automatically. This PR is a position
command which absolute position is 0. When E-Cam is not controlling the slave axis, this PR will
take the mechanism back to the origin.
PR#11: Jump to PR#4, restart the capture function and E-Cam function for the actions of the next
cycle.
March, 2015
2-45
Introduction of E-Cam Operation
2.8
ASDA Series Application Note
Simultaneously Using E-Cam Function and PR command
When servo is working at the command of E-Cam and a PR with incremental position command
is triggered at the same time, E-Cam command and PR command will be overlapped. Both
commands will change the output of the servo.
See Figure 2.64. When E-Cam is operating, if triggering a PR command of which target speed is
higher than E-Cam speed, the motor will overlap the PR command with E-Cam command. For
example, a motor operates at 1000 rpm under the control of E-Cam, when a PR which target
speed is 2000 rpm is triggered, motor will not stop operating at 3000 rpm until the PR command
is completed. Then it will switch back to 1000 rpm which is specified by E-Cam command.
Target speed is higher than E-Cam speed
Position (2)
PR Position
(2)
D =00ms,
ms,S=
S =2000
2000 rpm
rpm
#A D=
5000 PUU,
PUU, INC
5000
INC
Speed
Speed
0
Time
Speed
0
0
Time
ECAM + PR
(Same Direction)
PR
ECAM
Time
Figure 2.64 E-Cam Command plus PR command
See Figure 2.65. If triggering an incremental PR command which target speed is slower than
E-Cam speed and operate in reverse direction when E-Cam is operating, the motor will
counterbalance the PR and E-Cam command when PR is operating. For example, if a motor is
operating at 1000 rpm under the E-Cam’s command, when a PR command which target speed is
200 rpm at reverse direction is triggered, motor will keep operating at 800 rpm until this PR
command is completed. Then, it will switch back to 1000 rpm under E-Cam’s command.
Target speed is slower than E-Cam speed
PR
#B
Position (2)
Position
(2)
DD=
=00ms
ms,,S=
S =200
200 rpm
rpm
-5000
PUU,
INC
- 5000 PUU, INC
Speed
Speed
PR
0
0
ECAM
Time Speed
Time
0
ECAM+PR
Time
(Reverse Direction)
Figure 2.65 E-Cam command Counterbalances the PR Command
The method of overlapping E-Cam command and PR command is very useful. This method can
be used when desire to modify the speed or phase when E-Cam is operating. In Figure 2.66,
2-46
March, 2015
ASDA Series Application Note
Introduction of E-Cam Operation
take a three-synchronous-axis printing machine for example. Pulses from the encoder are sent
to the three slave axes as the source signal to make identical curves. Phases of the three slave
axes have to be identical. When phases are inconsistent, users can use PR command to overlap
E-Cam command so as to have the phase shifted. To have a positive phase shift, a positive
incremental position command can be used. Please make sure the speed (in forward direction)
is higher than the speed specified by E-Cam command. On the other hand, to have a negative
phase shift, please set a PR with negative incremental position command.
Slave
Slave
(PUU)
Slave
(PUU)
(PUU)
Master
Master
Master
Speed
Speed
Speed
Time
Time
Time
Phases are indentical
Phases are not identical
Slave
(PUU)
Slave
(PUU)
Master
Slave
(PUU)
Master
Speed
Speed
Master
Speed
Time
Time
EV1
Time
EV2
Figure 2.66 An Example of E-Cam Command Overlaps with PR Command
March, 2015
2-47
Introduction of E-Cam Operation
2.9
ASDA Series Application Note
Troubleshooting when E-Cam is not working properly
If E-Cam is not working properly, the following methods can be used to troubleshoot.
1.
Make sure source of the master axis is correct; this can be done by checking the setting of
P5-88.Y that specifies the source of the master axis. When input terminal is CN1, make
sure value of P5-18 is increasing; when input terminal is CN5, make sure value of P5-17 is
increasing. Please note that this method is only applicable to the external input. When
applying E-Cam function, it is suggested to use signal input externally as the source of the
master axis; virtual signal which generates from the servo drive is for testing purpose only.
2.
When E-Cam is enabled (P5-88.X = 1), count of pulse number from the master axis can be
accessed by P5-86. Its value must be an increasing value, if not, please reverse the pulse
direction (not the motor’s operating direction). Value of P5-86 has to be an increasing value;
otherwise, E-Cam axis will not be able to operate based on the E-Cam curve.
3.
Check the E-Cam curve scaling. Check the setting of P5-19 to see if the scale is
appropriate. If the scale is too small, the motor operation will be too subtle to be seen even
when E-Cam is working. PC scope can be used to check if the motor is operating subtlety.
4.
Check if data of the E-Cam curve is properly stored in data array. Data Array Editor can be
used to check if the values are stored.
5.
Make sure P5-81 specifies a correct start address in data array. If P5-81 is specifying a
wrong address, a desirable E-Cam curve cannot be created. Make sure the setting of
P5-82 is correct; the total number of points of E-Cam is value of P5-82+1. If incorrect, the
system is unable to carry out the setting of every point on E-Cam curve.
6.
Access the value of P5-88.S to acquire the clutch status. In Status 1, E-Cam is engaged
and slave axis operates according to the pulses received from the master axis. In Status 0
or 2, slave axis is still.
2-48
March, 2015
Application Examples
0
0
3.1 How to Use Capture Function to Create E-Cam Curves? .................................. 3-4
3.1.1 Description................................................................................................... 3-4
3.1.2 About the System and System Configuration ............................................. 3-4
3.1.2.1 Creating an E-Cam Curve ................................................................. 3-4
3.1.2.2 Settings for the Route of Master Axis (Rectangle Carrier) ................ 3-5
3.1.2.3 Settings for the Route of Slave Axis (Round Compression Axis) ..... 3-6
3.1.3 Servo System Structure and Configuration ................................................. 3-6
3.1.3.1 System Structure............................................................................... 3-7
3.1.3.2 Wiring ................................................................................................ 3-7
3.1.3.3 Parameter Settings for Master Axis (Rectangle Carrier)................... 3-8
3.1.3.4 Parameter Settings for Slave Axis (Round Compression Axis) ........ 3-10
3.1.3.5 Settings for Capture Function ........................................................... 3-16
3.1.3.6 E-Cam Parameter Settings ............................................................... 3-18
3.1.3.7 Test the System................................................................................. 3-20
3.2 Application to Winding Machine ......................................................................... 3-23
3.2.1 Description................................................................................................... 3-23
3.2.2 System Theorem and Scheme .................................................................... 3-23
3.2.2.1 Master Axis ........................................................................................ 3-23
3.2.2.2 Camshaft ........................................................................................... 3-24
3.2.3 Servo System Setting .................................................................................. 3-24
3.2.3.1. The Design of Tape ............................................................................. 3-24
3.2.3.2 The Meaning of E-cam Curve ........................................................... 3-26
3.2.3.3 Example ............................................................................................ 3-27
3.2.3.4 PR Programming and Execution....................................................... 3-30
3.2.3.5 System Adjustment ........................................................................... 3-34
3.2.3.6 The Design of E-cam Curve .............................................................. 3-36
3.3 Application to Labeling Machine ......................................................................... 3-39
3.3.1 Description................................................................................................... 3-39
3.3.2 System Plan ................................................................................................ 3-39
3.3.2.1 Master Axis – Axis of Conveyor ........................................................ 3-40
3.3.2.2 Camshaft Axis – Label Feeding Axis................................................. 3-40
March, 2015
3-1
Application Examples
ASDA Series Application Note
3.3.2.3 Label Positioning Sensor .................................................................. 3-40
3.3.2.4 Labeling Start Sensor........................................................................ 3-40
3.3.3 Setting of Servo System .............................................................................. 3-40
3.3.3.1 Camshaft is Enabled and Starts to Label ............................................ 3-40
3.3.3.2 Camshaft is Disabled and Label Positioning .................................... 3-42
3.3.3.3 PR Program and Execution .............................................................. 3-44
3.3.3.4 Structure of E-cam Curve ................................................................. 3-46
3.3.3.5 E-cam Curve Creation....................................................................... 3-48
3.3.3.6 Analysis of E-cam Curve ................................................................... 3-55
3.4 Printing Machine Application with Synchronization of Multiple Axes .................. 3-57
3.4.1 Description................................................................................................... 3-57
3.4.2 System Operation and Configuration .......................................................... 3-57
3.4.2.1 How to Configure Your System........................................................ 3-57
3.4.2.2 Analysis of System Operation ......................................................... 3-58
3.4.3 Servo System Setting .................................................................................. 3-58
3.4.3.1 PR Procedure and E-Cam Curve .................................................... 3-58
3.4.3.2 Simulative Operation ....................................................................... 3-60
3.5 Application to Gantry .......................................................................................... 3-64
3.5.1 Introduction .................................................................................................. 3-64
3.5.2 How Gantry works and the System Structure ............................................. 3-64
3.5.2.1 How does gantry work? ................................................................... 3-64
3.5.2.2 Positioning and Homing of Gantry ................................................... 3-65
3.5.2.3 Motion Following .............................................................................. 3-67
3.5.3 Servo System Settings ................................................................................ 3-68
3.5.3.1 Wiring ............................................................................................... 3-68
3.5.3.2 Sequential Logic Control of Positioning and Homing ...................... 3-71
3.5.3.3 Steps for Adjusting the Servo when Using Gantry Control .............. 3-77
3.6 Application Example of Packing Machine........................................................... 3-83
3.6.1 Description................................................................................................... 3-83
3.6.2 System plan ................................................................................................. 3-83
3.6.2.1 Master axis (Film feeding axis) ........................................................ 3-84
3.6.2.2 Camshaft (Flying shear) .................................................................. 3-84
3.6.2.3 Camshaft (Chain conveyor) ............................................................. 3-85
3.6.3 Servo system setting ................................................................................... 3-85
3.6.3.1 System configuration ....................................................................... 3-85
3.6.3.2 Function introduction ....................................................................... 3-86
3.6.3.3 Design of E-cam curve ....................................................................... 3-92
3.7 Application of Precision Positioning via Mark Reading ...................................... 3-95
3.7.1 Description................................................................................................... 3-95
3.7.2 System theorem and setting........................................................................ 3-95
3-2
March, 2015
ASDA Series Application Note
Application Examples
3.7.3 Setting of servo system ............................................................................... 3-95
3.7.3.1 DI setting.......................................................................................... 3-95
3.7.3.2 System configuration ....................................................................... 3-96
3.7.3.3 Motion command and PR program.................................................. 3-97
3.8 Application Example of Packing Machine with Phase Alignment Function ...... 3-101
3.8.1
Instruction .................................................................................................. 3-101
3.8.2
System Configuration ................................................................................ 3-101
3.8.3 Servo System Setup .................................................................................. 3-102
3.8.3.1
Configuration ................................................................................. 3-102
3.8.3.2
Features ......................................................................................... 3-104
3.8.3.3 Design of E-Cam Curve ................................................................... 3-123
March, 2015
3-3
Application Examples
3.1
ASDA Series Application Note
How to Use Capture Function to Create E-Cam Curves?
3.1.1
Description
This application example will demonstrate how Capture function on ASDA-A2 is used to create
an E-Cam curve. This chapter will focus on the procedure of creating an E-Cam curve and
explain how the system work and its settings. Before getting started, basic knowledge about PR
mode and E-Cam is required. To know more about these topics, please refer to chapter 1 and 2
of this application note.
3.1.2
About the System and System Configuration
This chapter will teach users to create E-Cam curves directly in the system. Capture function
enables ASDA-A2 to record the current position of the system. With this feature, an E-Cam curve
can be created based on the shape of the object and the required points for the curve can also
be recorded.
3.1.2.1
Creating an E-Cam Curve
When creating E-Cam curves, the motions of the master axis and the slave axis have to be
decomposed. The motion of master axis is making a circular motion which is 360° per circle. If it
is divided into 50 equal parts, whenever the master axis travels one equal part, one point has to
be created on the E-Cam curve for the slave axis. In this way, 50 points that corresponds to 50
equal parts on salve axis are recorded and thus making an E-Cam curve.
The example below will illustrate the idea. The cam is divided into 14 equal parts. How the first 5
points are created will be demonstrated with the motion analysis. Figure 3.1.1 shows the motion
step by step and Figure 3.1.2 presents the relation between the motion and E-Cam curve.
Step 0
Step 2
Step 4
Step 1
Step 3
Step 5
Figure 3.1.1 Motion Analysis of Master Axis and Slave Axis
3-4
March, 2015
ASDA Series Application Note
Application Examples
M3
M2
M4
M1
M0
M5
Slave position
(Round compression axis)
E3
E4
E2
E1
E5
E0
E4 E2 E1
E5
E3
M0 M1 M2 M3 M4 M5
E0
Master position
(Rectangle carrier)
Figure 3.1.2 Creating an E-Cam Curve
3.1.2.2
Settings for the Route of Master Axis (Rectangle Carrier)
When creating the E-Cam curve, the moving distance of the rectangle carrier has to be divided
into equal parts. In this example, the servo generates 10000 pulses per circle because E-gear
ratio is set to 1 : 1. However, in the real mechanism, the master axis, ASDAS-A series servo
motor, will go through a decelerator that reduce the speed to 1/5 of the original. Therefore, the
rectangle carrier will make one full circle until the servo motor makes 5 rotations. To create an
E-Cam curve with 50 points, the motion of the master axis has to be divided into 50 equal parts.
See its calculation below.
The pulse number generated when the rectangle carrier travels one circle:
10000 x 5 = 50000 (pulses)
The required pulse number (distance) of the master axis to travel each point on the E-Cam curve
corresponding to the slave axis:
50000 / 50 = 1000 (pulses)
So, the rectangle carrier will send 1000 pulses to the slave axis whenever it travels one point.
Then, it has to stop and wait for the slave axis to do sampling.
The more sampling points there are, the more precise E-Cam curve it is. On the other hand, the
time it takes will be longer. (ASDA-A2 series servo drive provides E-Cam curves with maximum
720 points.)
March, 2015
3-5
Application Examples
3.1.2.3
ASDA Series Application Note
Settings for the Route of Slave Axis (Round Compression Axis)
See (1) in Figure 3.1.3. It shows the positions of the rectangle carrier and round compression
axis after homing. Before creating an E-Cam curve, homing for each axis is required. That is, one
point must be regarded as the reference origin for each axis.
See (2) in Figure 3.1.3. After homing, we can move the compression axis to the nearest position
of rectangle carrier without obstructing its operating route. (Please be aware of the direction.)
The maximum traveling distance has to be taken into consideration when setting distance B.
Shorten distance B will shorten the time for creating the E-Cam curve.
When position B in (2) is selected, every time the E-Cam points are captured, the compression
axis returns to this position (not the origin) and wait for the next command. In (3), C is the
distance that the compression axis needs to travel to reach the rectangle carrier. If traveling
distance is set to C and when there is a backlash or tolerance, the round compression axis will
not be able to stay close to the carrier tightly (in this moving direction). In this case, this will cause
inaccuracy or change the precision level of the curve. In (4), distance D is the proper moving
distance for the compression axis. However, the round compression axis will never able to reach
this distance, which will be explained later.
A
B
(1)
(2)
D
C
(3)
(4)
Figure 3.1.3 Motion and Traveling Route of the Slave Axis
3.1.3
Servo System Structure and Configuration
This section will explain how to manually create an E-Cam curve. A host controller can be used
to automatically carry out the step and replace the manual steps. And this will be an automatic
system for creating E-Cam curves. The following describes how it works.
3-6
March, 2015
ASDA Series Application Note
3.1.3.1
Application Examples
System Structure
The master axis used here is an ASDA-A series servo drive and the slave axis used is an
ASDA-A2 series servo drive. There is a decelerator which reduces the speed to 1/5 of the
original speed. The slave axis drives the ball screw via the servo motor. See Figure 3.1.4 system
structure. On master and slave axis, approximation sensors are equipped with the system as the
reference origin for the system.
ORG sensor
The platform will
move according to
E-Cam curve from
A2 servo
A2 series servo drive
(slave axis)
1 : 5 decelerator
operates according to
E-Cam curve
ORG sensor
ASDA-A
series servo drive
Master axis
Pulse signal is sent
to A2 as the master
source signal of the
E-Cam curve
Figure 3.1.4 System Structure
3.1.3.2
Wiring
Regarding the master axis, DI signals that need to connect to the servo drive are DI.SHOM
(search for the origin), DI.ORGP (origin sensor), and DI.CTRG (internal trigger). Among these DI
signals, the function of DI.CTRG is to control the motion of the master axis, making it stop when it
travels one sampling point of the slave axis and allowing the slave axis to complete sampling.
Other signals are for internal use. Since controlling of ON/OFF is not required, actual wiring for
these will be saved, making the I/O wiring easier.
For the slave axis, DI signals that need to connect to the servo drive are mainly DI.SHOM
(search for the origin), DI.ORGP (origin positioning sensor), DI.EV1 (Event 1, for internal trigger),
and DI.CAPTURE (DI7, the trigger point set by the system; setting for register is not required.
When capture function is enabled, this DI will be enabled automatically.) Other DI signals that do
not need to control ON/OFF will be replaced by internal signals without actual wiring.
March, 2015
3-7
Application Examples
ASDA Series Application Note
DELTA ASDA A
DELTA ASDA A2
TYPE B
3 Phases 220V
R
S
T
U
V
W
P
D
C
M
1
U
V
W
M
2
CN2
R
S
T
L1
L2
CN1
OA
/OA
OB
/OB
3 Phases 220V
R
S
T
p+
D
C
CN2
L1c
L2c
R
S
T
CN1
21
22
25
23
43
41
36
37
PULSE
/PULSE
SIGN
/SIGN
VDD
COM+
17
11
17
11
VDD
COM+
COM-
45
45
COM-
SHOM
ORGP
CTRG
10
34
8
SHOM
10
ORGP
34
EV1
8
31 CAPTURE
DI #
Pin#
Function code
Abbr.
Description
DI #
Pin # Function code
Abbr.
Description
1
9
0x 001
SON
Servo On
1
9
0x 001
SON
Servo On
2
10
0x127
SHOM
Homing
2
10
0x127
SHOM
Homing
3
34
0x124
ORGP
O rigin
3
34
0x124
ORGP
O rigin
4
8
0x108
CTRG
PR Trigger
4
8
0x139
EV1
5
33
0x000
None
Not in us e
5
33
0x016
TCM 0
6
32
0x000
None
Not in us e
6
32
0x000
None
Not in us e
7
31
0x000
None
Not in us e
7
31
0x000
None
for Capture
Function only
8
30
0x000
None
Not in us e
8
30
0x000
None
Not in us e
Event 1
Torque Limit Select
Figure 3.1.5 Wiring and I/O Configuration
3.1.3.3
Parameter Settings for Master Axis (Rectangle Carrier)
In this example, ASDA-A series servo drive is selected as the master axis. This section will
mainly elaborate setting of function parameters. Settings related to performance have to be
adjusted according to the mechanism on-site. When use, please adjust the gain as high as
possible because the compression axis will knock against the rectangle carrier when capturing
data for the E-Cam curve. If the rigidity of the carrier is not strong enough, its position will be
changed (or slipped) because of the impact (or compression) and cause the inaccuracy of the
curve. Please take special attention to this issue. See Figure 3.1.6.
Figure 3.1.6 Change of Position of the Rectangle Carrier
3-8
March, 2015
ASDA Series Application Note
Application Examples
Function Parameter Settings for Master Axis (Rectangle Carrier)
Please see Figure 3.1.5 the wiring diagram for I/O settings.
P1-01 Control mode: set to 0x01 in PR Mode.
P1-47 Homing mode: Set to 0x202.
2: Homing in forward direction; DI.ORGP is regarded as the homing origin.
0: Operate in the opposite direction to look for Z pulse of the encoder when homing.
2: Enable homing function via DI.SHOM.
This setting is for the accuracy purpose. (When the ORGP is encountered by the origin, the
motor will return to look for Z pulse.) It is because the positioning precision level of external
ORGP (such as limit switch and approximate sensor) is lower than the internal Z pulse. That is
why Z pulse is regarded as the origin. And this might be the best choice for this type of control.
P1-44 (E-Gear Ratio (Numerator)): Set to 1.
P1-45 (E-Gear Ratio (Denominator)): Set to 1.
To have better resolution, the E-gear ratio doesn’t have to be changed because of the system
decelerator.
P1-16 (1st Position Command for Pulse): Set to 1000.
Please refer to section 3.1.2.2 Settings for the route of Master Axis (Rectangle Carrier) of this
application note. As DI.POS0, DI.POS1, and DI.POS2 are set to 0, when DI.CTRG is triggered,
the position command is set by P1-16.
P2-36 Moving Speed Setting of 1st Position: Set to 150 rpm, let the motor operate with slower
speed.
Sequence Diagram—Homing of the Master Axis
Motor
Speed
DI.SHOM
DI.ORGP
Z Pulse
Figure 3.1.7 Homing of the Master Axis
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Sequence Diagram—Traveling of the Master Axis and Sampling of the Round
Compression Axis
Sampli ng of slave
(compressi on) axis
Distance to the origin:
100 0 pulses
Moving
Distance of
Motor
1000
Pulses
Sampli ng of slave
(compressi on) axis
Distance to the origin:
200 0 pulses.
1000
Pulses
Sampli ng of
slave
(compressi on)
axis
Distance to the origin:
300 0 pulses.
1000
Pulses
DI.CTRG
Figure 3.1.8 Traveling of the Master Axis and Sampling of the Round Compression Axis
3.1.3.4
Parameter Settings for Slave Axis (Round Compression Axis)
An ASDA-A2 series servo drive is selected as the slave axis in this example. The following
explains function of parameter settings.
For DI/O settings please refer to Figure 3.1.5 Wiring Diagram.
P1-01 (Input setting of Control mode and Control Command): Set to 0x01 in PR mode.
P1-44 (Gear Ratio (Numerator)): Default 128.
P1-45 (Gear Ratio (Denominator)): Default 10.
From this setting, we can know that 100000 PUU will be generated when this axis travels one
circle.
P1-02 (Speed and Torque Limit Setting): Set to 0x10.
Function to set torque limit will be used to avoid great impact from the compression axis. Range
limit will be set by P1-12 (DI setting: TCM0 = 1, TCM1 = 0)
P2-35 (Condition of Excessive Position Control Deviation Warning): The setting value here must
be high enough so as to avoid excessive deviation. More details will be explained later.
P5-98 (PR# Triggered by Event Rising-Edge): Set to 0x01.
P5-99 (PR# Triggered by Event Falling-Edge): Set to 0x02.
Setting for EV1 (Event 1): when EV1 is triggered by rising edge and falling edge, PR#51 and
PR#52 will be carried out respectively.
Settings and configuration for PR will be demonstrated with ASDA-Soft software screenshots in
the following paragraph.
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Application Examples
Setting Screen for PR#0— Homing
Figure 3.1.9 Setting of PR#0 for the Slave Axis
Set Homing Method to X : 2 : Homing in forward direction: ORGP : OFF-> ON, as homing origin.
Then, Set Single Setting to Y : 0 : Return to Z pulse. When homing is completed, PR stops and
set P6-01 which specifies the origin to 0. These settings have to be changed based on different
applications.
PR#1 Setting Screen
Figure 3.1.10 Setting Screen of PR#1 for the Slave Axis
In this path, the written target is set to P1-12 and its torque setting is 50%, which can be adjusted
depending on circumstances. This PR has set an interrupt command.
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ASDA Series Application Note
PR#2 Setting Screen
Figure 3.1.11 Setting Screen of PR#2 for the Slave Axis
PR#2 is set to control the position, which command is absolute type. See Figure 3.1.11.
PR#5 Setting Screen
Figure 3.1.12 PR#5 Setting Screen for the Slave Axis
The program system writes value to P1-12. The toque force is set to 25%, which can be adjusted
according to the situation. This PR has set an interrupt command.
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PR#6 Setting Screen
Figure 3.1.13 Setting Screen of PR#6 for the Slave Axis
This PR path is set to a position command which is absolute type. See Figure 3.1.13.
PR#7 Setting Screen
Figure 3.1.14 Setting Screen of PR#7 for the Slave Axis
This path setting is for torque limit.
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PR#51 Setting Screen
Figure 3.1.15 Setting Screen of PR #51 for Slave Axis
This is a jump path, which will be carried out when EV1 (Event 1) is triggered by rising-edge.
PR#52 Setting Screen
Figure 3.1.16 Setting Screen of PR#52 for Slave Axis
This is a jump path, which will be carried out when EV1 (Event 1) is triggered by falling-edge.
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Application Examples
PR Program
Jump Cmd;
jump to PR#5
1
EV 1
PR JUMP
# 5 1 DELAY= 0
PR#5
5
EV 1
2
Jump Cmd;
jump to PR#1 6
PR JUMP
#52 DELAY= 0
PR#1
Torque Limit;
set to 50%
PR Position
# 6 D= 0, S = 200 rpm
- 800000 PUU, ABS
PR Write
#5 DELAY= 0
( I) P1-12=25
Torque Limit;
set to 50%
Position Cmd; move to
ABS position -800000
3
4
Torque Limit;
set to 10%
PR Write
#7 DELAY= 0
P1-12 =10
Position Cmd; move to
ABS position -300000
7
PR Position
# 2 D= 0,S= 500 rpm
-300000 PUU, ABS
PR Write
# 1 DELAY= 0
(I) P1-12 =50
PR Home
# 0 Offset =0
PR#0
Figure 3.1.17 PR Program of the Slave Axis
This is how ASDA-A2 deals with commands: when one command is sent, the next PR command
will then be sent. It does not wait for the command to be completed and then set the next one.
Below is how the mechanism works according to the PR paths above.
7
6
EV1
5
4
3
2
1 EV1
PR#0
D
C
-800000
F
B
A
-300000
0
E
DI7
Figure 3.1.18 Slave axis works according to the PR program
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Rising-edge Trigger EV1
When the system returns to the origin and after the first time EV1 is triggered by rising-edge, the
starting point is A instead of B. From the second time, it will start from point B because it is set to
absolute position in the PR path. First of all, set the torque force to 25% before issuing the
position command. This is because there will be a bigger striction when motor is started; if torque
force is set too small, the motor will not move or move only for a short while and then stop. Once
the motor is started successfully, kinetic friction will be rather smaller. Then, use step 4 (PR#7) to
decrease the torque force to 10%. This step is for avoiding the round compression axis knocking
the rectangle carrier too hard. Then, the compression axis moves to point C but it is never able to
reach the target distance D (-800000) due to the obstruction of the rectangle carrier. In this case,
the setting value of P2-35 (Condition of Excessive Position Control Deviation Warning) must be
bigger than distance F; Otherwise, AL009 (Excessive Deviation of Position Command) might
occur. Based on the possible position of the rectangle carrier, distance F in Figure 3.1.18 is the
most possible maximum distance that the compression axis can travel. When compression axis
reaches position C and stops, this will be the timing for sampling. DI7 has to be switched ON to
enable the Capture function and record the position. Capture function will be explained later in
section 3.1.3.5.
Falling-edge Trigger EV1
After DI7 is On and sampling is complete, falling-edge trigger EV1 and raise the torque level. Let
the compression axis move back to position B. Then, wait for the rectangle carrier to move to the
next sampling position. Allow the system repeat the steps from 1 to 7.
3.1.3.5
Settings for Capture Function
The main purpose of using Capture function is to record the position of the round compression
axis. With this function, this value can be easily written to data array on ASDA-A2. Capture
function settings can be done either by directly setting parameter value or ASDA-Soft, which is
rather easier.
Using Capture Function by Directly Setting Parameter Value
P5-36 (CAPTURE-Start Address of Data Array): Set to 0.
P5-38 (CAPTURE-The Number of Capturing Times): Set to 50; 50 points on E-Cam curve have
to be captured.
P5-39 (CAPTUR-Activate CAP Control): Set to 0xF030 (0xUZYX).
X: 0 means Capture function is not enabled.
Y: 3 means Main ECN (main encoder); Position of the compression axis is based on the main
encoder.
Z: 0 stands for No. When DI7 is triggered, the system starts to sample on the rising-edge.
U: F stands for the shortest time interval. This is for preventing errors (For example, inputting
multiple values into the servo drive when pressing some buttons once.
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Application Examples
When starting Capture function, the X of P5-39 has to be written to 1.
Using Capture Function with ASDA-Soft
When using software to set the above parameters, select Parameter Function on the function
bar and enable Capture/Compare function.
Figure 3.1.19 Using Capture Function
Figure 3.1.20 shows the screen after enabling Capture/Compare function:
Figure 3.1.20 Capture Function Setting
First of all, write 0 to P5-36 and write 50 to P5-38. Select 3: Main Encoder for P5-39 Y. Select 0:
ON for P5-39 Z. Fill in 15 for P5-39 U. Then click on Write CAP Parameters. The setting value
will be the same as that in the previous method (direct setting parameter value). To start the
Capture function, please click on the icon of CAP Disabled. When finishing capturing 50 data,
the function will be disabled automatically.
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3.1.3.6
ASDA Series Application Note
E-Cam Parameter Settings
After 50 data are captured, E-Cam parameters can be set for verification. Firstly, please open
E-CAM editor to set parameters.
Settings for E-Cam Table
Figure 3.1.21 Start Screen of E-Cam Editor
Open E-Cam Editor in ASDA-Soft. Select Manually Create a Table and then click Next.
Figure 3.1.22 E-Cam Table
In the window, parameters shown below have to be set.
P5-81 (Start Address of Data Array): Set to 0. The start address of data array is 0; all captured
data is stored from this address.
P5-82 (Area Number N): Set to 50; store 50 captured data.
Next, let the system read the captured value that stored in data array for the E-Cam curve. Select
Specify Array Address. Then, set Start Address to 0 and Area Size to 49 because only 50
captured data can be stored. Further, Click on OK, the value in data array will be read by the PC.
If clicking on Draw, the E-Cam curve will be shown (see Figure 3.1.23). If the E-Cam curve is
correct, please click on Burn Table Data to write the data into the servo drive. Please note that
this action can only be done when Servo Off. Otherwise, the table data will disappear when
power-off. Then, click Next to set pulse resolution of the master axis.
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Figure 3.1.23 E-Cam Curve
Figure 4 Setting Pulse Resolution of Master Axis
P5-83 (E-Cam Cycle Number: M): Set to 1. This value is subject to change based on the required
motion.
P5-84 (Pulse number of master axis): P: Set to 50000. The master axis (rectangle carrier) sends
50000 pulses whenever it makes one rotation. This E-Cam curve will be carried out once within
50000 pulses.
When setting completed, click on Download to download the setting values to the servo drive.
Then, click Next.
Parameter Settings for Slave Axis
Figure 3.1.25 E-Cam Parameter Settings
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Now, parameter settings for the slave axis have to be completed.
As the command source of the round compression axis is sent via Pulse, /Pulse, Sing, and /Sign,
Y: Command Source has to be set to 2.Pulse Cmd. Z: Engaged time is set to 0: Engage
Immediately.
As this is only for testing purpose, after the round compression axis completes homing, this
setting allows E-Cam engages immediately. Set U: Disengaged Time to 0: Do not disengage.
When setting is complete, click on Download. And button Enable E-Cam is used when starting
testing the E-Cam curve.
3.1.3.7
Test the System
After completing the settings above, parameter values can be adjusted and enable the whole
system works properly.
Adjusting the Master Axis
Regarding the master axis, parameter values listed below have to be edited so as to examine
whether the E-Cam curve is suitable for the application requirements.
P1-15 (1st Position Command for Rotation): Set to 25. Let E-Cam curve conduct trial run for 5
times. As the master axis will decelerate to 1/5 of the original speed and E-gear ratio is
1 : 1,
25/5 = 5. In this setting, the rectangle carrier will make 5 circles and the E-Cam curve will also
operate for 5 times.
P1-16 (1st Position Command for Pulse):Set to 0.
P2-36 (Moving Speed Setting of 1st Position): The value can be increased according to the
circumstances.
Adjusting the Slave Axis
P2-14 (DI5 Functional Planning): Set to 0x116 to cancel the torque limit.
As this is the first time testing the E-Cam curve, adjusting the position of slave axis is required to
avoid system damage. Please make sure the E-Cam curve is correct. Setting for adjusting the
slave axis is shown below.
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Figure 3.1.26 PR#0 Parameter Setting
In PR#0, set P6-01: Homing Definition Value to -10000. This setting will make the origin
right-shifted. In this case, the compression axis will not touch the rectangle carrier. Users may
check whether the system is working correctly by observing its motion. If correct, set this value to
0 (default value).
PR#0
D
C
-800000
-800000
B
0
-10000
A
0
Figure 3.1.27 Shifting of the Coordinate System
The red one is the original coordinate system; the green one stands for the new coordinate
system after shifting. No matter it is new or the original one, PR#0 will stop at position B after
homing. The part changed is the defined coordinate value. Therefore, in the new coordinate
system, round compression axis will not be in contact with the rectangle carrier. It only moves
along the green outline of the carrier. See Figure 3.1.28.
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Figure 3.1.28 Traveling Route of the Compression Axis (Slave Axis)
Steps to Test the System
1.
Allow the rectangle carrier (Master axis) return to the origin (DI.SHOM).
2.
Allow the round compression axis (Slave axis) return to the origin (DI.SHOM).
3.
Enable E-Cam. This can be done by setting P5-88 or directly click on Enable E-CAM of
ASDA-Soft.
Figure 3.1.29 Enabling E-Cam
4.Trigger DI.CTRG signal of the master axis (rectangle carrier).
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ASDA Series Application Note
3.2
3.2.1
Application Examples
Application to Winding Machine
Description
This chapter aims at the application of ASDA-A2 on wrapping machine. The configuration
function of tape can be done by electronic cam of ASDA-A2. The main parameters such as the
width of tape, the interval of tape and the length of bobbin can be modified easily. The detailed
description will be elaborated in later parts of this chapter.
3.2.2
System Theorem and Scheme
Bobbin is the master axis. When it rolls, it sends out the pulse to command the slave axis
simultaneously. The slave axis operates by its internal E-cam curve and the master axis to finish
the wrapping on bobbin. ASDA-A2 servo drive is mainly in charge of the configuration of tape.
Figure 3.2.1
3.2.2.1
Wrapping machine system
Master Axis
In master axis, when using different length of bobbin, adjusting the parameters of the slave axis
can complete the setting. When the master axis rolls, it sends out the pulse to command the
slave axis.
Figure 3.2.2
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Different length of bobbin
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Application Examples
3.2.2.2
ASDA Series Application Note
Camshaft
This axis places the tape according to the pulse of master axis. The interval and width of the tape
can be adjusted through the proper setting.
Figure 3.2.3
3.2.3
Different interval and different width
Servo System Setting
3.2.3.1. The Design of Tape
The start position of cam
There is a hole in the middle of bobbin. The tape can be directly inserted and attached on the
bobbin. The advantage to start wrapping from the middle point is that the tape will not loose
easily.
Figure 3.2.4
The start position of tape
The wrapping method of tape
The tape starts from the middle point of bobbin, goes to the end first and then goes back over
and over again to complete the wrapping on the bobbin. When the tape is at the two ends, leave
a specific length is a must. This is for consolidate and tighten the two sides. The following is the
Figure of wrapping.
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Stop at the
endpoint
Figure 3.2.5
Configuration of tape
The purpose of stopping at the endpoint
Logically, it divides the bobbin into equal parts as the length the tape stops at the endpoint. It is
for staggering the returning positions of tape, so that the tape will not overlap on bobbin and
cause the bulge. Furthermore, stop at the two endpoints for a while can strengthen the two sides.
Figure 3.2.6 is the example that divides the broadside into 8 equal parts. Users can plan the best
equal parts by different application.
Figure 3.2.6
Stop at the endpoint
If the two endpoints are not configured properly or controls the acceleration / deceleration at the
near-endpoint, it would cause the overlap and bulge at the two sides, see Figure 3.2.7 on the left.
The right one is the correct example.
Figure 3.2.7
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Incorrect and correct wrapping
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3.2.3.2
ASDA Series Application Note
The Meaning of E-cam Curve
The transverse axis of E-cam curve is the pulse number which sent out by master axis. The
vertical axis is the moving distance of ball screw, which is the wrapping length on bobbin. The
tape shall be placed in orderly arrangement on bobbin.
Figure 3.2.8
The meaning of E-cam curve
Use multiple E-cam curves
In this application, the system applies multiple groups of E-cam curve. The tape starts from the
middle of bobbin, when it reaches the endpoint, it stops at the preserved length (The setting of
preserved length is not included in E-cam curve. It is completed by lead pulse). Then, execute
another curve of opposite direction to return to another endpoint. Execute the command
repeatedly until it reached the setting value. The configuration of curve and motion is shown as
Figure 3.2.9 and the time sequence of motion is shown as Figure 3.2.10.
The pulse number that
master axis needs for
wrapping 0.5 layer
Half
wrapping
length
Wrapping
length
The pulse number that
master axis needs for
wrapping 1 layer
Wrapping
length
The pulse number that
master axis needs for
wrapping 1 layer
Figure 3.2.9
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Multiple groups of E-cam curve
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Application Examples
Figure 3.2.10 Time sequence of motion
3.2.3.3
Example
Figure 3.2.11
Application example
The master axis sends out 14400 pulses per revolution; the wrapping length is 190mm; the width
of tape is 15mm; the interval between each tape is 0.2mm; the pitch of ball screw is 5mm; gear
ratio of motor cam shaft and ball screw is 1:2.
The following is the calculation:
190mm/(15+0.2)mm = 12.5 cycle.
This is the amount of tape which can be placed on bobbin. However, since its first cycle is the
position where the tape stops, when it is applied to slave axis, it must minus one cycle. See as
Figure 3.2.12.
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Figure 3.2.12
Configuration of tape
(12.5 -1) * 14400 = 165600 (pulses)
This is the pulse number that master axis needs for wrapping one layer, which is the pulse
number for 11.5 cycles. This value is in ideal situation and not considering any error. The value
should be adjusted in real situation. Normally, the actual value is smaller than the estimated one.
This is because when estimating the length, the tape is in 90-degrees vertical to bobbin while in
real situation the tape is inclined to bobbin.
If it desires to stop at one eighth cycle at two endpoints, then the pulse number it needs will be
14400/8=1800 pulses, see Figure 3.2.6.
The configuration of E-cam curve is shown in Figure 3.2.13.
Figure 3.2.13
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Configuration of E-cam curve
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Application Examples
The pitch of ball screw is 5mm. As for the wrapping length, followings are the calculation method:
(190 mm-15.2 mm) / 5 (mm/rev) = 34.96 rev.
This is the value of the cam on ball screw. When the value corresponds to the motor, according
to the calculation of gear ratio, the value should multiply double, which is 34.96*2=69.92 rev.
The PUU for one cycle of gear ratio is 100000PUU (P1-44=128, P1-45=10), thus the PUU of the
cam needs to operate is 69.92 rev * 100000 PUU/rev = 6992000 PUU. This value is the ideal
value which needs to be slightly adjusted when in real situation.
The corresponding relation of E-cam curve is shown as Figure 3.2.14.
Command from the cam
6992000 /2 = 3496000 PUU
Pulse number of
master axis
165600 / 2 =
82800 pulses
Command
from the cam
Command
from the cam
6992000 PUU
6992000 PUU
Pulse number of
master axis
Pulse number of
master axis
165600 pulses
165600 pulses
Figure 3.2.14
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E-cam curve
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3.2.3.4
ASDA Series Application Note
PR Programming and Execution
Figure 3.2.15 PR blueprint
PR#0: Homing before the system starts to operate.
PR#1: After the homing is completed, it goes to the middle point of bobbin and enables the
operator to install the bobbin and the tape. The position should be adjusted according to different
length of bobbin.
Figure 3.2.16
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Original point and the middle point
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Application Examples
PR#2: Setup the E-cam curve magnification which means to set P5-19 to 69.92. Different length
of bobbin brings different magnification.
Figure 3.2.17
E-cam curve magnification
PR#3: Select the initial curve. There should be three E-cam curves in total in data array. This one
is the first. P5-81=100 is the half one of going trip.
Data array
100
360º
200
Start from
Command
the middle
from the cam point for the
50000 PUU
first time
Command
from the cam
100000 PUU
Go
Command
from the cam
100000 PUU
Return
360º
300
360º
Figure 3.2.18
E-cam curve command in data array
PR#4: Setup parameter. The corresponding pulse number of master axis is P5-84=82800.
Please refer to Figure 3.2.14.
PR#5: Setup parameter. The disengaged length of the cam is P5-89=82800.
PR#6: Setup parameter. P5-92=1800, the pulse number when stopping at the endpoint, which is
the lead pulse of the cycle. Please refer to Figure 3.2.6.
PR#7: Setup parameter to set the return trip (PR#10), which is the execution path after E-cam
disengaging. After disengaging, E-cam will call PR#9 to jump, thus, this is for setting up the
target that PR#9 jumps to.
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PR#10: Setup parameter to select the E-cam curve of return trip. Please refer to Figure 3.2.18.
PR#11: Setup parameter to set the pulse number that master axis needs for wrapping 1 layer.
Please refer to Figure 3.2.14.
PR#12: Setup parameter to set the pulse number that slave axis receives from master axis which
is the pulse number that enables E-cam to disengage.
PR#13: Setup parameter to set the path after E-cam disengaging for going trip.
PR#20: Setup parameter to select the E-cam curve of going trip. Please refer to Figure 3.2.18.
PR#21: Setup parameter to set the path after E-cam disengaging for return trip.
PR#9: Jump command. When E-cam curve operates to the position of 360 degrees, it will
disengage and execute this PR. This PR is the jump command which can jump to another PR
path.
PR#55: Setup parameter to enable E-cam. The setting content of E-cam is 0x94021. Among
them, 1 means to enable E-cam; 2 means master axis is the pulse command; 0 means E-cam
engages right after issuing the command; 4 means when E-cam operates to the position of 360
degrees, it will disengage and execute the lead pulse of P5-92. After it reaches the lead pulse, it
will engage right away and execute E-cam curve again and so on and so forth. 9 means after
E-cam disengaging the master axis, it will execute PR#9.
PR#56: Setup parameter to disable E-cam.
PR#51: Setup parameter to disable E-cam for executing the next PR.
PR#52: E-cam rapidly returns to the original point, not the starting point from the middle. It can
be changed according to different demand.
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Figure 3.2.19, the main flow chart of PR application
Figure 3.2.19 Time sequence of PR execution
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3.2.3.5
ASDA Series Application Note
System Adjustment
a. The length of bobbin remains and the width of tape is changed.
See Figure 3.2.20. Assume the tape is changed from 15 mm to 10 mm and the interval and the
length of bobbin remain at 0.2 mm and 190 mm respectively.
Figure 3.2.20 Change of tape width
∆Y, adjust the parameter of E-cam distance:
190mm – 10.2mm=179.8 mm;
179.8mm / 5 (mm/rev) = 35.96 rev, the cycle the ball screw travels;
35.96 * 2 =71.92 rev, converse to motor by E-cam;
PR#2: P5-19=71.92.
∆X, adjust the pulse number sent by master axis:
190mm / (10mm + 0.2mm) =18.62745 cycles;
(18.62745-1)cycle* 14400 (pulse/cycle) =253835 pulse;
PR#4: P5-84=253835/2=126917;
PR#5: P5-89=126917;
PR#11: P5-84=253835;
PR#12: P5-89=253835.
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Application Examples
b. The length of bobbin is changed and the width of tape remains.
See Figure 3.2.21. Assume the length of bobbin is changed from 190mm to 150mm and the
width of tape and the interval remain at 15mm and 0.2mm respectively.
Figure 3.2.21
Change of bobbin length
∆Y, adjust the parameter of E-cam distance:
150mm – 15.2mm=134.8 mm;
134.8mm / 5 (mm/rev) = 26.96 rev, the cycle the ball screw travels;
26.96 * 2 = 53.92 rev, converse to motor by E-cam;
PR#2: P5-19=53.92.
∆X, adjust the pulse number sent by master axis:
150mm / (15mm + 0.2mm) =9.8684 cycles;
(9.8684-1)cycle * 14400 (pulse/cycle) =127704 pulse;
PR#4: P5-84=127704/2=63852;
PR#5: P5-89=63852;
PR#11: P5-84=127704;
PR#12: P5-89=127704.
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ASDA Series Application Note
Looking for the middle point of bobbin:
PR#1: Incremental command 2850000PUU
Figure 3.2.22 Looking for the middle point of bobbin
3.2.3.6
The Design of E-cam Curve
In this application, to build the E-cam curve is quite easy, only by one linear line will do. It is not
suitable to plan acceleration/deceleration on two endpoints in this application. Otherwise, it might
overlap at the two endpoints because of the deceleration. See Figure 3.2.7 for the result and
Figure 3.2.23 for the causes. It proves that during the motor operation, either in forward or
backward direction, no additional acceleration and deceleration is applied in the application.
Thus, in mechanical design, low inertia and rigid mechanism should be the first priority. If the
gear box is directly applied on camshaft, the effect will be better than belt.
Figure 3.2.23 Tape overlap caused by acceleration/deceleration curve
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Application Examples
Only one linear line is needed to build in E-cam curve which is shown in the following Figure.
Figure 3.2.24 E-cam curve of half going trip
Figure 3.2.25 E-cam curve of the whole return trip
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Figure 3.2.26 E-cam curve of the whole going trip
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3.3
3.3.1
Application Examples
Application to Labeling Machine
Description
This chapter is aiming at the application of ASDA-A2 on labeling machine. Electronic cam is
applied to control the speed of delivering labels and enables the packages to be delivered in the
same speed so as to labeling. This application could be classified to flying shear. The length of
label should be adjustable, the position should be accurate when delivering labels and the
delivering speed should be the same as the main conveyor. For the convenience of operator,
only photoelectric switch is adjusted in this application, such as label location position and
labeling start position. (No controller and HMI is in the system since ASDA-A2 is good enough to
satisfy all demands.)
Besides the detailed description of labeling motion, this chapter will introduce how E-cam curve
is created in speed section by Delta’s ASDA soft. This curve has a very long constant speed
section, which is the table creation basis in rotary cutoff and similar applications.
Together with PR commands, E-cam can easily satisfy the controlling demand in ASDA-A2.
3.3.2
System Plan
The axis of conveyor is the master axis which is mainly for transporting objects. Camshaft axis is
in charge of controlling the pace of labeling according to the pulse speed sent by master axis,
see diagram 3.3.1. In this application, the label waiting position (controlled by label positioning
sensor) has to be very accurate. The position error should within 1mm only each time. As for the
design of E-cam curve and function, it must consider that the label length should be adjustable.
Thus, the setting of E-cam should be set to the longest length for operation.
Figure 3.3.1 Labeling machine system
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3.3.2.1
ASDA Series Application Note
Master Axis – Axis of Conveyor
It transports the to-be labeled objects, such as packing box. The pulse signals are sent out to
command the camshaft axis simultaneously in order to control the labeling speed.
3.3.2.2
Camshaft Axis – Label Feeding Axis
Following the command of master axis, the camshaft axis executes labeling according to the
pace of master axis. When delivering the label, the pace should be accurate and stable. It should
be controlled to operate the same speed with the master axis while labeling, otherwise the label
will be pasted uneven.
3.3.2.3
Label Positioning Sensor
The label positioning sensor decides the outstretched length of label while the label is waiting to
be pasted. It can be operated by moving the photoelectric switch (label positioning sensor).
3.3.2.4
Labeling Start Sensor
When DI7 receives the signal from labeling start sensor, it will control E-cam to engage and the
camshaft axis will synchronize with the master axis. When E-cam starts to accelerate and reach
the same speed as master axis, the label will just be pasted on the to-be-labeled object. It will not
disengage until the labeling is completed.
3.3.3
Setting of Servo System
3.3.3.1 Camshaft is Enabled and Starts to Label
When the object on the conveyor is detected by labeling start sensor, the camshaft is enabled.
The label axis follows the master axis until the labeling is completed. Then, the camshaft
disengages and its operation is controlled by label positioning sensor. See Figure 3.3.2 and
3.3.3.
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Figure 3.3.2 Labeling start
Figure 3.3.3 Side view of labeling process
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3.3.3.2
ASDA Series Application Note
Camshaft is Disabled and Label Positioning
The label positioning sensor determines the disengagement of camshaft and the outstretched
part positioning. It can be adjusted by different label lengths and different demand. See Figure
3.3.4 for the adjustment of outstretched part positioning.
Figure 3.3.4 Adjust the outstretched part positioning
The label positioning sensor is used to control the time the camshaft disengages, prepare the
label for the next cycle and control its outstretched part positioning (the stop position). This signal
sets up the trigger event and calls the corresponding PR to complete the disengaged control of
the camshaft and the outstretched length of the label. See Figure 3.3.5.
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Figure 3.3.5 Label outstretching and positioning
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3.3.3.3
ASDA Series Application Note
PR Program and Execution
Figure 3.3.6 PR program and execution
PR#0: Homing. Due to the design of mechanical structure, when enabling the function, regard
the stop position as the homing position will do.
PR#1: Initialize Capture function. After Capture function is completed, call PR#50.
PR#2: Jump to the initialized program, PR#11.
PR#10: Relative position command controls the label stop position, see Figure 3.3.7. When the
camshaft returns to the original point, this program will not be executed, unless it is in
normal cycle.
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Figure 3.3.7 Label stop position
PR#11: Setup parameter to disable EV1 rising edge trigger command in order to prevent the
alarm occurs.
PR#12: Setup parameter to reset the Capture amount. Only one position is needed to capture for
E-cam function. Thus, set this parameter to 1.
PR#13: Setup parameter to enable Capture function.
PR#14: Setup parameter to enable E-cam function. Use Capture function to engage the
camshaft.
PR#50: After the Capture is completed, this PR command will be triggered. As a jump command,
this PR will jump to the next one. The auto function is not applied here. When the
capture is completed, next PR (disable EV1 falling edge trigger) will be executed with a
delay.
PR#51: Enable EV1 falling edge trigger. The label positioning sensor has entered into label
position. Thus, enable it to detect the label disengaged position (label’s end).
PR#55: When label positioning sensor leaves the label, EV1 falling edge trigger will be activated.
E-cam no long controls the system at the moment. Setup E-cam command to disengage
camshaft.
PR#56: Incremental command, which is the traveling distance after disengaging from label. It
should consider the maximum spacing between two labels. To setup the maximum
spacing the machine may operate. See Figure 3.3.8.
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Figure 3.3.8 Spacing between labels
PR#57: When executing this PR, the label positioning sensor has left label position. EV1 falling
edge trigger will not continuously be triggered twice in control procedure. In order to
prevent the error occurs, disable EV1 falling edge trigger first and enable it later by PR
command at an appropriate time.
PR#58: Enable the detection for rising edge trigger to prepare the next label. Thus, re-enable the
detection.
PR#60: Trigger EV1 rising edge trigger and jump to PR#10.
3.3.3.4
Structure of E-cam Curve
When an object on conveyor is detected by labeling start sensor, the E-cam function is enabled.
During the labeling process, the speed of master axis and camshaft axis must be the same.
Otherwise, the label will be pasted uneven. See Figure 3.3.9 for cross reference of E-cam curve
and the to-be-labeled object (e.g. packing box).
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Figure 3.3.9 Labeling and E-cam curve
From Figure 3.3.9, a long constant speed section is needed in E-cam curve. Thus, the maximum
label length the machine may operate should be considered. See Figure 3.3.10.
Figure 3.3.10 labeling length and E-cam curve
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3.3.3.5
ASDA Series Application Note
E-cam Curve Creation
According to the actual machine, the roller diameter of master axis is 5 cm. The encoder sends
out 1600 pulses for each revolution. See Figure 3.3.11. Thus, the pulse number sent by master
axis per revolution is:
1600 pulse / (π*50 mm) = 10.185916 (pulse/mm).
Figure 3.3.11 Roller of master axis and encoder specification
As for camshaft axis, the roller diameter is 5cm and the electronic gear ratio is 1:1, which is
shown in Figure 3.3.12.
Figure 3.3.12 Dimension of camshaft axis
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From the above Figure 3.3.12, the label length brought by each roller revolution is π*5 cm =
15.708 cm. To meet the requirement of maximum 23 cm, the curve must be longer than 23 cm
since the acceleration / deceleration time should be left. 23 cm is the traveling distance that
master axis and camshaft axis operates at the same speed. Then, to create the E-cam curve
based on this value. In Figure 3.3.13, master axis is at constant speed while camshaft axis has
acceleration and deceleration. Thus, within the same time, considering the acceleration and
deceleration time of camshaft, master axis travels farther than camshaft axis. In actual operation,
camshaft axis must be enabled in advance so as to complete labeling in constant speed section.
That is to say, from Figure 3.3.13, the traveling distance is Constant Speed Area < Camshaft axis
< Master axis. The creation of E-cam curve will be introduced in the following parts.
Figure 3.3.13 E-cam curve
Through the setting of electronic gear ratio, system not only can consist with the command
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resolution, but increase its readability. In this example, the traveling distance for each camshaft
axis resolution is π*5 cm =15.708 cm. In order to make the data more readable, users can set
157080PUU for each cycle the camshaft travels, which is 0.001 mm per PUU. Thus, set P1-44
to 128000 and P1-45 to 15708. When P5-19 is set to 1 (E-cam curve scaling), the relative pulse
command is (157080PUU / 15.708 cm) = 1000 PUU/mm of each mm on camshaft axis. See
Figure 3.3.14.
Figure 3.3.14 E-gear setting
If users desire to create a curve of 31.416 cm (314.16 mm), then 314.16 (mm)* 1000(PUU/mm) =
314160 PUU.
In ASDA-A2, Speed Section is used to create E-cam table. Please refer to the following steps.
a. Select the way to create E-cam table
Select Speed Section to create E-cam table. See Figure 3.3.15.
Figure 3.3.15 Select Speed Section
b. Setup the actual machine dimensions
Master axis is 10.185916 Pulse/mm and camshaft axis is 1000 PUU/mm. When creating E-cam
curve, the system will refer to the above simulation data. Please make sure the information is
correct, which is the pulse number and PUU the system needs when master axis and camshaft
axis moves 1 mm. See Figure 3.3.16.
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Figure 3.3.16 Simulation information
c. Set slave axis lead
Setup the longest lead of labeling, 23 cm and consider the acceleration / deceleration section,
this curve must be designed longer than 23 cm. According to the previous experience, take 30
cm for a rough estimation (About 10% more, including 5% of acceleration and 5% of
deceleration). Thus, the calculation is 300(mm)* 1000 (Pulse/mm) = 300000 Pulse. Fill this value
into Lead. In addition, fill 100 into P5-81, Data Array start position, which can be set according to
the actual condition.
Fill 200 into P5-82, E-CAM Areas: N(5~720). The bigger the value is, the more perfect the curve
will be. It is suggested to fill in 200 at least. Users can set different values to see different results.
See Figure 3.3.17.
Figure 3.3.17 Setting of E-cam lead
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d. Set master axis lead
It is estimated that master axis will travel 33 cm (10% more). Therefore, if P5-83 is set to 1, then
P5-84 = 10.185916(pulse/mm)*330(mm) = 3361.
Figure 3.3.18 Pulse number setting of master axis
e. Create an E-cam curve
Refer to mark 1 in Figure 3.3.19, setup Waiting Area, Acceleration Area, Constant Speed
Area, Deceleration Area and Stop Area. Among the setting, motor inertia ought to be
considered in Acceleration / Deceleration Area. If the motor inertia is larger, the acceleration /
deceleration curve will be steeper which might result in command delay, motor overload or
regeneration error. Thus, if acceleration / deceleration cannot be calculated precisely, do field
test first. In addition, when creating curve, a longer Constant Speed Area is more ideal, since it
is applied in real working area. Meanwhile, it is better to leave some time for Stop Area;
otherwise, it might be unable to complete homing. See mark 2 in Figure 3.3.19, the setting of S
Curve No. is for smooth E-cam curve so that the command will not be changed dramatically. The
ideal setting value is equal to the value of Stop Area, such as 10. Then, press Create Table
which is marked 3, the system will create the table and the curve.
Mark 4 shows the speed of master axis is 9.817477387, which is the target speed the camshaft
needs to follow (This value varies with Master Simulation Speed, but it will not influence the
curve creating.). Move the cursor to Constant Speed Area, see mark 5. In speed field, the value
is 9.867 (>9.8174477387, Master Simulation Speed). Thus, the speed of camshaft axis is slightly
faster than master axis. Users can adjust Acceleration / Deceleration Area or master / slave
axis lead to make the two values the same.
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Figure 3.3.19 Create E-cam curve
f. Use camshaft axis to adjust the speed in Constant Speed Area
To adjust the curve by Acceleration / Deceleration Area or slave axis lead will be introduced
here (Both can be adjusted simultaneously.). In Figure 3.3.20, after adjusting Acceleration /
Deceleration Area, the Constant Speed Area of camshaft axis can comply with the speed of
master axis (Please see the result in mark 4 and 5 in Figure 3.3.20.). During the process, several
times of trying for a proper value are needed. This method is suitable for unchangeable pulse
number of master axis (P5-84). Without saying, the value of P5-84 can be changed in the
application of labeling machine. From Figure 3.3.21, users can acquire the desired speed curve
by adjusting camshaft axis lead (mark 1). From mark 4 and 5 in 3.3.21, users could know that the
speed of master axis is 9.817477387 ≒ which is the same as slave axis in Constant Speed
Area.
In Figure 3.3.20, the length of Constant Speed Area is 300000 PUU * (360°-60°) / 360° /
1000(PUU/mm) = 250 (mm), which is longer than 23 cm. 60° is the time for Acceleration /
Deceleration Area.
In Figure 3.3.21, the length of Constant Speed Area is 298600 PUU * (360°-65°) / 360° /
1000(PUU/mm) = 244.69 (mm), which is longer than 23 cm. 65° is the time for Acceleration /
Deceleration Area.
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Figure 3.3.20 Adjust the E-cam curve in Acceleration / Deceleration Area
Figure 3.3.21 Adjust the E-cam curve of camshaft axis lead
g. Adjust the speed in Constant Speed Area by master axis
Data showed in Figure 3.3.22, mark 1 is the same as Figure 3.3.19. Here, adjust the pulse of
master axis (P5-84) in Figure 3.3.18 from 3361 to 3376 (the result after trying several times)
which is shown in Figure 3.3.22. After adjusting, the curve of constant speed can be seen in
mark 4 and 5 of Figure 3.3.22. The curves consist with the design of the system. Curves in
Figure 3.3.20 and Figure 3.3.22 can be used as the E-cam curve of this labeling machine but
with different adjustment. One of them cannot adjust the pulse from master axis while the other
one cannot adjust the pulse from slave axis.
In Figure 3.3.22, the length of Constant Speed Area is 300000 PUU * (360°-65°) / 360° /
1000(PUU/mm) = 245.8 (mm), which is longer than 23 cm. 65° is the time for Acceleration /
Deceleration Area.
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Figure 3.3.22 Adjust the E-cam curve of master axis lead
3.3.3.6
Analysis of E-cam Curve
In Figure 3.3.23, mark 5 shows the traveling distance of master axis and camshaft axis at 30°
(before entering the Constant Speed Area).
Master axis: 3376*(30/360) = 281.333 (pulse), 281.333 / 10.185916 (Figure 3.3.23, mark 4) =
27.62 mm.
Slave axis (Move the cursor to 30° and access the position field): 15744.672 (Figure 3.3.23,
mark 5) / 1000 (Figure 3.3.23, mark 4) = 15.74 mm.
From the above calculation, master axis travels 27.62 mm while slave axis only travels 15.74 mm
before entering the Constant Speed Area. The difference between both influence the position of
labeling start sensor, see Figure 3.3.24.
Before the camshaft enters the Constant Speed Area, it will travel 15.74 mm. If the highest
speed of master axis is S (the highest speed the labeling machine could operate), then it will take
T time (= 27.62/S) to travel 27.62 mm. Before entering the Constant Speed Area, the
acceleration A of camshaft axis in Acceleration Area is:
A (Acceleration) = (S (target speed) – 0 (accelerate from 0) / T
α (angular acceleration)= A / r (rotary shaft radius)
T (torque) = J (inertia)
*α (angular acceleration)
From the above calculation, T (the torque needed during acceleration) can see if this E-cam
curve can meet the requirements or not.
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Figure 3.3.23 Analysis of E-cam curve
Figure 3.3.24 Acceleration Area and labeling start sensor
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3.4
Application Examples
Printing Machine Application with Synchronization of
Multiple Axes
3.4.1
Description
This section mainly describes the position synchronization application for shaftless color process
printing. In this application, the position error is not compensated by ASDA-A2, but the host
controller by sending the signal for position synchronization.
3.4.2
3.4.2.1
System Operation and Configuration
How to Configure Your System
When applying shaftless printing machine, position of all printing rollers have to be synchronized.
If any of the printing rollers is deviated, position correction and compensation is needed. It can
be done by E-Cam and PR overlap function provided by ASDA-A2. In this application, ASDA-A2
is unable to judge the compensation time and the amount it needs to compensate for the
deviated position; however, it can control the synchronization of all printing rollers.
Figure 3.4.1 System Configuration
Passing on the pulse from master axis
Master axis needs to command the slave axis by passing on the pulse (for moving the material).
Each axis has to be set with the function of pulse sending. The delay time set on each axis is 50
ns and will not weaken the signal strength.
EV1 position compensation
When EV1 is triggered by the controller, it will call the corresponding PR. This PR will execute
one incremental command and complete the command with the speed higher than synchronous
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speed. This could correct the relative position by promptly accelerating or decelerating the
printing roller while it is still synchronized with the master axis.
3.4.2.2
Analysis of System Operation
When the system works normally, all slave axes follow the master with the same speed.
Figure 3.4.2 Normal operation of the system
When the host controller detects any of the axes is left behind, it will send EV1 signal. This is for
urging the left-behind axis to move quickly and adjusting its position.
Figure 3.4.3 Host controller notifies the slave to do speed compensation
3.4.3
3.4.3.1
Servo System Setting
PR Procedure and E-Cam Curve
Master axis shall synchronize with slave axis. Both will be in linear relationship. The slave axis
has to issue a PR with incremental command which connecting to this event (e.g. EV1). When
the event is triggered, it will execute the corresponding PR command and start to compensate
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the position.
Distance setting of PR incremental command
If EV1 is the DI signal for position compensation and P5-9 8 =0x0001, when this DI is triggered,
PR#51 will be executed. See the setting of PR#51 as below:
Figure 3.4.4 PR incremental command
In figure 3.4.4, mark 3, we choose 10: INC Incremental Position, CMD=Previous CMD+DATA
(incremental command). SPD: Target speed index (Target speed) is selected in mark 4. The
speed must be higher than synchronous speed. It can be adjusted in P5-66 by the host controller.
Mark 5 indicates the position that needs to be compensated. The position value can be positive
or negative. Positive value means the printing roller moves forward, while negative value means
the printing roller moves backward. This value also can be changed in P7-03 (PR#51) by the
host controller.
E-Cam curve setting
E-Cam curve and master axis are in linear relation. See figure 3.4.5 for the corresponding
relation between master axis and E-Cam.
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E-Cam speed curve
E-Cam position curve
Pulse
number
of slave
axis
Pulse number of master axis
Figure 3.4.5 Traveling distance of master axis corresponds to the distance of E-cam
In figure 3.4.5, you can see the operation speed of master axis and slave axis presents a straight
line, which means it is in normal operation. Slave axis and master axis run at the same speed. All
printing rollers can adopt the same curve.
3.4.3.2
Simulative Operation
Following shows the result of simulative operation. We use time axis as the master axis and
capture the operation curve by PC scope. See below for its setting and operation result.
Figure 3.4.6 Table of E-Cam curve
E-Cam speed curve
E-Cam position curve
Figure 3.4.7 E-Cam curve
Figure 3.4.8 Set up the pulse number of master axis
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See figure 3.4.9 for E-Cam operation without compensation.
Figure 3.4.9 E-Cam operation curve without compensation
When forward shifting the phase, the printing roller moves forward for 3000 PUU. See the setting
and operation curve below:
Figure 3.4.10 PR setting of forward phase shifting
E-cam command will overlap with PR. Since the operation speed of PR command is faster than
E-Cam command, the phase will be moved instantaneously. See figure 3.4.11.
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Figure 3.4.11 E-Cam operation curve of forward phase shifting
See PR setting for backward shifting the phase (= moves backward)
Figure 3.4.12 PR setting of backward phase shifting
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Figure 3.4.13 E-Cam operation curve of backward phase shifting
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3.5
ASDA Series Application Note
Application to Gantry
3.5.1
Introduction
This chapter explains the gantry setting and how gantry works when it is used on Delta ASDA-A2
series products. Users may increase or reduce control signals based on their needs. For other
description of functions and commands, please refer to user manuals of Delta servo drive.
3.5.2
3.5.2.1
How Gantry works and the System Structure
How does gantry work?
Concerning the gantry control, two axes that control the platform must move with the same
speed. A considerable deviation of moving speed between two axes might damage the
mechanism. Thus, synchronizing the motion of two axes is the first priority. See the
demonstration in Figure 3.5.1.
Moving in parallel
Position
sensor
Ball
screw
Position
sensor
Figure 3.5.1 System Structure
The build-in gantry control function from Delta ASDA-A2 allows users to use the related
applications. The controller will simultaneously follow the motion automatically. When position
deviation goes beyond the permitted range, alarm will occur and system will stop working. In this
application, an open-loop control is used by the host controller and ASDA-A2 servo system; the
mission of the host controller is to send position commands, exercise sequential logic control,
and give orders to the servo system to conduct initialization. That is, a host controller is in charge
of the alignment and homing control of two axes. If regarding Z pulse as the homing origin, a host
controller requires the capability to respond to the shortest Z pulse signal of 66 μs from
ASDA-A2.
If misalignment of two axes does not occur on users’ mechanism, positioning function is not
needed. Otherwise, it requires positioning before gantry starts working because no chance will
be given to adjust the two axes’ relative position after it starts. The following is a reference of
positioning and homing provided by Delta.
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3.5.2.2
Application Examples
Positioning and Homing of Gantry
When gantry starts working, completed positioning and homing is required. Positioning is
completed by a position sensor installed on the side of each axis. This position sensor must be
correctly installed as this is the only part that enables the gantry to correct its parallel position. On
gantry’s moving platform, the sensing object with certain length is installed so that its length can
be used to change gantry’s moving speed. In this case, the positioning time can be shortened
and precision level is improved. Also, please adjust the length and running speed of the sensor
according to system requirements. Figure 3.5.2 shows the positioning control; after finishing
positioning, positioning point can be regarded as the homing origin (shown in figure (3) of Figure
3.5.2). Or, as shown in figure (4) of Figure 3.5.2, the nearest Z pulse can also be the homing
origin (either moving forward or backward to look for Z). The setting will be based on different
circumstances and users’ needs.
Moving platform returns to
positioning point at high-speed
Sensing
object
Figure (1) Returning to
positioning point at high-speed
Position
sensor
Moving platform encounters
position sensor and returns to the
positioning point at low-speed
Figure (2) Encountering position
sensor and operating at low-speed
Moving platform reaches the
positioning point and stops moving
Figure (3) Reaching the
positioning point
Moving platform returns to the original
point (Z pulse) of the servo drive
Figure (4) Returning to search for Z pulse
and regarding it as the original point
Z Pulse of the
servo drive
Figure 3.5.2 Returning to Positioning Point and Homing Origin
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Figure 3.5.3 demonstrates the relative position between the sensing object and the position
sensor. This is an example of a grooved-type photoelectric sensor.
Figure 3.5.3 The Relative Position of the Position Sensor and Sensing Object
Figure 3.5.4 demonstrates the status before positioning. If position deviation between two axes
has been existed, one of the axes will arrive at the low-speed zone earlier than the other. When
any of the axes reaches the low-speed zone, the entire system will operate at low speed. Due to
the deviation, the axis entering the low-speed zone first will reach the positioning point earlier.
See the example shown in figure 3.5.4, Axis 1 that reaches the positioning point first will stop and
waits for Axis 2 to arrive. After both two axes reach the positioning point, both axes can then
move forward (or backward) at the same time and look for Z pulse as the homing origin.
Positioning point can also be regarded as homing origin. It is determined by different applications
and demands.
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Low-speed
zone
Axis 1
Axis 1
Moving
platform
Position
sensor
Axis 2
Axis 2
Sensing
object
Figure (1) Entering low-speed zone
Figure (2) One axis is in position
Axis 1
Axis 1
Axis 2
Axis 2
Figure (3) Both axes are in position
Figure (4) Both axes
synchronously return to Z pulse
Figure 3.5.4 System Positioning and Homing
3.5.2.3
Motion Following
When completing positioning and returning to the homing origin, the host controller has to issue
position commands. Then, ASDA-A2 will synchronize the motion of the two axes with its
remarkable performance. When reaching the position, ASDA-A2 is able to report its arrival to the
host controller. In this gantry control, ASDA-A2 is operated in PT mode; it does not accept the
position command from the host to speed up or slow down. Therefore, the host controller itself
should plan the acceleration/deceleration time to achieve stability and efficiency.
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3.5.3
3.5.3.1
ASDA Series Application Note
Servo System Settings
Wiring
Figure 3.5.5 shows the wiring of the entire system. Users may apply different applications
according to actual needs. Figure 3.5.6 shows the detailed wiring.
a. DI signal
SON (0x01): System Start-Up; when system is activated, the start signal of each system is
required.
CCLR (0x04): Pulse Clear; clear the pulse counter.
ARST (0x02): Alarm Reset; when any abnormality occurs, it is used to reset the system via the
host controller or users may control it with the button. To avoid repeated starting up
and shutting down the system during trial run, this signal can be used to clear the
abnormality.
GTRY (0x0A): Gantry Stop (Pause); the following function of gantry does not work when this
signal is on.
EMGS (0x21): Emergency Stop; external switch. Make sure that both two axes can
synchronously receive this signal.
INHP (0x45): Pulse Input Inhibit; when this signal is on, any input pulse signal will not be
admitted. Please note that this signal can only be set via DI8.
b. DO signal
TPOS (0x105): Reach the Target Position, a reference for the host controller.
SRDY (0x101): System Ready, waiting for the start-up command.
SON (0x102): Servo on; servo system is able to receive commands from the host controller.
BRKR (0x108): Brake Release; for a motor system that uses brake, it has to be equipped with
the function of brake release.
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Host Controller
Axis 1
Axis 2
(1)
(3)
(2)
(4)
(5)
(1) DI/O signal used for communicating between
Axis 1 and the host controller
(2) DI/O signal used for communicating between
Axis 2 and the host controller
(3) Position command to Axis 1 and 2 sent by the
host controller
(4) Position pulse reference command to Axis 2
sent by from Axis 1
(5) Position pulse reference command to Axis 1
sent by Axis 2
Figure 3.5.5 System Wiring Diagram
c. Pulse signal of position command
The pulse signal of host controller is directly parallel-connected and fed to both axes
simultaneously. If using open collector, please carefully apply the wire and the power to avoid
short circuit. ASDA-A2 supports three types of pulses; please refer to the manual for further
information. If Z pulse is regarded as the homing origin, Z pulse from one of the axes should be
sent back to the host controller.
d. The pulse signal communication between two axes
On Axis 1, CN1 will send pulse signals OA, /OA, OB, and /OB to OptA, /OptA, OptB, and /OptB of
CN5 on Axis 2. Same as this wiring, on Axis 2, pulse signals OA, /OA, OB, and /OB from CN1
has to be sent back to CN5 of Axis 1, receiving by OptA, /OptA, OptB, and /OptB. This wiring is
specially designed for the gantry, be sure to correctly connect them.
e. A detailed reference for wiring
Figure 3.5.6 is the detailed wiring reference. Users may take this reference to amplify or reduce
the signal. This reference is for the wiring of servo system only. Direct signal input to the host
controller such as position sensor is not included in this diagram. Be sure to reserve the DI/DO
port on host controller.
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Figure 3.5.6 System Wiring Diagram (for reference)
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3.5.3.2
Application Examples
Sequential Logic Control of Positioning and Homing
Concerning the gantry control method of ASDA-A2, the control logic of positioning and homing
has to be completed by the host controller. The control sequence of a host controller and how it
works is explained in previous sections. The detailed control flow chart is hereby presented.
Users can decide whether to use either the positioning point or Z pulse as the homing origin.
a. Two axes symmetrically return to positioning point
If no abnormality occurs when gantry is working, two axes will be in symmetry when performing
homing as shown in Figure 3.5.7.
Figure 3.5.7 Two Axes Symmetrically Return to Positioning Point
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b. The timing diagram of two axes symmetrically return to positioning point
Two Axes Symmetrically Return to
Positioning Point
Delay Time
Command from Host
Controller is Sent to Axis 1
and 2
Command Received by
Axis 1
ORG Signal of Axis 1
Axis 1 Pulse Inhibit Signal
(INHP)
Axis 1 Pulse Clear Signal
(CCLR)
Axis 1 Gantry Pause
Command Received by
Axis 2
ORG Signal of Axis 2
Axis 2 Pulse Inhibit Signal
(INHP)
Axis 2 Pulse Clear Signal
(CCLR)
Axis 2 Gantry Pause
0
Time
Figure 3.5.8 Timing Diagram of Two Axes Symmetrically Return to Positioning Point
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c. Two axes return to positioning point asymmetrically
Shown in Figure 3.5.9, if any unexpected problem occurs during the operation that results in
asymmetry of two axes, the position of two axes can be corrected by homing.
Figure 3.5.9 Two Axes Asymmetrically Return to Positioning Point
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d. Timing diagram of two axes return to positioning point asymmetrically
Two Axes Asymmetrically Return to
Positioning Point
Low-speed
zone
Delay Time
Command from Host
Controller is Sent to Axis 1
and 2
Command Received by
Axis 1
ORG Signal of Axis 1
Axis 1 Pulse Inhibit Signal
(INHP)
Axis 1 Pulse Clear Signal
(CCLR)
Axis 1 Gantry Pause
Command Received by
Axis 2
ORG Signal of Axis 2
Axis 2 Pulse Inhibit Signal
(INHP)
Axis 2 Pulse Clear Signal
(CCLR)
Axis 2 Gantry Pause
0
Time
Figure 3.5.10 Timing Diagram of Two Axes Asymmetrically Return to Positioning Point.
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e. Descriptions about homing
As Z pulse is set to be the homing origin, this figure below demonstrates how it searches for Z
pulse of Axis 1. Please see the descriptions below.
Figure 3.5.11 Homing
Figure 3.5.12 presents the position command that the host controller has to issue when homing.
This figure shows the path when position command is executed.
Figure 3.5.12 Homing Position and Command
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f.
ASDA Series Application Note
Signal control procedure of homing
Homing
Command from Host
Controller is Sent to Axis 1
and 2
Command Received by
Axis 1
ORG Signal of Axis 1
Axis 1 Pulse Inhibit Signal
(INHP)
Level 0
Axis 1 Pulse Clear Signal
(CCLR)
Axis 1 Gantry Pause
Level 0
Command Received by
Axis 1
ORG Signal of Axis 2
Axis 2 Pulse Inhibit Signal
(INHP)
Level 0
Axis 2 Pulse Clear Signal
(CCLR)
Axis 2 Gantry Pause
Level 0
0
Time
Figure 3.5.13 Timing Diagram of Homing
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3.5.3.3
Application Examples
Steps for Adjusting the Servo when Using Gantry Control
The following steps are about the gantry setting and parameter adjusting.
Step 1: Check the wiring
Please refer to the application in section 3.5.3.1 and make sure the wiring is correct.
Step 2: Set up the inertia ratio of the system
Pause the gantry function. Check all the settings of every mechanism and servo drive such as
emergency stop and positive/negative limit. Adjust the mode to J-L (for inertia monitoring) via
monitoring panels of the two servo drives. Let the host controller issue a pulse command and
make the gantry mechanism move back and forth with low speed so as to make sure the
mechanism is working fine. Then, gradually speed up the gantry and monitor the inertia
displayed on the panel. Wait until the inertia becomes stable and then write the inertia ratio into
parameter P1-37 of each controller respectively (When mechanism structure is asymmetric,
inertia ratio will vary with each controller). Inertia ratio is the calculation basis for servo motors’
operation; this value must be correct.
Step 3: Output pulse setting for monitoring
Concerning the use of gantry synchronization, it is important to consider controller’s receiving
speed of monitoring pulse (which is CN5’s capability of pulse receiving). The limit is calculated as
below.
MotorSpeed
* P1  46 * 4  8 * 10 6
60
Calculation Example:
The pulse command from one host controller at maximum speed is 50000 pulse/s. And the
E-gear ratio is 20 times. When the encoder completes a full rotation, the feedback pulse is
1280000 (without going through the E-gear).
(Pulse command * E-gear ratio) / Actual pulse number * 60 sec. = Motor speed per minute
(RPM),
(50000 * 20) / 1280000 * 60 = 46.875 RPM = the maximum motor speed set by the control
command
Based on the above formula, the permitted maximum setting value of P1-46 (Pulse Number of
Encoder Output) can be decided. Improper gain adjusting on a controller might lead to speed
overshoot when the motor is operating; meanwhile, the motor speed might exceed the maximum
speed set by the command; therefore, the overshoot level should be taken into consideration.
For instance, if a margin of 10% is reserved, it has to be increased depending on the
circumstances when using special mechanism.
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(46.875 * 110% ) / 60 * (P1- 46) * 4 < 8 * 106
Two servos’ setting of P1-46 has to be the same; this is the output resolution of the motor. The
higher the resolution is, the better control of the gantry will be. But, if it exceeds the controllable
range, accuracy would be affected when calculating the deviation between two axes.
After setting up P1-46, please set up P1-72 (Resolution of Linear Scale for Full-Closed Loop
Control): (P1-72) = (P1-46) * 4, both settings of the two servos should be the same.
Step 4: Set up the permitted deviation value of synchronization
Set up P1-73 the permitted deviation value of the two axes (for both servos). When the deviation
exceeds the range, AL.040 will occur. Thus, be sure to consider the position displacement
deviation of two axes that the actual mechanism can tolerate. If the set deviation value goes
beyond the actual mechanism’s tolerance, the mechanical system may be damaged.
For instance, the pitch of the ball screw is 10 mm, P1-46 = 60000 and P1-72 = 240000. If P1-73
is set to 30000 pulse, the deviation of two axes can be calculated as
30000
* 10  1.25mm
240000
, when the deviation of two axes is over 1.25 mm, the alarm will occur.
Step 5: Check if phases of monitoring pulse and feedback pulse are compatible
Prepare the scope from PC software. As demonstrated in Figure 3.5.14, enter the monitoring
address and check if the system setting is correct.
1. At the bottom of the scope, select ADR and 32 bit of CH1 and enter 0x3F9060 in yellow blank,
which is the feedback pulse number of linear scale port (CN5) in the servo drive. This would be
a 32 bit value (monitoring the moving direction of synchronous servo drives).
2. Select 32 bit of CH2 and select Feedback Position in white blank. This is the feedback pulse
number of the motor (monitoring the moving direction of the servo drive that connected to the
scope).
3. Let the host controller issue position command and make two motors moving at the same time,
and then monitor the variation of PC scope. See Figure 3.5.4, the increasing amount of signal
of CH1 and CH2 are in reverse. If DI signal of CN5 is not moving in the same direction, as long
as the gantry synchronous control is activated, the alarm will be triggered because of
exceeding the permitted deviation of two axes. For the setting in this system, when the value
of P1-74 is set to 100, the feedback signal of CN5 will be in reverse direction.
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Figure 3.5.14 The Phases of Feedback Pulse in the Opposite Direction
4. If the setting is correct, the signal will be the same as shown in the figure below; the increasing
amount is in the same direction. (The zigzag signal shown in yellow is normal because value
resetting is done to avoid overflow.)
Figure 3.5.15 The Monitoring Phase of Feedback Pulse is Identical
5. Then, connect the PC scope to the other servo drive and make sure the phase of feedback
pulse is correct.
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Step 6: Activate the synchronous control
Activate the synchronous control via P1-74; set digit in ones to 2, the synchronous control of
gantry will be activated.
Step 7: Trial runs
1. Let gantry function remain in pause so as to assure the mechanism is safe when
adjusting parameters.
2. After setting the bandwidth to a proper value (adjust from small to large), let host controller
issue position commands and observe the position deviation and synchronization of two
axes via PC scope. Same as the setting in figure 3.5.16, select CH1, ADR, and 32 bit and
then enter address 0x3F9F98; this would be the position deviation between both axes and
the unit is pulse (using full closed-loop resolution P1-72 as a basis). If the deviation of two
axes exceeds the setting value, alarm will occur. In general, there is no chance that the
loading conditions of two axes are exactly identical, the acceleration/deceleration process
will thus leading to a rather large position deviation.
Figure 3.5.16 Monitoring Position Deviation of Gantry
3. When conducting trial runs, be sure to adjust the parameters to proper values; the bandwidth
settings of the two controllers has to be identical so as to avoid alignment deviation due to
their different response time. When executing the acceleration/deceleration command from
the host controller, the position deviation has to be within the setting range of P1-73;
otherwise, the alarm will occur.
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Step 8: Synchronizing test and parameters adjustment
1. Be sure to complete the steps described above. Then, please use parallel connection to
connect the gantry mechanism between two motors and then start testing the gantry.
2. Please do Step 2 mentioned above again. Re-estimate the system inertia; otherwise, the
system setting will not be accurate and unable to work properly. If the mechanism is not
symmetric, inertia ratio of two axes would be different.
3. The system has to be in protection of miss-synchronization and the deviation value of P1-73
must be absolutely correct.
4.
Basically, the bandwidth settings of both servo drive and gantry synchronous control has to
be identical. The bandwidth of the servo drive can be calculated and set in Auto Gain Tuning
via ASDA Soft; Gantry bandwidth can be set via P2-57 (The Bandwidth of Synchronous
Control). See Figure 3.5.17.
Error tolerance
set in P1-73
big
small
Bandwidth
proportion
100 %
10 %
Bandwidth proportion = Servo bandwidth / (Servo
bandwidth + synchronous bandwidth)
Servo
10
bandwidth 0%
0
Synchronous
%
bandwidth
90
%
10
%
80
%
20
%
70
%
30
%
60
%
40
%
50
%
50
%
40
%
60
%
30
%
70
%
20
%
80
%
10
%
90
%
Figure 3.5.17 Setting Up Bandwidth Proportion
Regarding the synchronous bandwidth, users have to set P2-57 (The bandwidth of Synchronous
Control) only. The system will automatically calculate the value of P2-54~P2-56 (the related
parameters of synchronous control). When the bandwidth setting of synchronous control is wider
than the bandwidth of servo drive, the following result between two motors is better. (However,
the following for the host controller will be relatively worse). Please note that when “Bandwidth of
synchronous control + Bandwidth of the servo drive> Permitted bandwidth of the system”, it is
easier to cause resonance. If bandwidth cannot be increased in order to achieve better following,
please try to increase the value of P2-55 (Integral Compensation to Synchronous Position).
However, if the value of P2-55 is set too high, system vibration will occur. When deciding the
bandwidth, be sure that the setting value of P2-25 is much bigger than the bandwidth setting;
otherwise, the result might not be satisfactory and system might become unstable if worse.
When adjusting the bandwidth of the synchronous control, start from small to large.
The synchronous control of the gantry is shown in Figure 3.5.18.
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Figure 3.5.18 Gantry’s Synchronous Control Structure
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3.6
3.6.1
Application Examples
Application Example of Packing Machine
Description
This chapter aims at the application of ASDA-A2 on packing machine, which is for suing the
compensation of flying shear and mark tacking. If the film has improper tension adjusting,
mechanical slips or the distance between marks is different, ASDA-A2 has the automatic
correction feature to correct the errors. Moreover, functions such as to avoid empty pack, to stop
cutting when the package is in wrong position so as to avoid damaging the mechanism, function
of initial position adjusting, to produce the adequate E-cam curve base on different width of cutter
as well as the masking function between marks all provided by ASDA-A2.
It offers a novel way for servo drive users in packing industry, including the servo system with
motion command and brings a faster and more smoothing operation. Dramatically increase the
performance and reduce the cost of design and development. Especially the function of mark
tracking, it is definitely a great tool for the application of flying shear.
3.6.2
System plan
The packing system consists of three main parts, see Figure 3.6.1. The film feeding axis is the
master axis. When it is delivering the film, it issues the pulse to command the slave axes. The
first slave axis is the cutting axis for sealing and cutting while the second one is the chain
conveyor which is used for delivering packages. The name of the first and second slave is only
for explanation in this chapter and is not named in sequence in real application. It is the typical
packing system. E-cam and motion control function of ASDA-A2 can satisfy the demand of each
main control in this framework.
Figure 3.6.1 Packing system
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3.6.2.1
ASDA Series Application Note
Master axis (Film feeding axis)
This axis is for delivering the film for packing. The delivery should be smooth, e.g. the
mechanical tension should not be too big or it might extend the length of film. However, if the
tension is loose, the film feeding bobbin would slip easily. The above two situations would cause
the problem that the pulse number sent by master axis does not consist with the length of film.
Although the error could be corrected by ASDA-A2, a smoothing film delivery is still a vital task
for packing machine.
3.6.2.2
Camshaft (Flying shear)
The design of flying shear should consider the proportion of actual cutting length and flying shear
spacing. The disproportion would cause the dramatic speed change while cutting and might
become the bottleneck of improving the productivity. Take Figure 3.6.2 as the example, for the
same length of cutting within the same time, the distance the single cutter travels is two times of
two cutters (the distance between tools). If the required cutting distance is short, single cutter is
easier to reach the limit (acceleration / deceleration limit and torque limit) than two cutters. This is
because the single cutter needs to travel longer distance for a cycle. With the same speed, it
needs a faster acceleration and deceleration. Thus, this issue should be taken into consideration
when designing the mechanical structure. Using ASDA-A2 to control flying shear, camshaft
would have the mark tracking function. Please see later parts for further details.
Figure 3.6.2 The comparison of cutting travel distance
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3.6.2.3
Application Examples
Camshaft (Chain conveyor)
Chain conveyor receives the pulse sent by master axis and synchronizes with master axis. With
ASDA-A2, this axis has the function of pulse tracking and mark correction which will be
elaborated later.
3.6.3
3.6.3.1
Servo system setting
System configuration
While the master axis delivers the film, it sends the pulse to camshaft simultaneously. Since
ASDA-A2 has built-in function of pulse by-pass, when sending pulse to slave axes, the delay
time of each axis is 50 ns and the signal will not be attenuated. Repeater is included in ASDA-A2
servo drive, thus, it will not increase the cost when applying to multi-axis. Apart from pulse, mark
signal also needs to be distributed to two slave axes so that the system can conduct the function
of mark correction, see Figure 3.6.3.
Figure 3.6.3 System configuration
For different color of mark, e.g. black mark with white background or vice versa can be done by
changing the setting of ASDA-A2. No need to change the photoelectric switch to read the mark,
see Figure 3.6.4.
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Figure 3.6.4 The setting of different color mark
3.6.3.2
Function introduction
Adjusting the cutting position
A great development of ASDA-A2 on packing machine is the function of mark correction. The
packaging film has ductility, thus it is very sensitive to different tension. When the tension is too
big, it would extend the length of packaging film; if the tension is loose, the packaging film slips
easily. These two situations would cause the default pulse number cannot consist with the cutting
length and result in incorrect cutting. Synchronous capture axis of ASDA- A2 is design for
improving this situation. When the film is deformed or slips, the cutter is unable to aim at the
default cutting point, the system will be compensated by this function and the cutting position will
be adjusted to the right position. See Figure 3.6.5.
Figure 3.6.5 The cause of incorrect cutting position
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Build-in function of masking and cutting with missing marks
The system inspects the actual length by marks printed on packaging material. Thus, mark plays
an important role to the system. To make sure the mark can be read by the system is a vital task.
In order to avoid the spot interference between marks, ASDA-A2 is embedded with masking
function which can setup the start position of reading the mark. Besides, when the mark is poor
printing, the system is still able to trim according to the last cutting length and makes the
correction when the mark appears again.
Figure 3.6.6 Masking and cutting with missing marks
Function of initial position adjusting
When changing the packaging film, the system needs to adjust the position of cutter and mark.
Synchronous capture axis function of ASDA-A2 can apply the synchronous error created
manually to complete the function of position adjusting. Enter the pulse number into P5-79 and
memorize the total correction amount in P5-87. After re-power on, the system will trim the
packaging film according to the setup offset position before the previous power-off.
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Figure 3.6.7 Function of initial position adjusting
Empty pack skip function
ASDA-A2 uses the feature of motion command overlap. With the assistance of the controller, it
can skip the empty pack. The inertia produced by mechanism when stops instantaneously
should be considered. Thus, when in high speed or heavy load, this function is not suitable for
operation. See Figure 3.6.8. This function can deal with the problem of one empty pack or more
than one empty pack. The prerequisite is to properly arrange the photoelectric switch of empty
pack sensor 1 and 2. When the flying shear is at 0 degree or a proper position (the reference
point for detection), empty pack sensor 1 might detect if there is any package on chain conveyor.
If it is in situation 1, it means no empty pack. One empty pack is shown in situation 2. If there is
more than one empty pack, then it is in situation 3. Thus, the condition of detecting empty pack
should be:
No empty pack: (Signal of E-cam is at 0 degree) AND (Empty pack detection 1)
One empty pack: (Signal E-cam is at 0 degree)
AND (NOT Empty pack detection1)
More than one empty pack: ((Situation 2 ) OR (Situation 3)) AND (Empty pack detection1) AND
(NOT Empty pack detection2)
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Figure 3.6.8 Photoelectric switch for detecting empty pack
When empty pack is detected, the controller will trigger EV in a proper time and conduct offset
compensation. Since ASDA-A2 has the feature of command overlap, skip empty pack can be
done by this function. Base on the arrangement of sensors which shown in Figure 3.6.8, when
the number of empty pack is more than one, the system could detect if the next pack exists or not
before the previous command execution is completed. The continuous trigger event of the
controller would cause command overlap. Meanwhile, when the number of empty pack is a lot,
the controller could stop the master axis (film feeding axis) and keep all camshafts in engaging
status after packing. After all empty pack is gone, operate the master axis again and the system
will return to the original operation status. Figure 3.6.9 shows the description of command
overlap.
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Figure 3.6.9 The combination of empty pack command
Cutting skip with incorrect object position
Before cutting, if the package is in wrong position, in order to avoid the wrong cutting and
damage the mechanism, proper defense mechanism is a must. See Figure 3.6.10.
Figure 3.6.10 Shift of package
Double-layer of protection is provided by ASDA-A2. If the wrong position of package is detected
before entering the cutting area, the disengaged condition could be changed to periodically
disengaging. (P5-88.U=C. If P5-88.U is set to 4 as the disengaged condition, when P5-92=0 and
the camshaft is in high speed operation, it will cause non-continuous speed at 360 degrees of the
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curve. Set P5-88.U to C could avoid the situation and have the same function as P5-88.U=4,
periodically disengage. Firmware version after V1.027 Sub.6 supports P5-88.U=C). It also can
satisfy the demand of one or more cutting skips through adjusting lead pulse (P5-92). See Figure
3.6.11.
Figure 3.6.11 Controls cutting by periodical lead pulse
If the system cannot detect the wrong position of the package before entering the cutting area,
then users can apply torque limit function of the servo drive. It could limit the strength of cutter.
When the cutter reaches the setting value of torque limit, the DO signal will be issued to inform
the controller to stop delivering the film. And the alarm will be cleared by the operator. The
camshaft remains at engaging status at the moment and stops operation since the pulse stops
issuing. After removing the package, the master axis will keep delivering the film and the system
will continue the previous cycle. See Figure 3.6.12. Use torque limit as the mechanism protection
when the package is in wrong position, the system program should be taken into consideration. If
the system is in normal operation, and its toque value is close to the maximum value that servo
drive can output, then this way is inappropriate.
Figure 3.6.12 Use the torque limit to protect the mechanism
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3.6.3.3 Design of E-cam curve
Types of flying shear curve
A variety of flying shear curves is offered by ASDA-A2. See Figure 3.6.13. There are three kinds
at the moment. One is to build the curve which has no synchronous zone by PC software. The
other one is to build the curve which has synchronous zone and remains at 51 degrees by PC
software or macro command. The last one is to build an adjustable curve that has synchronous
zone but can only be done by macro command. The advantage of building the flying shear curve
in servo drive is that when the cutting length changes, users only need to setup the relevant
parameter on HMI interface. After issuing the macro command, the curve is built. This is a great
design for multi-process recipes machine. The definition of the calculation in synchronous zone
and cutting length proportion will be elaborated later.
Figure 3.6.13 Camshaft curve
Meaning and calculation of synchronous zone
The synchronous zone on flying shear curve is the sealing length of wrapping paper, which is the
arc length of cutting action. (If the cutter is not wide enough, the cutter width and arc length of
cutting action can be regarded as the same distance) During the cutting process, when it travels
to the synchronous zone which is the position the cutter starts to seal, if the cutting speed does
not equal to the film feeding speed, the packing film will be lengthen or squeezed. That proves
that the synchronous zone is vital to flying shear application and has to be accurate. The
calculation is shown in Figure 3.6.14.
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Figure 3.6.14 Calculation of synchronous zone
Limit of cutting length
Figure 3.6.13 indicates three kinds of cutting length proportion. The so called cutting length
proportion represents the ratio of the wrapping length to the distance the cutter travels, see
Figure 3.6.15. In Figure 3.6.13, synchronous zone remains at 51º degrees and the allowable
cutting length proportion is 0.05 ~ 2.5 when using software to create the E-cam curve. When the
cutting length is close to the minimum value, 0.05, the system will accelerate / decelerate
dramatically during flying shear operation. As the result, it easily reaches the limit (The limit of
motor operation). Thus, designing the mechanism should avoid the extreme condition during
machine operation.
Figure 3.6.15 Cutting length proportion
If the desired cutting length is 2.5 times greater than the cutting length proportion. Use parameter
P5-92 (lead pulse) could make the cutter immobile. So it can cut as long as the user desired. See
Figure 3.6.16.
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Figure 3.6.16 Use lead pulse to lengthen the cutting length
Cutting speed compensation
While cutting, the cutting speed will be faster or slower than the film feeding speed base on some
specific requirement. When the cutting speed is slower than the speed of synchronous zone, the
film will be squeezed. If the cutting is faster, then it will lengthen the film. It is easy to do speed
compensation by ASDA-A2. See Figure 3.6.17.
Figure 3.6.17 Compensation of synchronous speed
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3.7
Application Examples
Application of Precision Positioning via Mark Reading
3.7.1
Description
ASDA-A2 has built-in motion control function. It can quickly complete motion control command
and be applied to the application that requires quick response and precise positioning. The
general controller cannot satisfy the demand of some applications, which might needs different
speed control, but ASDA-A2 could show its excellent performance in this area. The example
elaborated in this chapter aims at positioning control. In a length of moving distance, the system
has to complete precision positioning via mark reading.
This example uses PR control, COMPARE/CAPTURE function of ASDA-A2 to complete
positioning application. Unlike the traditional motion control method, ASDA-A2 provides a more
flexible, better function and more instant setting. A higher cost is needed when applying to the
controller, since a high-level of controller to ensure the timely communication is a must.
ASDA-A2 servo system offers a smoothing motion and simple setting, which dramatically
enhance the system performance and reduce the cost of design and development.
3.7.2
System theorem and setting
During operation, mark reading function has to be enabled in a section. Outside the section, the
function has to be disabled for reducing the interference. If the sensor detects the mark within the
mark reading section, the current command will be replaced by another one. Then, move a
length of distance starting from the mark. That is the so-called positioning function. Although it is
a continuous cycle, it will not produce accumulative error (because every cycle is a refresh start).
If the sensor does not detect the mark result from poor printing, the system will move the default
length automatically. So that it could prevent the problem of mark losing or mark undetectable
and cause incorrect positioning. No matter the mark is able or unable to be read, CAPTURE and
COMPARE function of ASDA-A2 can ensure the smoothing moving speed and accurate position.
3.7.3
3.7.3.1
Setting of servo system
DI setting
Users need to connect the photoelectric switch to DI7 of ASDA-A2 and setup a DI that is enabled
every cycle. This DI function can be triggered by SHOM or EV or it can be replaced by parameter
P5-07.
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3.7.3.2
ASDA Series Application Note
System configuration
Figure 3.7.1 is the description of system plan.
The section
that CAP
function is
enabled
30,000 PUU
The moving distance
after being triggered
Moving
direction
Moving
distance
5
End position
100,000
PUU
4
3
80,000
PUU
70,000
PUU
2
60,000
PUU
1
Start position
0 PUU
Figure 3.7.1 System plan
First, set data array address 50 to 60000, which is the start position of mark printing. Then,
set data array address 51 to 80000, which is the end position. COMPARE function will use
these two addresses for mark detection.
The description of mark 1 ~ 5 in Figure 3.7.1 is shown below:
1.
Reset the coordinate to 0 and initialize the COMPARE function (The COMPARE point
refer to data array address 50 = 50 = 60000 PUU). Then, setup the moving distance
of absolute command to 100000 PUU.
2.
When motor moves to 60000 PUU, the COMPARE function will be enabled (DO4 is
ON). Setup and enable CAPTURE function and initialize another COMPARE function.
This will refer to the content 80000 PUU of data array address 51.
3.
If CAPTURE reads the mark in printing section, the system will disable COMPARE
function and call PR to execute CAP so as to interrupt the original command. This will
enable the motor to move another 30000 PUU starting from the mark, which is the
mark reading function of each cycle. If CAPTURE is unable to read the mark, the
original motion command will be executed.
4.
When the position is at 80000 PUU, if the sensor does not detect the mark,
CAPTURE will not be triggered. Then, the COMPARE function will be enabled and
call another PR to disable CAPTURE function. It means no mark will be read after this
position.
5.
No matter the mark is read or not, it will go to this position as the end position for a
cycle.
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3.7.3.3
Application Examples
Motion command and PR program
Motion command and PR program are shown in Figure 3.7.2. PR program will be elaborated in
this chapter.
Figure 3.7.2
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1.
ASDA Series Application Note
The main PR function of each cycle:
a
Set PR#8 to Homing mode at the start position (Use the current position as original
point).
b
Enable the first COMPARE function.
c
Specify the JUMP path of PR#45 to PR#20.
d
Execute position command (Absolute command: 100000 PUU): In each cycle, the
system starts from the start position and operates 100000 PUU till it moves to the end
position.
Use the current position
as original point
PR
#0
PR Write
#1 Delay = 0
(I) P5-59 = 0x641030
Home X = 8
Offset = 0
PR#1
CMP data address
PR
#3
(I)
Disable CMP function
Write
Delay = 0
P5-56 = 50
Select the jump PR
PR Write
#7 Delay = 0
(I) P6-91 = 20
CMP counter
PR
#4
(I)
Write
Delay = 0
P5-57 = 0
Disable CAP function
PR Write
#2 Delay = 0
(I) P5-39 = 0x2038
CMP amount
PR Write
#5 Delay = 0
(I) P5-58 = 1
PR
#3
Enable CMP function
PR
#6
(I)
Write
Delay = 0
P5-59 = 0x641031
PR
#7
Moving distance
PR
#8
(I)
Position (2)
D = 0, S = 5 rpm
100,000 PUU, ABS
Figure 3.7.3 System initialization
2.
Before entering the mark reading area, the main PR functions are as the followings:
a
When the position is at 60000 PUU, CMP function is triggered. Then, it will call PR#45
(This function will be provided after firmware version of v1.038 sub07).
b
PR#45 jumps to PR#20. This jump function will jump to different PR according to
different program.
c
PR#23 changes the jump path of PR#45 to PR#30.
d
Enable CAPTURE function and prepare to read the mark.
e
Reinitialize COMPARE function and regard the content of data array address 51 as
the output of CMP function.
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Jump to different PR when CMP is completed
PR Jump
#45 Delay = 0
(I) PR#20 or PR#30 (Write by PR#7 and PR#23)
Disable CMP function
PR Write
#20 Delay = 1ms
(I) P5-59 = 0x641030
CMP data address
CMP amount
PR Write
#21 Delay = 0
(I) P5-56 = 51
PR Write
#22 Delay = 0
(I) P5-58 = 1
PR
#23
Select the jump PR
Enable CMP function
CAP amount
Enable CAP function
PR Write
#23 Delay = 0
(I) P6-91 = 30
PR Write
#24 Delay = 0
(I) P5-59 = 0x641031
PR Write
#25 Delay = 0
(I) P5-38 = 1
PR Write
#26 Delay = 0
(I) P5-39 = 0x2039
Figure 3.7.4
3.
PR
#20
The system enters the mark reading section
In mark reading section, when the mark is detected by the sensor, the following PR will be
executed. The main functions are described below:
a
When the mark is detected, CAPTURE function will be triggered. After CAP is
completed, the system will execute PR#50.
b
Disable COMPARE function. Since the mark is read, there is no need to use another
CMP function to disable CAP function.
c
Since the mark is detected, regard here as the reference position. Reset the motion
command and setup CAP, 30000 PUU to replace the original command. The system
will move 30000 PUU to the end position starting from the mark and end this cycle.
Figure 3.7.5
4.
The system detects the mark
In mark printing section, the mark is not read. But it is at 80000PUU. The CMP function is
triggered and calls PR#45. Main functions are shown below:
a
When COMPARE is completed, it will call PR#45. Then, jump to PR#30 to disable
CAPTURE function. This can prevent the mark is misread outside the mark printing
section.
b
The original motion command is not changed. The system keeps operating. After it is
at 100000PUU, this cycle is over.
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Figure 3.7.6
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The system does not detect the mark
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3.8
Application Examples
Application Example of Packing Machine with Phase
Alignment Function
3.8.1 Instruction
This chapter aims at the application of horizontal packing machine which uses the material
feeding axis as master axis and film feeding axis and cutter axis as slave axes. With cam
positioning and synchronous capture axis, it fulfills the function of modification by mark tracking.
In addition, this chapter also introduces the function of empty pack skip and cutting skip by
macro. The application examples of ASDA-A2 on horizontal packing machine has already been
described in Chapter 3.6. In Chapter 3.6, the film feeding axis is the master axis and the cutter
axis and material feeding axis are regarded as slave axes. In production line, packing machine
connects to the other devices via the material feeding axis. Therefore, when the speed changes,
the packing machine can still work easily.
3.8.2 System Configuration
The packing system includes three parts, the master axis and two slave axes. See Figure 3.8.1
below, the material feeding axis is the master axis. When delivering the package, it will transmit
pulse and command the slaves. Film feeding axis is one of the slaves and delivering the
wrapping film is its main task. Another slave is the cutter axis, which controls the cutting time.
Four sensors are used in this application. Synchronous capture axis sensor detects the chain of
the master axis and the signal will be sent back to DI7 of the two slaves. The purpose is to
monitor the operation of the master axis via slaves. When problems occur such as skid, pulse
leaking or the different distances among chains, slaves can fix it in time. Cam positioning sensor
is used for detecting the mark of the wrapping film. The detected signal can be sent back to any
DI (except DI7) on film feeding axis. It is used for adjusting the position automatically according
to the relationship between the read signal and cam curve. Cutting skip sensor is installed in
front of the cutter axis. The purpose is to check the package position in order to prevent the
cutting knife cutting the content in the package when operating. Empty pack skip sensor is
installed in front of the packing area in order to check if there is any unpacked item. If yes, before
the unpacked item reaches the packing position, the slave will stop operating for a cycle. Thus, it
can reduce the waste of materials.
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Figure 3.8.1 Systematic Diagram of Packing Machine
3.8.3
3.8.3.1
Servo System Setup
Configuration
The pulse of master axis on two camshafts is from the output pulse of material feeding axis. The
film feeding axis and cutter axis can therefore operate in accordance with the speed of material
feeding axis by pulse by-pass function.
In order to synchronize the phase of different axis of the whole system, there are two functions of
phase adjustment.

Synchronous Capture Axis: this function will be enabled on film feeding axis and cutter axis.
The detected signal of positioning on master axis connects to DI7 of two axes. Since DI7 is
the high-speed pin input, synchronous capture axis has to connect to high-speed pin. There
is no need to set DI7 as specific DI function, (For instance, the function code can use the
default 0x100.).

Cam Positioning: this function is used in film feeding axis. This sensor detects the mark of
the wrapping film and sends signals back to the film feeding axis as the reference for
positioning. Signal can enter via any DI in one condition; DI has to be set to 0x35 (signals
normally close) or 0x135 (signals normally open).
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Figure 3.8.2 System Configuration – Synchronous Axis
Another two sensors are for cutting skip and empty pack skip:

The signal of cutting skip sensor only needs to be sent back to cutter axis. And the signal
can enter via any DI. The DI needs to be set to trigger PR and enable macro instruction via
PR writing function so as to prevent the missing cutting.

The signal of empty pack skip sensor needs to be sent back to the master first. Usually, the
detection of preventing empty pack will be conducted in previous packs. The sensor is
normally installed in some distance from the packing materials. When the sensor detects
the empty pack, the master has to be in charge of calculating the package difference
between sealing and cutter axis. When the empty pack is in sealing and cutter axis, the PR
procedure of empty pack skip of two slaves will be triggered. Signals can enter into the
drive via any DI. However, the DI has to be the one which can trigger PR. This DI needs to
trigger macro to stop film feeding axis and cutter axis when the empty pack reaches the
position. Until the next package enters the operation zone, two slaves start to operate.
Thus, it can save the packaging materials. The empty pack skip function of Delta Servo
System can apply to single or multiple packs. However, when applying this function, the
capability of the machine should be taken into consideration. The operational speed for
some machines does not suitable for this operation. For example, if the machine runs at the
speed of 3000 rpm and the package is only 4 centimeters long. Users need to consider
whether it is feasible.
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Figure 3.8.3 System Configuration – Signal of Empty Pack Skip and Cutting Skip
3.8.3.2
Features
Synchronous Capture Axis
Synchronous capture axis applying here is to ensure it can automatically adjust its motion and
overcome the problem of incorrect packaging and wrong cutting position when master axis
(material feeding axis) transmits the abnormal pulse to the slaves (film feeding axis and cutter
axis).
In flying shear application, camshaft operates in accordance with the operational distance set by
the receiving pulse of master axis. Therefore, if the master axis is unable to output the set pulse
length, slaves will be unable to cut or pack in correct position. See figure 3.8.4. Assume the salve
axis is set to perform the cutting operation after receiving every 10000 pulses from the master
axis. If the master axis moves the same distance and pulses transmitted are fixed to 10000, then
the camshaft will not go wrong on cutting. If the master axis moves the same distance, but the
slave axis receives 11000 pulses instead of 10000 pulses, the slave axis will still perform the
cutting operation when receiving the 10000th pulse and it will therefore have shorter cutting
length. If the master axis moves the same distances, but the slave axis receives 9000 pulses
instead of 10000 pulses, the slave axis will perform the cutting operation when receiving the
10000th pulse and it will therefore have longer cutting length.
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Figure 3.8.4 Relation of the Pulse from the Master Axis and the Cutting Length
In order to solve the problem of abnormal pulse sent by master axis, the pulse number between
two marks can be regarded as the basis. And the difference between the actual receiving pulses
of two marks can be the basis for adjusting the cutting length. See figure 3.8.5. After comparing
the pulse number triggered by DI7 for two times and the pulse number set by master axis, the
differences will be adjusted by correcting mechanism. The adjusted signal is the synchronous
capture axis. Use the adjusted synchronous capture axis as the master axis to drive the
camshaft. And the pulse of master axis corresponded by the camshaft will be adjusted by
synchronous capture axis. Therefore, even when the pulse number of master axis is incorrect,
the camshaft still can do the adjustment in time.
Figure 3.8.5 Synchronous Capture Axis

If the user wants to use synchronous capture axis, signal of the mark sensor must be input
by DI7 of CN1 of ASDA-A2 Servo;

The source of master axis of E-cam must set to 5. This setting is to select synchronous
capture axis as the source of master axis;

The engaging condition must set to 2 and use capturing to control the engaging time;

The pulse number between two marks must be set in P5-78. The setting of P5-78 must be
correct, or the system has no basis for comparison. Generally, P5-78 = P5-84. If P5-83 = 1,
then the distance between two marks is the distance the cam curve travels for a cycle. See
figure 3.8.6. In every cycle, the actual pulse number output by master axis between two
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marks will be compared with the standard pulse number set by P5-78 and be calculated the
difference. The difference will be saved in P5-79 and applied by the camshaft to adjust the
error.

P5-80 can set the correction rate which is for correcting the value of P5-79. The bigger
P5-80 is, the faster P5-79 can be to reach zero. However, the speed variation will be
greater. Some mechanism does not allow such huge correction within the short time. Users
need to set up the value according to the real situation.
Figure 3.8.6 Operational Theorem of Synchronous Capture Axis
The main task of synchronous capture axis is to adjust the error which is long-term accumulated.
Therefore, the correction rate of P5-79 should be around zero, which value is either positive or
negative. When the value is increasing or continuous decreasing and cannot back to zero, it
means the mechanism might need to be re-adjusted. Or improper setting or pulse loss caused by
the noise might also be the reason.
Figure 3.8.7 shows the PR setting that the cam uses the synchronous axis as the source of
master axis:
PR#21: Synchronous capture axis must read the mark, thus the function of reading marks must
be enabled. P5-39.Y = 2, the source of master axis is pulse command (CN1). P5-39.U = 2, the
minimum triggering intervening time is 2 ms.
PR#21: Set up E-Cam. The setting of P5-88.X = 2 is that after engaging, if the cam stops
because of Alarm or Servo OFF, the cam will remain engaging. The cam can operate directly
after Servo ON. P5-88.Y = 5, the source of master axis is synchronous capture axis. P5-88.Z = 2,
the engaging time is right after reading the mark. P5-88.U = C is to set the cam to cycling mode
and disable the cam after disengaging.
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PR#22: P5-38 is to set up the captured quantity. The capture function captures one data every
cycle. Therefore, P5-38 = 1.
PR#23: Enable Capture Function, P5-39.X = 1.
PR#24: Enable E-Cam, P5-88.X1 = 1.
Figure 3.8.7 PR Setting of Synchronous Capture Axis Application on Cam
Cam Positioning
The application of cam positioning is illustrated in Figure 3.8.8. Users need to set the target
position first. The system will follow the setting and adjust it according to the difference between
the actual position and the setting one by calculating every cycle. The target position, which is
where the sensor installed, is set up by the pulse number of master axis. Take the application on
wrapping film positioning as the example. When the sensor detects the mark of the wrapping film,
the signal will be sent back to the drive. The system will check if the master axis is in the setting
position and calculate the difference of the camshaft so as to do the adjustment. For instance, if
the cam needs 36000 pulses to travel a cycle (e.g. P5-83 = 1, P5-84 = 36000), and the master
axis has 19000 pulses when setting positioning. Also, from the E-cam curve, the corresponding
position which is 9000 PUU can be known. When reading the mark, if the pulse number of
master axis is 17000, the system knows it has 2000 pulses difference from the positioning target,
the system will therefore calculate the error, 2000 pulses. With the error number calculated from
the cam curve, the correction rate which is 500 PUU can be known. This is called cam
positioning. Therefore, with the correction rate, positioning will be completed by overlap
commands.
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Figure 3.8.8 Theorem of Cam Positioning
Parameters from P2-73 to P2-76 have the function of cam positioning. The followings detail the
description of each parameter.
Step 1: Set relevant settings of the input DI
The DI pin which connects to the sensor needs to be set to 0x35 (normally close) or 0x135
(normally open). And the DI will be therefore set to DI.ALGN which is for cam positioning only.
P2-75 is for setting the target position of cam positioning and can be observed by the pulse of
master axis. Take figure 3.8.9 as the example. When P5-83 = 1/P5-84 = 10000, the pulse
number of master axis the cam curve needs to travel for a cycle is 10000. If P2-75 is set to 5000,
when the system receives DI signal of cam positioning, the camshaft shall operate to the
corresponding position of 180°, or the system will adjust the position of camshaft automatically.
The setting range of P2-75 is from 0 (P5-84/P5-83) to -1. If the setting value is out of range,
entering value is not allowed and the error will be shown. If the entering value was within the
range but becomes out of range because of the modification of P5-83 or P5-84, value of P2-75
will be cleared to 0 automatically.
In order to overcome the switching delay of DI input signal, users can use P2-74 to set the delay
compensation. For preventing poor printing of mark and cause misreading of DI, users can use
P2-73.DC to setup the masking area. If DI.ALGN is triggered in masking area, the system will not
read this signal. Only if it is in the proper position (outside the masking area), is the system able
to read and calculate it for adjustment. Here is the masking calculation method which bases on
the percentage.
M >= (P5-84 / P5-83) X P2-73.DC%
This masking function only allows forward direction pulse. Reverse direction pulse will not be
able to work.
The current position of cam can be read from monitoring variable v03EH. When DI is triggered,
the system will compare the monitoring variable with the setting value of P2-75. If two values are
different, it will conduct cam positioning.
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Step 2: Filter setting
In order to have a more smooth operation of the cam and reduce the position error caused by DI
noise (for example, the vibration during the delivering of the wrapping film will cause slight
difference when DI is reading the mark), the filter can help for increasing the stability of
positioning.
P2-73.YX sets the filter range. When DI.ALGN is triggered and enables positioning, the system
will detect the current position of the cam. If the previous position error is less than the setting
range (%), the filter will average the current error with the previous error. Then, adjust the
position. If the previous position error rate is higher than the setting value, the filter will adjust the
position directly without averaging.
P2-76.Y sets the filter’s strength. The setting range is from 0 to F, which is 2^Y square average.
Filter will not function if it is set to 0. The bigger the setting value is, the slower the adjustment will
be. For stabilizing the movement, it can avoid the prompt adjustment and the disturbance caused
by sensor’s noise when positioning. If the setting value is too big, it will be unable to conduct the
positioning. Therefore, it is suggested to set to 3.
Errors can be seen via monitoring variable v055h.
Step 3: Set up the adjustment direction
P2-76.UZ is the forward allowable range of the adjustment direction after positioning. The range
is between 0 and 100%.
When setting to 0: Reverse direction only.
When setting to 25: 25% for forward direction; 75 % for reverse direction.
When setting to 50: it is the shortest distance of positioning. 50% for forward direction; 50% for
reverse direction.
When setting to 80: 75% for forward direction; 25% for reverse direction.
When setting to 100: Forward direction only.
When P2-76.UZ = 0 or 100, the system will adjust the whole cycle of E-cam even when there is
only a minor error. Thus, it might not be appropriate in some applications. If it is not for the
special demand, it is suggested to set to 50%, using the shortest distance for adjustment. For
some applications, if it is set to the shortest distance and the system is not allowed to do reverse
adjustment, then P1-22.U can be applied. There is one condition when applying the setting of
prohibiting adjusting positions in reverse direction. The system must be the one which will
produce errors when operating both in forward and reverse direction. Positioning is designed for
eliminating the long-term accumulated errors. For a normal system, errors will sometimes be in
positive value and sometimes be negative. When the reverse adjustment is prohibited, once the
forward adjustment exists, the error will be eliminated. If the system only produces errors in one
direction, for example, only in forward or reverse direction, then it means the method is not
working.
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Step 4: Set up the maximum allowable correction rate
When a big position error exists, the movement of every adjustment might be big and thus easily
causes motor vibration or overload. The setting of P2-73.UZ could separate the adjustment for
positioning into several times and can moderate the adjustment. However, it takes longer time.
When conducting the positioning, the limit of every maximum allowable correction rate is as
follows:
| C | <= (P5-84 / P5-83) X P2-73.UZ%
Masking range
1
P
Time
compensation
of signal delay
slaves
PUU
0
Pulse
number of
master
(P5-84 ) axis
/ ( P5 -83)
Example:
P 5 - 84 = 10000 , P5 - 83= 1,
P 2 - 75 = 5000 ,
5000 / 10000 *360 º = 180º
DI ALGN
Current position
V 03 Eh
P2-75
2
Range of the filter
<= P2-73.YX
Suggestion: P 2 76 Y= 3
Filter works and
averages the errors
before doing the
adjustment
Strength of the filter
P2-76.Y
Uses % to show errors
3
limit
Current
position
Current
position
Adjustment direction
backward
<= P2-76. UZ
100 %
P2-76.UZ = 0
P2-76.UZ = 25
For preventing the
dramatic change, the
value needs to be set
in a reasonable range
Filter does not
work and does
the adjustment
immediately
P2-76.UZ = 50
4
P2-76.UZ = 75
P2-76.UZ = 100
forward
75 %
25%
50 %
25%
50 %
75 %
100 %
Target
position
Maximum allowable correction rate
<= P2-73.UZ
5
Enable
registration
Conduct the adjustment
by triggering PR
P2-73. BA
Figure 3.8.9 Cam Positioning Setup
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Step 5: Set PR and enable positioning
After positioning, the difference of the E-cam position will be saved in specified PR data of
P2-73.BA. When the system needs to do the adjustment, this PR could conduct it in an
appropriate time. Thus, users have to specify this PR and set it up in P2-73.BA in advance, or
cam adjustment cannot be made. PR setting is shown in figure 3.8.10. It should be set as
incremental position control and allows overlap and interrupt. Speed, acceleration and
deceleration should be set to the reasonable value as well. There is no need to set the value of
position command. It is because when cam positioning is complete, the system will write the
error into the system automatically. The value will be overwritten and updated in any condition.
Figure 3.8.10 PR Setting
After setting up all parameters, P2-76.X can be used to enable cam positioning.
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P2-76.X
Bit
2
1
Function
Two point
phase
trigger PR
immediately
Description
0 :Single point
correction
0: Manually
trigger PR set
by P2-73.BA
1: Adjust the
phase of
material
feeding axis
0
Enable
registration
0: disable
1: enable
1:
When
DI.ALGN
signal enters,
PR set by P273.BA will be
triggered
automatically
_
Figure 3.8.11 Setting to enable E-cam
In Figure 3.8.11:

P2-76.X0 is the switch of positioning. When P2-76.X0 = 1, positioning function is enabled.

P2-76.X1 is for setting up the triggering time of adjusting PR (PR set by P2-73.BA).
Assume P2-76.X1 = 1, when the signal of DI.ALGN is triggered, if the system detects the
error, the system will write the error into PR set by P2-73.BA and execute PR to correct the
error automatically. If P2-76.X1 = 0, when DI.ALGN signal is triggered, the system will still
write the error into PR set by P2-73.BA. However, PR will not be executed automatically.
The user has to judge the execution time and manually trigger PR.

P2-76.X2 is for reading the relation of marks and camshaft. Take figure 3.8.12 as the
example. The cutter axis of ‘mechanism a’ is the slave axis which travels according to the
E-cam curve. Film feeding axis with marks is the master axis. The sensor of cam
positioning reads the marks on wrapping film which transmits by film feeding axis and
transmits DI.ALGN signal to the cutter axis for adjustment. When the slave axis is doing the
adjustment, it will not influence the transmission of wrapping film. When applying to this
mechanism, please set P2-76.X2 = 1. For ‘Mechanism b’ in figure 3.8.12, the cutter axis is
the master axis and the film feeding axis is the slave axis. Therefore, the film feeding axis
travels is in accordance with the E-cam curve. DI.ALGN signal needs to be sent to the film
feeding axis. When executing cam positioning, the transmission of wrapping film will be
influenced by the adjustment. Thus, this application needs to set as P2-76.X2 = 1.
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P2-76.X2 = 0
DI.ALGN:
0x35
Slave
Axis
P2-76.X2 = 1
DI.ALGN:
0x35
Slave
Axis
Master
Axis
Master
axis
a
b
Figure 3.8.12 Mechanisms which can apply the funciton of cam positioning
In this example, the target of cam positioning is material feeding axis. The system will
automatically call PR for adjustment (P2-76.X1 = 1) when DI.ALGN is triggered every time. It is
also for adjusting the phase of material feed axis (P2-76.X2 = 1). Thus, P2-76.X = 7 in this
application.
Empty Pack Skip
When the conveyor is in one position, the sensor needs to detect the item. If the sensor is unable
to detect the item in correct position, it means the item does not exist and will regard it as empty
pack. When the empty pack travels to the packing area, the slave axis has to stop packing, or it
will cause empty packing.
See the practical application in figure 3.8.13. One cycle of the E-cam equals the chain travels a
section. Thus, the first DO output by the cam position can detect the empty pack (in a specific
position). The second output of cam position is applied by the temporal position of cutter axis and
film feeding axis (The cutter has to stop at a safe position, not the cutting position). All the
operational procedures are as follows:
When outputting the DO (0X11A) signal, the controller has to read the signal comes from empty
pack sensor at the same time. If it detects signals, it means the item is on the conveyor and
regarded as a non-empty pack. If there is no signal comes from the sensor, the item will be
regarded as an empty pack. The controller has to record and count. Assuming the distance from
the detection point to cutting position is two packs, after the previous two finish packing and the
empty pack moves to the cutting position, the controller needs to call PR of cutter axis and film
feeding axis (figure 3.8.3) if it outputs DO.0x118 signal. Two slave axes execute macro 10 (P5-97
= 0x10, Figure 3.8.17) respectively in this step. Then the two slave axes will stop for a cycle and
start from the next cycle automatically. This macro allows continuous multi-triggers. It will stop for
a cycle in every trigger. If there are two empty packs, then macro 10 has to be triggered for two
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times continuously. Only if the master axis continues travelling, will the slave axis start to operate
automatically after the stopped cycle. When setting the macro, P5-39 has to be 0. Also, the
E-cam has to be engaged and operates in forward direction.
The function of DO.0x118 mentioned above is to determine the time camshaft stops. General
speaking, the position camshaft stops should not obstruct the operation of master axis. It is
suggested that the camshaft should stop at zero position (the starting point of cam curve). It is
because that from the static status to operate, the camshaft needs to accelerate. Moreover, the
acceleration curve will be planned at the beginning of E-cam curve. Then, when the camshaft
starts to operate again after one cycle, it will follow the plan. If it plans like that, DO.0x118 can
support another function. When the sensor of empty pack receives no signal, the controller
automatically counts the required cycle the camshaft needs to operate and stops at the starting
point of the next cycle.
Detection of
empty pack
Situation 1
No empty
pack
Situation 2
Single empty
pack
position (PUU)
Slave
axis
0。
0
DO.0x118
45。
90 。 135
。
。
180。 225。 270
P5-90 = 180
。
315 。 360。
((Pulse)
Master
axis
P5-91 = 280
DO.0x11A
P2-78 = 90
P2-79 = 225
Figure 3.8.13 Detection of empty pack
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Slave axis
One cycle
One cycle
Cam
position
Stop
operating
Start
operating
Master
axis
Figure 3.8.14 Macro10
Macro 10 usually goes with PR special filter P1-22. It is for alleviating the disturbance caused by
the dramatic change of commands. P1-22.YX sets for the limit of acceleration time. When PR (or
cam) commands change too severe, this setting can smooth the mechanical operation.
Unlike the traditional filter, this special filter (figure 3.8.15) works only when the acceleration and
deceleration time shorter than the setting value. If the command time is shorter than the setting
value, special filter will change the setting from the original acceleration and deceleration time to
the filter’s time. If the time is longer than the filter’s time, the filter executes its command
according to the original time and will not change the command. The acceleration and
deceleration time of the filter is defined between 0 and 3000 rpm. If it is set to 300 ms and the
speed is at 1000 rpm, then the acceleration and deceleration time is 100 ms. When the speed is
at 1500 rpm, the acceleration and deceleration time is 150 rpm and so on. The good points of
using the filter is that it will gradually stops and its final position will not go wrong. The system will
automatically count the spare distance. When resuming the operation, the system will deduct
from it. See Figure 3.8.15.
Figure 3.8.15 PR Special Filter
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If the user worries that PR special filter will cause reverse operation, use the setting of P1-22.U
to avoid it. When the function is working, it will prohibit reverse command. The system will save
the prohibited amount. Not until the forward amount is more than the reversed one will the
system output the forward command. Therefore, there is no need to concern the inaccurate final
position.
Figure 3.8.16 Reverse Prohibited
Figure 3.8.17 is the PR Setting of Triggering Empty Pack Skip Procedure
When using macro10,
must set P5-93 to 0.
PR# Write
DLY = 0 ms
60(I) P5-93 = 0
Trigger macro 10
Applying special filter to slow
down the speed when it stops
Write
PR# DLY = 0 ms
61(I) P5-97 = 0 x 10
Write
PR# DLY = 0 ms
62(I) P1-22 = 0 x 1022
Figure 3.8.17 Empty Pack Skip PR
Avoid Wrong Cutting
When the material is misplaced before cutting, to avoid cutting the material and damage the
mechanism, a proper defense mechanism is needed.
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Correct packing position
Incorrect packing position
Figure 3.8.18 Material is misplaced
Using E-Cam output angle and the sensor could avoid and detect the material that is placed in a
wrong position. See Figure 3.8.19, when DO.0x118 is On, if the sensor does not detect the
material, it might mean the material is in a wrong position. To avoid wrong cutting, anti-cut
procedure should be activated.
Anti-cut
detection
Position (PUU)
Slave
axis
0。
DO.0 x 118
45。
。
90
。
135
180
。
225。 270
P5-90 = 180
。
。
315
。
360
(pulse)
Master
axis
P5-91 = 280
Figure 3.8.19 Anti-cut detection
When anti-cut PR is triggered, enable macro F to calculate the moving distance between current
and target position (0 degree of the cutting curve) first. Then, use macro 8 to stop the slave axis
for a cycle and make it return to 0 degree. See Figure 3.8.20. When E-Cam is engaged, macro F
can write the correcting amount (= the position error between current and target position) into the
specified PR data.
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Pulse number of master axis after
rotating a cycle: (P5-84/P5-83) = L
Slave axis
position (Y)
Alignment
correction value
= Y_Drift
Master axis position (X)
Current
engaged
position
Alignment target
position P5-96
Figure 3.8.20 Macro F
When PR is triggered, the system will set P5-19 to 0 and trigger macro 8 to enable the setting of
P5-19 = 0. The motor will stop since the E-Cam curve scaling is 0. After macro 8 is triggered, the
setting of P5-19 can be changed back to the original one (P5-19 = 1). When the cutter stops, use
macro F to calculate the error between cutter’s current and original position. Then, write the error
into the PR data and trigger it to return the axis to the original position. At the moment, the cutter
axis is engaged, but master axis still keeps sending pulses to cutter axis. The reason the cutter
does not operate is simply because P5-19 = 0. The disengaged condition is set as No. 4 cycle
mode, when this cycle is completed and disengaged again, P5-19 = 1 and the cutter axis starts
operating.
Figure 3.8.21 Avoid empty pack
Anti-cut PR procedure, see figure 3.8.22:
PR#6: Parameter setting of macro F is to set up going trip PR. This application is to move the
cutter axis to 0 degree from current position. Setting up return trip PR is not needed.
PR#7: Parameter setting of macro F is to set up available forward rate. Set the going trip as the
available max. proportion of forward path. The setting is based on the mechanism. If the
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Application Examples
mechanism can only operate at forward direction, then this setting should be set as 100%.
PR#8: Parameter setting of macro F is to set up the alignment target position. Pulse from master
axis is its unit. The setting range is between 0 and (P5-84 / P5-83) – 1.
PR#9: Trigger macro F. This macro will calculate the moving distance between the current
position and target position which is set by P5-96. Then write the moving distance into PR that is
specified by P5-93.
PR#10: Set P5-19 to 0. When the setting value of P5-19 is working, the E-Cam curve will be set
to 0 and the E-Cam will stop operating.
PR#11: Trigger macro 8. It allows the setting of P5-19 (E-Cam scaling) becomes effective when
E-Cam is engaged.
PR#12: Change the E-Cam scaling back to the original one.
PR#13: When triggering macro F, the calculated moving distance will be written into this PR as
the target the position command needs to move. After this PR is triggered, the cutter axis will
move to the position which is set by P5-96.
Set up PR of going trip
Available forward rate (%)
Write
PR
PR#6
#
DLY = 0 ms
(1)
2
(I) P5-93 = 0x0D
PR Write
PR#7
#
DLY = 0 ms
(1)
4
(I) P5-95 = 40
Enable macro F and calculate
the moving distance of E-Cam
Set up E-Cam curve
and stop E-Cam
PR Write
PR#9
# DLY
DL= 0 ms
m
=1
(1)
4 P5-97
Y = 0xF
s
(I)
P5- =0x
PR Write
#1
PR#10
DLY = 0 ms
2
(1)
P5-19 = 0
(I)
Resume E-Cam scale
E-Cam moves
PR Write
#1
PR#12
DLY = 0 ms
(1)
2
P5-19 = 1
Set up the position after triggering
macro F and returning to 0 degree
PR Write
# DLY
DL= 0 ms
m
PR#8
=0
(1)
3 P5-96
Y =0s
(I)
P5-
=0x
Trigger macro 8 and enable the
setting of P5-19 immediately
PR
PR#11
#1 Write
DLY = 0 ms
(1)
2 P5-97 = 0x8
PR Position
PR#13
#
D = 0, S = 1500 rpm
(1)
0 PUU, INC
7
(I)
Figure 3.8.22 Anti-cut PR procedure
The time setting of E-Cam disengaged is very important when using this way to avoid mitcut.
P5-88.U should be set to C (8+4), which means to set up cyclic mode and the function to disable
E-Cam after disengaging. Otherwise, macro 8 cannot work. It has to set up P5-88.X1 (Set
P5-88.X to 3 when E-Cam is activated) when E-Cam is engaged. If E-Cam is still engaged
because of alarm or servo off, this setting is to ensure PR#13 can still work when E-Cam stops.
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Troubleshooting after alarm is cleared
If mechanism stops operating because alarms occur, it might result in relative phase shift. If the
system could correctly correspond the phase of master axis to the E-Cam before operation, it
can save the material during the phase correction process.
For film feeding axis, the additional setting is unnecessary since it has applied the function of
synchronous capture axis and E-Cam positioning. When the alarm is cleared, the system will
automatically read the mark and position.
For cutter axis, macro D can be used to do cam positioning before operation. When motor is
servo Off or stops because of the alarm, if the actual position is different from the E-Cam position,
macro D can calculate the error amount after re-servo on. And the value will be written into the
specified incremental position control PR. Then, trigger this PR and return the E-Cam to the ideal
position.
The following conditions have to be established when using macro D:
1. Macro D can only be used in the cyclic E-Cam curve which starts from the same position
every cycle.
2. E-Cam axis is still engaged when Servo Off or alarm is cleared (P5-88.X1 = 1).
3. E-Cam curve scaling has to be set to 1. (P5-19 = 1).
4. Value of P2-52 has to be set as the error between the slave axis position at the end of the
cycle and the position at the beginning of the cycle (Last point - First point). See Figure
3.8.23.
5. Motor’s start position has to be at 0 degree of E-Cam curve.
Figure 3.8.23 Marco D
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When desire to move the cutter to the target position, motor can operate either at forward or
reverse direction. Users can set up available forward rate or avoid point to plan the operating
direction.
When setting P5-93.BA to 1, the system will determine the operating direction according to the
setting of available forward rate, which is set by P5-95. See Figure 3.8.24 for the description of
available forward rate. Its setting is converted by the proportion when motor runs a cycle. For
example, when available forward rate is set to 25%, if motor exceeds the target position for 1/4
cycles (25/100 = 1/4) at forward direction the motor will search the target position at reverse
direction. In the application, if both forward and reverse directions are allowed, it is suggested to
set the rate to 50%. This setting enables the motor to complete the command with the shortest
distance.
Figure 3.8.24 Setting of available forward rate
If forward and reverse directions are both allowed, but cannot pass the specified position, users
can set up an avoid point. When P5-93.BA = 0, the system will determine if the motor shall run at
forward or reverse direction according to the current position, target position and avoid point. The
position of avoid point can be set up by P5-95. In cutting applications, if desire to move the cutter
when the system stops, users can set the cutting position as the avoid point for avoiding the
cutter cutting the material.
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Figure 3.8.25 Setting of avoid point
If reverse direction is not allowed, users can set up reverse inhibit (P5-93.DC = 1). Then, the
command of reverse direction will be neglected. That is to say, the motor will start its operation
when it receives the command of forward direction. It can protect the mechanism which does not
allow reverse direction.
Figure 3.8.26 shows the setting when the cutter axis re-operates after it was stopped by servo off
or an alarm:
PR#43:
P5-93.YX = 2E: Set up the specified PR. Macro D will write the error between the current and
target position into this PR. Triggering this PR can do positioning. 2E (hex.) means to specify
PR#46 as the PR for positioning.
P5-93.UZ = 00: It has to be 0.
P5-93.BA = 01: Use available forward rate to determine the motor operation direction.
P5-93.DC = 01: Enable the function of reverse inhibition.
PR#44: Set available forward rate to 0. The motor only can operate at reverse direction. However,
when setting up P5-93.DC, the function of reverse inhibition has been activated. Thus, the motor
will be unable to operate to the target position. But the function of phase alignment still works.
The cutter axis stands until the phase of master axis corresponds to the correct phase of cutter
axis. Then, the cutter operates according to E-Cam curve.
PR#45: Enable macro D. It automatically calculates the error between the current and target
position and write into the specified PR.
PR#46: When triggering macro D, the calculated moving distance will be written into this PR as
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Application Examples
the distance the position command needs to move. After this PR is triggered, the cutter axis will
move to the target position.
Setting before enabling macro D
PR
#1
PR#43
(I)
2
Write
DLY = 0 ms
P5-93 = 0x0101002E
Setup available
forward rate
PR
PR#44
#12
(I)
Enable macro D
PR
#1
PR#45
2(I)
Write
DLY = 0 ms
P5-95 = 0
Write
DLY = 0 ms
P5-97 = 0xD
PR for cam registration
PR Position
PR#46
#
D = 0, S = 1500 rpm
(I)
7
0 PUU, INC
(I)
Figure 3.8.26 PR procedure when E-Cam do positioning again
3.8.3.3
Design of E-Cam Curve
In this system, E-Cam curves for operating film feeding axis and cutter axis have to be set up.
Film feeding axis operates at constant speed according to master axis, thus, its E-Cam curve is
the oblique straight line, which can be done by Manually create a table in E-CAM Editor. E-Cam
curve of cutter axis is the curve of flying shear, which can be done by Rotary Shear– W/O
Sealing Zone or macro command (if it has constant speed area).
Followings are the mechanism specification:
Gear number at motor side # (A)
5
Gear number at cutter side # (B)
5
Diameter of the encoder (d2)
20 mm
Pulse number per resolution (N)
10000
Cutter number
(C)
1
Diameter of the cutter (d1)
200 mm
Cutting length (L)
500 mm
Figure 3.8.27 Mechanism specification
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E-Cam curve of cutter axis
The E-Cam curve of cutter axis can be done by E-CAM editor of ASDA-Soft. This example uses
Rotary Shear – Adjustable Sealing Zone to create an E-Cam curve. Users can create the curve
by setting up the required mechanism specification and angle. Please refer to Chapter 2 or
ASDA-Soft User Manual for detailed descriptions. The pulse number of master axis in this
example is calculated by software based on mechanism specification, P5-84 = 79577 (P5-83 =
1). The setting of E-gear ratio of cutter axis is P1-44 = 128 / P1-45 = 1. After creating the curve,
store it into data array to complete the setting.
Figure 3.8.28 Rotary Shear – Adjustable Sealing Zone
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E-Cam curve of film feeding axis
The E-Cam curve of film feeding axis can be done by E-CAM Editor of ASDA-Soft. Assume the
gear ratio between motor and mechanism is 1:5 and the cutting length is 500 mm, 1 mm of
resolution corresponds to 100 PUU and 500 mm needs 50,000 PUU. The mechanism operates
50,000 PUU, it means the motor operates 50,000 x 5 = 250,000 PUU. The gear ratio of film
feeding axis can be set as P1-44 = 128 / P1-45 = 5. See Figure 3.8.29. It uses Manually create a
table to create the curve for film feeding axis and input 250,000 as the total length to create an
E-cam curve for constant speed operation. The E-gear ratio setting of film feeding axis is the
same as the one of cutter axis, which is P5-83 = 1 / P5-84 = 79577.
Figure 3.8.29 Manually create an E-Cam curve for film feeding axis
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0
4.1 DO Output with Fixed Distance ..................................................................................... 4-2
4.1.1 Description ............................................................................................................. 4-2
4.1.2 System Configuration ............................................................................................. 4-2
4.1.3 Servo System Setting ............................................................................................ 4-3
4.2 How to Use E-Cam Function to Compensate Tolerances on Lead Screw ................... 4-8
4.2.1 Description ............................................................................................................. 4-8
4.2.2 How does the System Work? ................................................................................. 4-8
4.2.2.1 Inconsistency between Command and Machine Position Caused by
Tolerances on Lead Screw .......................................................................... 4-8
4.2.3 Servo System Configuration .................................................................................. 4-9
4.2.3.1 The Conversion of Command and Compensation from Servo Drive .......... 4-9
4.2.3.2 Measurement and Measuring Result ........................................................ 4-11
4.2.3.3 Using E-Cam on ASDA-A2 for Compensation .......................................... 4-13
4.3 PT Command Transferred from Analog Voltage ......................................................... 4-17
4.3.1 Description ........................................................................................................... 4-17
4.3.2 System Configuration ........................................................................................... 4-17
4.3.3 Servo System Setting .......................................................................................... 4-18
4.3.3.1 Wiring ........................................................................................................ 4-18
4.3.3.2 Operation steps ......................................................................................... 4-19
4.4 Speed Change during Execution of PR Position Command ....................................... 4-22
4.4.1 Description ........................................................................................................... 4-22
4.4.2 How does system work? ...................................................................................... 4-22
4.4.3 Servo System Setting .......................................................................................... 4-23
4.4.3.1 Tips for Applying PR .................................................................................. 4-23
4.4.3.2 PR Program Setting .................................................................................. 4-23
4.5 Macro for E-Cam Application ....................................................................................... 4-26
4.5.1 Macro C................................................................................................................ 4-26
4.5.2 Macro D................................................................................................................ 4-27
4.5.5 Macro 10 .............................................................................................................. 4-35 March, 2015
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Chapter 4 Application Techniques
4.1
4.1.1
ASDA Series Application Note
DO Output with Fixed Distance
Description
With the built-in COMPARE function of ASDA-A2, users can enable DO signal output after the
motor operates for a distance. More than one DO output can be flexibly programed and its output
length can also be modified. For applying this application, the related background knowledge
about internal control (PR) and COMPARE function of ASDA-A2 servo drive is required. The
built-in function can satisfy the demand without modifying the hardware, which not only reduces
the cost of mechanism but improves the flexibility. Four digital outputs (DO1 / DO2 / DO3 / DO5)
are the maximum when there is no other extension DO. Please note that, DO4 is only for
COMPARE function and cannot be applied in this application.
4.1.2
System Configuration
Here are the examples of two digital outputs. The output time of one example is overlapped and
the other is not.
Figure 4.1.1 shows the time when two DOs are overlapped.
DO1 ON
DO1 OFF
DO2 ON
Figure 4.1.1
DO2 OFF
The Output Time of Two DOs is Overlapped
Figure 4.1.2 shows the time when two DOs are not overlapped.
DO1 OFF
DO2 ON
DO2 OFF
Figure 4.1.2 The Output Time of Two DOs is not Overlapped
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Chapter 4 Application Techniques
See the example in figure 4.1.1. The output time of two DOs is overlapped. Followings are the
system configuration:
1.
Use PR write-in function to write four values, input 1 to input 4 (the timing when DO1
and DO2 is on and off) into data array and regard them as the timing when Compare
outputs. The first compare value (input 1) is the timing to set DO1 on; while the
second value (input 2) is the timing to set DO2 on; the third compare value (input 3) is
the timing to set DO1 off and the fourth one (input 4) is the timing to set DO2 off.
2.
When the motor is activated, enable the 1st compare function. The compared value is
the first value (input 1) entered into data array. Then, call PR#45. Use Jump function
to call one PR so as to set P4-06 to 0x0001 and to set DO1 on.
3.
Then, change the jump path of PR#45 as the next path that will be written into the
value of P4-06.
4.
Repeat step 2 ~ 3 to execute the 2nd, 3rd and 4th compare function. When the 2nd
compare value (input 2) is written into data array, DO2 is on. When the 3rd compare
value (input 3) is written to data array, DO1 is off. When the 4th compare value (input 4)
is written to data array, DO2 will be off.
See the example in figure 4.1.2. The output time of two DOs is not overlapped. Step 4 is different
in this example. In step 4, when the second compare value (input 2) is written to data array, DO1
is off. When the third compare value (input 3) is written to data array, DO2 is on. And when the
fourth compare value (input 4) is written to data array, DO2 is off.
4.1.3
Servo System Setting
PR program
Following describes the PR program when the output time of two DOs is overlapped.
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Chapter 4 Application Techniques
ASDA Series Application Note
Activate the motor Disable CMP function
Activate
the motor
and enable
compare
(CMP)
function
PR Jump
#53 Delay = 0
(I) PR#9
PR Speed
#09 Delay = 0
(I) 10 rpm
CMP
amount
PR Write
#11 Delay = 0
(I) P5-58 = 1
PR Write
#10 Delay = 0
(I) P5-59 = 0x11030
CMP data
address
PR Write
#12 Delay = 1 ms
(I) P5-56 = 10
Enable CMP function
PR Write
#13 Delay = 0
(I) P5-59 = 0x11031
Jump to different path when CMP function is complete
Execute
this PR
when CMP
function is
complete
PR
#45
(I)
PR
#11
PR#30
Jump
Delay = 0
PR#30 or PR#33 or PR#36 or PR#39
(write by PR#31/PR#34/PR#37/PR#40)
PR#33
PR#36
PR#39
This will be
executed
after the 1st
compare
value is
written to
data array.
This will be
executed
after the
2nd
compare
value is
written to
data array.
4-4
Setup DO status
PR
#30
(I)
Write
Delay = 0
P4-06 = 0x01
Setup DO status
PR# Write
33 (I) Delay = 0
P4-06 = 0x3
Select the jump path
PR Write
#31 Delay = 0
(I) P6-91 = 33
Jump to the second
compare function
PR
#32
(I)
Jump
Delay = 0
PR#14
Jump to execute the
Select the jump path third compare function
Write
PR#
Delay = 0
34 (I)
P6-91 = 36
Jump
PR#
Delay = 0
35 (I)
PR#18
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Chapter 4 Application Techniques
Setup DO status
This will be
executed
after the 3rd
compare
value is
written to
data array.
This will be
executed
after the 4th
compare
value is
written to
data array.
PR
#36
(I)
Write
Delay = 0
P4-06 = 0x2
Setup DO status
Select the jump path
Jump to execute the
third CMP function
PR Write
#37 Delay = 0
(I) P6-91 = 39
PR Jump
#38 Delay = 0
(I) PR#22
Select the jump path
PR Write
#39 Delay = 0
(I) P4-06 = 0x0
PR Write
#40 Delay = 0
(I) P6-91 = 30
Figure 4.1.3 System PR Configuration
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Chapter 4 Application Techniques
1.
ASDA Series Application Note
Write the value required by compare function in data array. Here can setup the output
timing and output duration of DO. See below for the main PR functions:
a
Use P5-11 to specify the start address when writing value to data array.
b
Use P5-12 to continuously write the value into data array.
c
PR#2 setup the timing of DO1 on.
d
PR#3 setup the timing of DO2 on.
e
PR#4 setup the timing of DO1 off.
f
PR#5 setup the timing of DO2 off.
Figure 4.1.4 PR Illustration for Setting up Data Array
2.
See below for the main PR functions when enabling compare function:
a
PR#09: Activate the motor. In this example, the source axis of compare function is set
to the output pulse from the encoder.
b
PR#12: Specify the compare start address in data array. This value is the timing of
DO1 on.
c
PR#13: Enable compare function.
Figure 4.1.5
4-6
PR Illustration of Compare Function
March, 2015
ASDA Series Application Note
3.
Chapter 4 Application Techniques
Once the compare function is complete, a signal will be outputted and the compare function
will be disabled. Then, PR#45 jumps to different PR so as to setup DO status.
a
PR#30 / PR#33 / PR#36 / PR#39: Setup P4-06 so as to change the output status of
DO1 and DO2
b
PR#31 / PR#34 / PR#37 / PR#40: Change the jump path of PR#45 so as to fulfill the
condition for the next compare
c
PR#32 / PR#35 / PR#38: Jump to execute the next compare
d
The second, third and fourth compare function should be identical to the first one.
Specify the compare address to the correct address (PR#16 / PR#20 / PR#24).
Jump to different path when CMP function is complete
This will be
executed
after
compare
function is
complete
PR
#45
(I)
PR#30
Jump
Delay = 0
PR#30 or PR#33 or PR#36 or PR#39
(write by PR#31/PR#34/PR#37/PR#40)
PR#33
PR#36
PR#39
This will be
executed
after the 1st
compare
value is
written to
data array.
This will be
executed
after the 2nd
compare
value is
written to
data array.
This will be
executed
after the 3rd
compare
value is
written to
data array.
This will be
executed
after the 4th
compare
value is
written to
data array.
Setup DO status
Jump to the second
CMP function
PR Write
#30 Delay = 0
(I) P4-06 = 0x1
PR Write
#31 Delay = 0
(I) P6-91 = 33
PR
#32
(I)
Setup DO status
Select the jump path
Jump to the third
CMP function
PR
#33
(I)
Write
Delay = 0
P4-06 = 0x3
PR Write
#34 Delay = 0
(I) P6-91 = 36
PR
#35
(I)
Jump
Delay = 0
PR#14
Jump
Delay = 0
PR#18
Select the jump path
Jump to the third
CMP function
PR Write
#36 Delay = 0
(I) P4-06 = 0x2
PR Write
#37 Delay = 0
(I) P6-91 = 39
PR Jump
#38 Delay = 0
(I) PR#22
Setup DO status
Select the jump path
Setup DO status
PR Write
#39 Delay = 0
(I) P4-06 = 0x0
Figure 4.1.6
March, 2015
Select the jump path
PR Write
#40 Delay = 0
(I) P6-91 = 30
PR Illustration for DO Setup
4-7
Chapter 4 Application Techniques
4.2
ASDA Series Application Note
How to Use E-Cam Function to Compensate Tolerances on
Lead Screw
4.2.1
Description
In the application of precision machinery that adapts an open-loop system, manufacturing
tolerance on pitch of lead crew will cause inconsistency between command and position of
machine. System of ASDA-A2 is able to create a compensative E-Cam curve based on the
measurement of the lead screw to solve this problem, keeping the resolution of command from
the host controller remains the same.
4.2.2 How does the System Work?
4.2.2.1
Inconsistency between Command and Machine Position Caused by
Tolerances on Lead Screw
When pitches on lead screw are identical, the correspondence between command and pitch will
be consistent so no compensation is needed.
Command = 10000 Pulse
1
Command = 10000 Pulse
2
Command = 10000 Pulse
3
Command = 10000 Pulse
4
Command = 10000 Pulse
5
Figure 4.2.1 Command from the Host Controller and the Lead Screw without Tolerance
When pitches are not identical, the distance specified by the command and the actual moving
distance of the lead screw will not be identical. That is, the actual moving distance that every
pulse corresponds to is different. In this case, the resolution of command is changed.
Command = 10000 Pulse
1
Command = 10000 Pulse
2
Command = 10000 Pulse
3
Command = 10000 Pulse
4
Command = 10000 Pulse
5
Pitch
tolerance
Figure 4.2.2 Command from the Host Controller and Lead Screw with Tolerance
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March, 2015
ASDA Series Application Note
4.2.3
4.2.3.1
Chapter 4 Application Techniques
Servo System Configuration
The Conversion of Command and Compensation from Servo Drive
E-Cam system of ASDA-A2 can adjust the command resolution of the host controller and keep it
consistent with the moving distance of the mechanism. If tolerance of pitch exists, the system is
able to adjust the E-Cam curve according to the actual moving distance of the lead screw,
making every pulse correspond to the same amount of moving distance and eliminating the
impact brought from different tolerances. In this setting, values from command of the host
controller, E-Cam command from the servo drive have to correspond to each other, and actual
moving distance of the mechanism. See Figure 4.2.3.
2
E-Cam command
from the Servo drive
Host
Controller
1
Command from the
host controller
3
Actual moving
distance of the
mechanism
Figure 4.2.3 The Correlation of Command of Host Controller, E-Cam Curve, and Machine Moving Distance
If a host controller which pulse command resolution is 0.1 mm/pulse and the required moving
distance of mechanism is 20 mm, the required pulse number will be 20 mm / 0.1 mm = 200 pulse.
If there is no tolerance on lead screw and the servo does not modify the command, the
correlation is 1 pulse  1 PUU 0.1 mm. (See Figure 4.2.4) PUU is the unit of command from
Delta’s servo drive.
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Chapter 4 Application Techniques
Command
from the servo
ASDA Series Application Note
Conversion capability of
E-Cam curve toward command
from host controller
PUU
Moving distance
of the mechanism
200
PUU
20 mm
200 pulse
Command from host
controller (pulse)
1 pulse  1 PUU  0.1 mm
Figure 4.2.4 The Proper Correlation when No Tolerance Exists
When there is a tolerance on the lead screw, the actual moving distance is 22 mm. The
correlation will be: 1 pulse 1 PUU  0.11 mm. Regarding this motion, the command resolution
was 0.1 mm/pulse and now becomes 0.11 mm/pulse. This is caused by the tolerance between
pitches.
Command from
Servo Drive
PUU
Conversion capability of E-Cam
curve toward command from host
controller
Moving distance
of mechanism
200
PUU
22 mm
200 pulse
Command from host
controller (pulse)
1 pulse  1 PUU  0.11 mm
Figure 4.2.5 The Inconsistent Correlation when Tolerance Exists
In this case, an E-Cam curve can be used to modify the command resolution. If the new
correlation of E-Cam curve is 1 pulse  0.9091 PUU  0.1 mm, the correlation between host
command and the actual moving distance will be 1 pulse  0.1 mm. By applying the E-Cam
function, the command resolution of the host controller can be identical without being affected by
the tolerance. There is one thing worth noticing, the feedback pulse number from motor will differ
from the command value. For example, when the command is 220 pulse, the feedback pulse
from motor is 200 PUU and the actual moving distance of mechanism is 22 mm.
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March, 2015
ASDA Series Application Note
Chapter 4 Application Techniques
Change the conversion
capability of E-Cam curve
toward command from
host controller
Command from
servo drive
PUU
Moving distance
of Machine
200
PUU
22 mm
Command from host
controller (pulse)
220 pulse
1 pulse  0.9091 PUU  0.1 mm
Figure 4.2.6 The Correlation after Compensation by E-Cam Curve
4.2.3.2
Measurement and Measuring Result
If equally divide the lead of the lead screw by the host controller and use laser interferometer to
measure the actual moving distance and then record these data, the ideal condition is presented
below in Figure 4.2.7.
Let’s say command resolution is 0.1 mm / pulse.
Origin
Command from
0
Host Controller pulse
1000
pulse
2000
pulse
3000
pulse
4000
pulse
5000
pulse
Command from 0 1000000 2000000 3000000 4000000 5000000
PUU
PUU
PUU
PUU
Servo Drive PUU PUU
Machine Position
0
mm
100
mm
200
mm
300
mm
400
mm
500
mm
Figure 4.2.7 Ideal Measurement Result when No Tolerance Exists
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Chapter 4 Application Techniques
ASDA Series Application Note
Actual Position of
Machine
(mm)
Command from Servo
(PUU)
5000000
PUU
500
mm
4000000
PUU
400
mm
3000000
PUU
300
mm
2000000
PUU
200
mm
1000000
PUU
100
mm
0
PUU
0
pulse
1000
pulse
2000
pulse
3000
pulse
4000
pulse
Command
from Host
Controller
(pulse)
5000
pulse
Figure 4.2.8 The Correlation Curve when No Tolerance Exists
In the actual measurement, there must be tolerance. See Figure 4.29. Thus, the E-Cam curve
will be used to compensate and restore the resolution to 0.1 mm/pulse between every division.
Origin
Command from
Host Cotroller
0
pulse
Command from
Servo Drive
0
PUU
Measured
Machine Position
0
mm
Actual Command
Resolution
1000
pulse
1000000
PUU
102
mm
0.102
mm/
pulse
0
mm
100
mm
2000 3000
pulse pulse
4000
pulse
5000
pulse
3000000
5000000
PUU
PUU
2000000
4000000
PUU
PUU
208
mm
0.104
mm/
pulse
298
mm
0.098
mm/
pulse
200
mm
404
mm
0.106
mm/
pulse
300
mm
502
mm
0.098
mm/
pulse
400
mm
500
mm
Figure 4.2.9 Measurement Result when Tolerance Exists
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March, 2015
ASDA Series Application Note
Chapter 4 Application Techniques
Command from
Servo Drive
(PUU)
Actual Position of
Machine
(mm)
5000000
PUU
502
mm
4000000
PUU
404
mm
3000000
PUU
298
mm
2000000
PUU
208
mm
1000000
PUU
102
mm
0
PUU
0
pulse
1000
pulse
2000
pulse
3000
pulse
4000
pulse
Command from
Host Controller
(pulse)
5000
pulse
Figure 4.2.10 The Correlation when Tolerances Exist
4.2.3.3
Using E-Cam on ASDA-A2 for Compensation
Using E-Cam curve to compensate the command from the host controller is like creating a
tailor-made position curve for the lead screw. By doing so, the command resolution will not be
changed due to the pitch tolerances that causing the inconsistency between the host controller
and machine moving distance. The result after compensation is shown in Figure 4.2.11. With the
compensation, no matter it is on which division of the lead screw, the correlation between
command from host controller and moving distance of mechanism will be 1 pulse  0.1 mm.
Command from the Servo
(PUU)
5000000
PUU
1000
pulse
2000
pulse
3000
pulse
4000
pulse
Machine Position
(mm)
5000
pulse
502
mm
4000000
PUU
404
mm
3000000
PUU
298
mm
2000000
PUU
208
mm
1000000
PUU
102
mm
0
PUU
0
pulse
1020
pulse
2080 2980
pulse pulse
4040
pulse
5020
pulse
Command from
the host (pulse)
Figure 4.2.11 The Compensation Curve
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Chapter 4 Application Techniques
ASDA Series Application Note
Steps to create E-Cam curve are shown below:
1. E-Cam curve on ASDA-A2 is created based on corresponding positions. Pulse of the master
axis is the command from the host controller, which corresponds to the pulse number based
on 360°. The other axis represents motor’s position, which unit is PUU.
Relative position of Motor
Position of the slave axis
(PUU)
5000000
PUU
4000000
PUU
3000000
PUU
2000000
PUU
1000000
PUU
Position of the
maser axis
0
PUU
0°
72°
144°
216°
288°
360°
0
pulse
1000
pulse
2000
pulse
3000
pulse
4000
pulse
5000
pulse
Command
from the host
(pulse)
Figure 4.2.12 E-Cam Curve and Measurement Diagram
2. Select Cubic Curve Creation. See Figure 4.2.13.
Figure 4.2.13 Select the Way to Create E-Cam Table
3. Right click the mouse button to insert points. The total points will be the measuring points plus
the origin. See example in Figure 4.2.9, the total required points are 6 (Figure 4.2.14). Set
Curve Type for each point to [1]: constant line.
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March, 2015
ASDA Series Application Note
Chapter 4 Application Techniques
Figure 4.2.14 Total points = measuring points + origin
Figure 4.2.15 Set Curve Type of Every Angle to [1]: constant line
4. Please refer to Figure 4.2.9 and Figure 4.2.10. Calculate the angle of the master axis and
take 0.1 mm/pulse as the basis of command resolution.
0 mm 0 Pulse  0°  0 PUU
102 mm  1020 pulse  360 * 1020 / 5000=73.44°  1000000 PUU
208 mm  2080 pulse  360 * 2080 / 5000=149.76°  2000000 PUU
298 mm  2980 pulse  360 * 2980 / 5000=214.56°  3000000 PUU
404 mm  4040 pulse  360 * 4040 / 5000=290.88°  4000000 PUU
502 mm  5020 pulse  360 * 5020 / 5000=361.44°  5000000 PUU
As the last one has exceeded 360°, edit the data and keep it within the range (360°):
500 mm  5000 pulse  360°  5000000 * 5000 / 5020 = 4980080 PUU
5. Fill in the data mentioned above. Then, set Sample ang. (sampling angle) to 1°. Click on
Create Cubic Curve Download table Burn Table Data. This will be the curve specially
made for this lead screw.
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Chapter 4 Application Techniques
ASDA Series Application Note
Figure 4.2.16 Creating E-Cam Curve
4.2.3.4
Notice
Please pay special attention to the following notice when using E-Cam curve to compensate the
manufacturing tolerances on lead screws.
1. The origin shall not be changed. When it is changed, please re-measure and re-create an
E-Cam curve to avoid wrong compensation.
Origin
1020
pulse
2080 2980
pulse pulse
4040
pulse
5020
pulse
Changing of origin will
change the
corresponding position
between command and
machine, causing
wrong compensation.
Actual position of the machine (mm)
Figure 4.2.17 Wrong Compensation Caused by Change of Origin
2. Use this function in PR mode instead of the default PT mode.
3. For other operation and setting details about E-Cam, please refer to ASDA-A2 User Manual,
teaching materials or contact service center of Delta Group.
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March, 2015
ASDA Series Application Note
4.3
4.3.1
Chapter 4 Application Techniques
PT Command Transferred from Analog Voltage
Description
In ASDA-A2 control mode, analog signal can directly control speed and torque. For example, if
wish to use analog signal (+10V/-10V) to find motor position, the positioning function that
transfers analog speed to pulse can be used. The required parameters and setting methods are
described in this section.
4.3.2
System Configuration
The range of input voltage is from +10V to -10V. The input voltage value corresponds to the
motor position.
Figure 4.3.1 Analog input corresponds to motor position
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Chapter 4 Application Techniques
4.3.3
4.3.3.1
ASDA Series Application Note
Servo system setting
Wiring
Analog signal is input via Pin42 (V-REF) and Pin44 (GND) of CN1. Its wiring method is identical
to speed mode.
Figure 4.3.2 Wiring
Servo drive’s operation mode has to be set in PT mode. To avoid danger, please correctly setup
E-gear ratio. 1:1 (P1-44 = 1 / P1-45 = 1) is recommended.
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March, 2015
ASDA Series Application Note
4.3.3.2
Chapter 4 Application Techniques
Operation steps
Step 1: Setup operation mode
Set the operation mode to PT:P1-01 = 0x0000
Step 2: Setup E-gear ratio
It is strongly recommended to set E-gear ratio as 1:1 (P1-44 = 1 / P1-45 = 1). This is for avoiding
the over speed of the motor.
Step 3: Setup the maximum rotating number of analog position command
Setup the maximum rotating number of motor in P1-66. The range of analog input voltage is
between -10V and +10V. Thus, when setting the rotating number as voltage +10V, it represents
the rotating number in forward direction. When setting voltage -10V, it represents the rotating
number in reverse direction. Analog input voltage and motor rotating number are in linear relation.
Users could infer the rotating direction and number from the setting of P1-66 and the value of
input voltage. For example, if E-gear ratio is 1 and P1-66 is set to 100, when the input voltage is
+10V, the motor will rotate 100 cycles in forward direction. When the input voltage is +3V, motor
will rotate 30 cycles in forward direction. On the other hand, when the input voltage is -7V, motor
will rotate 70 cycles in reverse direction. Please note that the maximum rotating number is 200.
Step 4: Select the initial position setting method
P1-64.Y can be set to judge the motor’s position when servo on. When P1-64.Y = 0, motor’s
position when servo on will be regarded as the position of 0V. If the instant input voltage is not 0V,
motor will operate to the position that corresponds to the current input voltage. That is to say, if
the input voltage is not 0 when servo on, motor runs. See figure 4.3.3, the input voltage is +5V, it
will servo off after motor rotates 50 cycles. Then, adjust the input voltage to +7V. Since the 50th
cycle will be regarded as the position corresponded to 0V when servo on, motor will operate
another 70 cycles.
Figure 4.3.3 Regard the servo-off position as the original point
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Chapter 4 Application Techniques
ASDA Series Application Note
When P1-64.Y = 1, servo drive will regard the motor’s current position as the position
corresponded to analog command. Thus, motor will not operate when servo on. See figure 4.3.4,
the input voltage is +5V, motor operates 50 cycles then servo off. Adjust the input voltage to +7V,
then, the 50th cycle where motor currently stops will be regarded as the position corresponded to
+7V when servo on. That is why motor does not run.
Position
Command
1
0
50
0V
5V
Servo off the drive when it is
5 V. Adjust the command to
7 V and servo on again.
Command 2
0V
7V
When servo on, the servo drive would regard
the motor current position as the position
corresponded by current voltage command.
Figure 4.3.4 Voltage command corresponds to the current position when Servo ON
Step 5: Setup the operation method of analog input command
DI: 0x0C sets the latch function of analog position command. When this DI is on, motor will be
held at current position. During the time when DI is on, motor will not operate even when the
analog command is changed. When this DI is off, the motor will complete the command during
the time the DI is triggered. See figure 4.3.5, the input voltage is +5V, motor operates 50 cycles.
Then DI is on. During the time of DI on, adjust the input voltage to +7V. When DI is off, motor will
operate 20 cycles to the position of 70th cycle.
Figure 4.3.5 DI for position latch
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March, 2015
ASDA Series Application Note
Chapter 4 Application Techniques
DI: 0x0D sets the clear function of analog position command. When this DI is on, motor will be
held at current position. Despite the change of analog command during the time of DI on, the
motor will stay in current position even when this DI is off. However, the position where motor
stays will be corresponded to the new analog command. Thus, the coordinate system of motor
which corresponds to analog command will be redefined. See figure 4.3.6. When the input
voltage is +5V, turn on this DI after the motor operates 50 cycles. Adjust the input voltage to
+70V when DI is on. Motor will not operate when DI is off.
Figure 4.3.6 DI for position clear
Step 6: Enable the function of transferring analog to PT
Set P1-64.X to 1 to enable this function. Then, users can use analog voltage command to control
PT position.
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Chapter 4 Application Techniques
4.4
4.4.1
ASDA Series Application Note
Speed Change during Execution of PR Position Command
Description
For the application of point-to-point operation, PR function in ASDA-A2 is a great tool for easy
setting and wiring. Also, the host controller is not required during operation and thus can greatly
enhance the efficiency and reduce the cost. Since motion is completed by triggering a series of
PR during operation, PR setting has to be completed in advance. To change the speed during
operation, please set up the PR for it beforehand. If not, use controller to issue the command to
change the required speed.
4.4.2 How does System Work?
During the operation between two points, when issuing the command of speed change, the
motor will operate with the new speed immediately. However, the next reverse command will be
executed until the current position command is complete. See figure 4.4.2.
Speed
curve
Position
curve
Figure 4.4.1 Point-to-point operation
Figure 4.4.2 Change the speed in half way in point-to-point operation
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March, 2015
ASDA Series Application Note
4.4.3
4.4.3.1
Chapter 4 Application Techniques
Servo System Setting
Tips for Applying PR
1) Change PR definition via parameters
All PR definition and related information can refer to relative parameters. Change the setting of
corresponding parameters can modify PR definition. Please refer to Chapter 7 of ASDA-A2 user
manual for further information about PR.
Here, we use PR#1 and PR#3 to setup the definition of PR#13 and the target jump path defined
by PR# 13 respectively.
2) Shared PR Setting
In PR mode, ASDA-A2 provides 16 sets of acceleration/deceleration, 16 sets of delay time and
16 sets of target speed for setting up PR program. If more than one PR share one target speed,
when the value of this target speed is changed, all PR settings that shared this target speed will
be modified. Speed setting for all position commands here is set as the third speed command
(P5-63). As long as the value of the thrid speed is changed (which means to write the desired
changed speed to P5-63), speed from all motion command is changed.
3) Selection of position commands
When the previous position command is interrupted by the incremental command which has zero
moving distance, motor will run to the target position (0 + destination set by previous position
command) set by previous command. That is how users can change motor’s speed during
operation. When entering the changed speed, trigger the position command to interrupt the
previous command, then, new position command will be operated with the chagned speed. Thus,
motor will immediately change its speed to the target position which defined by previous
command.
4.4.3.2
PR Program Setting
PR#1: Write-in parameter. If the speed changed when it is executing the position command
(PR#4) at reverse direction, the next position command will be executed at forward direction
(PR#2).
PR#2: Position command. Execute the position command at forward direction. This PR has no
interrupt. Thus, another motion command will be executed after this command is complete.
PR#3: Write-in parameter. If the speed changed when it is executing the position command
(PR#2) at forward direction, the next position command will be executed at reverse direction
(PR#4).
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Chapter 4 Application Techniques
ASDA Series Application Note
PR#4: Position command. Execute the position command at reverse direction. This PR has no
interrupt. Thus, another motion command will be executed after this command is complete.
PR#5: Jump command. To keep the motor operating at forward and reverse direciton.
PR#11: Write-in command. Write the desired changed speed to this PR via the host controller
(write in P6-23). This PR will enter the value to P5-63 (internal speed#3). Since all speed
command is determined by P5-63, once the value is changed, all speed will be changed.
PR#12: Enter the desired changed speed. The operating speed shall be promptly changed.
This PR is the position command. It interrupts currently executing motion command. The
previous unfinisihed command will be compelte by the changed speed.
PR#13: Jump command. Jump to the next position command. Its target is determined by PR#1
or PR#3.
PR#51: Jump command. Trigger this PR when activating the system. Jump to PR#1 to enable
position command in point-to-point operation.
PR#52: Jump command. Write the desired speed to P6-23 via the host controller. Then, trigger
this PR to jump to PR#11 so as to change the motor speed.
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Chapter 4 Application Techniques
Enable position command
PR Jump
#51 DELAY = 0
(I) PR#1
EV1
PR#1
Trigger this PR when
changing the speed
PR
#52
(I)
EV2
Jump
DELAY = 0
PR#11
PR#11
The next position
command (PR#13) after
complete the setting of
speed change
Position command
Execute position
command
PR
#1
(I)
Write
DELAY = 0
P6-27 = 2
PR
#2
The next position
command (PR#13) after
complete the setting of
speed change
Position
D = 0, S = 200 rpm
150000 PUU, INC
PR
#3
(I)
Write
DELAY = 0
P6-27 = 4
PR#4
Jump to PR#1 so that the
system can keeps operating
Position command
Position
PR D = 0, S = 200 rpm
#4 -150000 PUU, INC
Write the required speed to
PR#11 (P6-23) via the
controller. Then, this PR would
immediately change the speed
of position command.
Operation
PR Write
when
#11 DELAY = 0
changing
(I) P5-63 = 800
the speed
PR
#5
(I)
Jump
DELAY = 0
PR#1
Complete the
unfinished position
command after the
speed is changed
PR Position
#12 D = 0, S = P5-63
(I) 0 PUU, INC
PR#1
Jump to next position command
PR
#13
(I)
Jump
DELAY = 0
PR#4
PR#4
Figure 4.4.3 PR program
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Chapter 4 Application Techniques
4.5
4.5.1
ASDA Series Application Note
Macro for E-Cam Application
Macro C
With this macro, the current pulse number of the master axis and position of the slave axis can
be redefined without changing motor’s position.
Macro C allows the system to change the engaging position promptly
and calculate the remaining pulses. Then, E-Cam can complete the
operation according to the E-Cam curve after engaging.
The specified
engaging
position
Slave
axis
E-Cam
position
The remaining
pulses within one
cycle
Command
position
Master
axis
Figure 4.5.1 Macro C
The following macros are available from version V1.035 sub00 (included):
Command code
000Ch
Change position X, where E-Cam is engaged: E-Cam disengages after
rotating one cycle at forward direction.
General parameters
N/A
Macro parameters
P5-93 = New engaged position X. Unit: pulse number of master axis.
Monitoring variable 062(3Eh): It displays the current engaged position
(X) of master axis.
This macro command can change the engaged position even when E-Cam is engaged. It will
automatically calculate the residual engaged length. E-Cam will disengage after rotating one
cycle at forward direction. Users have to set P5-88.U to 2, 4, 6; otherwise, the E-cam will not
disengage.
E-Cam will disengage when alarm occurs or the power supply is cut off. If users desire E-Cam to
re-engage at the last disengaged position and continue its operation, it is recommended to
record the disengaged position (X) and resume the operation by this macro command. Please
note that when E-Cam is disengaged, the servo position might slightly shift and therefore cause
position error when E-Cam re-engages again.
The Engaged direction is in forward direction (Master axis operates at forward direction):
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Note: When using this macro command, it would be better to execute this command before
operating the master axis.
Failure code F0C1h
When executing this macro command, E-Cam is not in engaged status.
The engaged position can be modified only when E-Cam is engaged.
Failure code F0C2h
The setting value of P5-93 is in error. The value cannot less than 0. It
should > = 0.
Failure code F0C3h
The setting value of P5-93 is in error. The value has to less than the
value of (P5-84 / P5-83)
4.5.2
Macro D
When E-Cam position and command position is not on the E-Cam curve, this macro allows the
system to figure out the command position of the master axis and current correction value of
motor’s position. Then the correction value will be written to the PR to conduct incremental
positioning. The motor can thus move back to the position corresponded by the command of the
master axis. This macro command only can be applicable to periodic cycle and when every cycle
starts from the same position.
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Slave
One
Cycle
E-Cam
Position P
R
P
R
Command
position
ECAM_H
in P2- 52
Master
PR Position command is incremental
E-Cam operates to the target
P
position in reverse direction
R
P
E-Cam operates to the target
R
position in forward direction
Figure 4.5.2 Macro D
The following macros are available from version V1.038 sub48 (included):
Command code
000Dh
Calculate the error between E-Cam and indexing coordinates for PR
positioning.
General Parameters
N/A
Macro Parameters
P5-93.Low_Word = DCBA: UZYX (8 digits, HEX)
YX (PR number) = 0 ~ 0x3F (it is invalid when the value is set to 0)
UZ: The value has to be set to 0.
BA (Function of P5-95):
0 (Use avoid point);
1 (Use available forward rate, V1.038 sub53)
DC (Inhibit reverse rotation):
0 (invalid),
1(Inhibit reverse rotation, V1.038 sub53)
P5-95: Avoid point (cannot pass this point) = 0 ~ 100 (%) of E-Cam cycle
or available forward rate 0 ~ 100 (%)
Monitoring variable 091 (5Bh): It displays the current indexing coordinate position (PUU)
When E-Cam is engaged, and the motor is stopped because of Servo Off or alarm occurs, it would
cause position error between the actual position and E-Cam position. After re-servo On, this macro
command can be used to calculate the correction value and write the value into the specified PR
for incremental positioning. So that the motor can return to the ideal E-Cam position.
When using this macro command:
1. P5-88.X1 = 1 to make E-Cam keep engaging when servo Off and continue to calculate E-Cam
position.
2. The height of indexing coordinate and E-Cam coordinate should be the same:
P2-52 = ECAM_H (The moving distance when E-cam operates one cycle)
3. E-Cam table scaling (P5-19) must be 1.0 time
4. When E-Cam is engaged for the first time, 0 degree of E-cam should aim at 0 degree of indexing
coordinate.
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Note 1: ECAM_H (height of E-Cam table) = E-Cam table (last point - first points)
Note 2: Indexing coordinate = (absolute coordinates/P2-52) take remainder.
Note 3: Use PR command for incremental positioning control.
When motor moves from the current position to the target position, it can operate at forward or
reverse direction. Due to the cyclic operation, the motor will travel to the specified position either at
forward or reverse direction. However, the moving distance is different between both. Use avoid
point to plan the timing of forward and reverse rotation.
*Avoid point: the point that cannot be passed by the planned PR.
E-Cam current position
E-Cam current position
E-Cam avoid point Θ, which is set by P5-95
0°
Θ = 360° x P5-95%
Cannot pass
Θ
Actual traveling distance
Failure code F0D1h
E-Cam is not engaged when executing this macro command. E-Cam
should be engaged.
Failure code F0D2h
The value of P5-93.YX (PR number) exceeds the range: 1 ~ 0x3F
Failure code F0D3h
The value of P5-95 (available forward rate) exceeds the range: 0 ~ 100 (%)
Failure code F0D5h
The position correction value does not exist. This macro command might
be triggered twice.
Failure code F0D6h
When re-servo On, E-cam is not engaged.
Failure code F0D7h
The height (Y axis) of E-Cam table is not equal to the value of P2-52.
Failure code F0D8h
P5-19 is not equal to 1
Failure code F0D9h
P5-93.BA, P5-95 exceeds the range: 0 ~ 1
Failure code F0DAh
The setting value of P5-93.DC (reverse inhibit) exceeds the range: 0 ~ 1
Failure code F0DBh
The function of reverse inhibit has failed. Do not use macro command #D,
#10h consecutively.
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4.5.3
ASDA Series Application Note
Macro E
This macro performs E-Cam alignment and writes the correction value into the specified PR.
Please complete relevant settings such as target position and other PRs in advance. When
macro E is triggered, the system will figure out the correction value and write it to the specified
PR. This PR can be triggered to make the slave axis move to the target position.
Slave
Cam
Position
P
R
P
R
Master
The target position of E-Cam when
macro C is triggered
Figure 4.5.3 Macro E
The following macros are provided after version V1.038 sub26 (included):
Command code 000Eh
Perform E-Cam alignment immediately and write the correction
value into the specified PR.
Macro parameters
P5-93 = DCBA:UZYX (8 digits, HEX)
YX (PR number) = 0 ~ 0x3F, it is invalid when the value is set to
0.
UZ (Max. alignment correction rate) = 0 ~ 0x64 (%)
A (Trigger the specified PR directly) = 1: On, 0: Off
DCB = has to be set to 0
P5-94 (DI delay time compensation) = -25000 ~ +25000; Unit:
usec.
P5-95 (available forward rate) = 0 ~ 100 (%)
P5-96 (target position of alignment X); Unit: pulse number of
master axis = 0 ~ (P5-84/P5-83) – 1.
Monitoring variable 062 (3Eh): It displays the current engaged position of master axis (X)
This macro command can move the engaged position to the alignment target position (X) when
E-Cam is engaged. And write the alignment correction value into the specified PR.
During E-Cam operation (When E-Cam is engaged), if desire to quickly align the E-cam position
to the mechanical referral point, sensor can be used to trigger DI.EVx to execute this macro
command.
After E-Cam alignment is completed, the engaged position will move to the new position. The
excess or not enough moving distance after E-Cam operates one cycle is called alignment
correction value. It will be written into PR specified by P5-93.YX. PR incremental command can
be used to compensate this value so that the slave axis position will remain and offset the phase
of E-Cam to align the referral position of machine. For some applications, set value of P5-93.YX
to 0 will do without applying this PR. Please note that PR can be executed only when triggering
the host controller.
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Pulse number of master axis after
rotating a cycle: (P5-84/P5-83) = L
Slave axis
position (Y)
Alignment
correction value
= Y_Diff
Current
engaged
position
Master axis position (X)
Alignment target
position P5-96
*P5-93.UZ is able to limit the max. correction rate. The alignment target position ★ will be
different from P5-96.
| aignment target position★ – current engaged position| / L <= P5-93.UZ %
*DI time delay compensation can be set via P5-94, it can correct the error caused by different
operation speed.
When E-Cam moves from current position to the target one, it can rotate at forward or reverse
direction. Due to the cyclic operation, it can reach the target position either at forward or reverse
direction. However, the moving distance between both is usually different. Use available forward
rate to plan the timing of forward and reverse rotation.
*Available forward rate: The available max. proportion of forward path
Failure code F0E1h
When executing this macro, E-Cam is not engaged. E-Cam has to
engage to execute alignment correction.
Failure code F0E2h
The setting value of P5-93.YX (PR number) exceeds the range: 0 ~ 0x3F
Failure code F0E3h
The setting value of P5-93.UZ (Max. alignment correction rate) exceeds
the range: 0 ~ 0x64 (%)
Failure code F0E4h
The setting value of P5-94 (DI delay time compensation) exceeds the
range: -10000 ~ +10000
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Failure code F0E5h
The setting value of P5-95 (Available forward rate) exceeds the range: 0
~ 100 (%)
Failure code F0E6h
The setting value of P5-96 (alignment target position) exceeds the range:
0 ~ (P5-84/P5-83) - 1
4.5.4
Macro F
When the master axis is stopped but E-Cam is still engaged, this macro allows the slave axis to
move to the given position and return. Users have to complete all relevant parameter setting
beforehand. When macro F is triggered, the data for moving the slave axis will be written to the
PR of going and return trip. When PR is triggered during going trip, the slave axis will move to the
target position. While PR is triggered during return trip, the slave axis will return to the original
position. That is, to move the slave axis while the system is stopped, this macro can be applied.
Slave
E-Cam
position
Macro F will calculate the deviation
between target and current position and
write this value to the set PR data. Both
going and return trip has to be set.
Triggering these two PRs can temporarily
move the slave axis.
PR
PR
Master
No pulse input, pulse
number of master axis
remains the same
Figure 4.5.4 Macro F
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The following macros are available from version V1.038 sub26 (included):
Command Core 000Fh
Calculate the moving distance between current and target
position for PR positioning.
N/A
General Parameters
Macro parameters
P5-93.Low_Word = UZTX(4 digits, HEX)
YX (PR number of going trip) = 0 ~ 0X3F, it is invalid if the
value is set to 0.
UZ (PR number of return trip) = 0 ~ 0X3F, it is invalid if the
value is set to 0.
P5-93.Hi_Word = it has to be set to 0.
P5-95 (Available forward rate)= 0 ~ 100 (%)
P5-96 (target position X); Unit: pulse number of master axis
=0 ~ (P5-84/P5-83) -1.
Monitor variable 062 (3Eh): It displays the current engaged position (X) of master axis.
This macro command calculates the moving distance between current and target engaged
position (X) and writes into the specified PR.
During E-Cam operation, if users desire to move the slave axis to the specified position when
master axis stops and still in engaged status, this macro command can calculate the correct
moving distance (Y_Drift) of going trip for PR positioning.
When master axis resumes the operation, use another PR to run the moving distance of return
trip (-Y_Drift), it returns to the original position (moving distance of going trip + moving distance
of return trip = 0.) E-Cam position remains the same.
Pulse number of master axis after
rotating a cycle: (P5-84/P5-83) = L
Slave axis
position (Y)
Alignment
correction value
= Y_Diff
Current
engaged
position
Master axis position (X)
Alignment target
position P5-96
Note: No matter it is going trip or return trip, use incremental command when using PR.
When E-Cam moves from current position to the target one, it can rotate at forward or reverse
direction. Due to the cyclic operation, it can reach the target position either at forward or reverse
direction. However, the moving distance between both is usually different. Use available forward
rate to plan the timing of forward and reverse rotation.
*Available forward rate: The available max. proportion of forward path
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Failure Code F0F1h
Failure Code F0F2h
Failure Code F0F3h
Failure Code F0F5h
Failure Code F0F6h
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When executing this macro, E-Cam is not engaged. E-Cam has to
engage to change the engaged position.
The setting value of P5-93.YX (PR number of going trip) exceeds the
range: 0 ~ 0x3F
The setting value of P5-93.UZ (PR number of return trip) exceeds the
range: 0 ~ 0x3F
The setting value of P5-95 (Available forward rate) exceeds the range:
0 ~ 100 (%)
The setting value of P5-96 (alignment target position) exceeds the
range: 0 ~ (P5-84/P5-83) - 1
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4.5.5
Chapter 4 Application Techniques
Macro 10
After Macro 10 is triggered, the slave axis will stop operating. Then, it will start operating again
after stopping for one cycle. In the application of packaging machine, using this macro can skip
the empty pack.
Slave
One cycle
One cycle
E-Cam
position
Stop
operating
Start
operating
Master
Figure 4.5.5 Macro 10
The following macros are available from version V1.042 sub09 (included):
Command code 0010h
General parameters
Macro parameters
E-Cam stops for one cycle and resumes its operation at next cycle.
N/A
Value of P5-93 has to be set to 0.
After E-Cam is engaged, this macro command can stop the slave axis for a cycle of distance
regardless the E-Cam degree.
The following conditions have to be fulfilled when using this macro command.
1. E-Cam must be in engaged status.
2. E-Cam must be the forward operation curve (including straight line) so it can temporally stop
for a cycle.
Refer to the figure below, triggering this macro command, E-Cam will stop for one cycle
regardless the degree (X) where E-Cam is.
Note 1: ECAM_H (E-Cam pause distance) = table (last point – first point) x P5-19 (the effective
scaling)
Note 2: This function can accumulate times. If the command is triggered for N times
consecutively, E-Cam will stop for N cycles. The accumulated pause distance cannot
exceed (>2^31), or the macro command will be disabled.
Note 3: When E-Cam resumes the operation, the accumulated pause distance will be cleared to
0.
Failure code F101h When executing this macro command, E-Cam is not engaged.
Failure code F102h The setting value of P5-93 is incorrect: It has to be set to 0.
E-Cam has to operate at forward direction. Please check the E-Cam table
Failure code F103h and make sure P5-19 > 0.
The accumulated pause distance exceeds 2^31. Do not execute this
Failure code F104h macro command consecutively.
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