Electro Cam Plus PS-6144 Series, Programming & Installation Manual

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1-1 Introduction
Mechanical Cam Switches
Mechanical Cams The PS-6144 Programmable Limit Switch electronically simulates mechanical cam
switches. A cam switch consists of a roller limit switch whose arm rides on a cam as
shown in Figure 1. The cam shaft is driven by a machine at a 1:1 ratio, so that the cam
switch turns on and off at specific positions in the machine cycle. Cam limit switches
have the following disadvantages:
• The roller, the cam, and the limit switch wear out.
• The machine must be stopped during adjustment.
• On/off patterns are limited, and changing the pattern may require replacement of one
cam with another. For example, a cam that switches on and off twice in one revolution
would need to be replaced with a different cam if three on/off pulses per revolution
were required.
• They cannot run at high speeds because of contact bounce and excessive mechanical
wear.
Figure 1—Basic Cam Switch
Programmable Limit Switches
PS-6144ʼs & Resolvers The PS-6144 Programmable Limit Switch uses a resolver (see Figure 2 on page 2)
instead of a cam to indicate machine position. A resolver uses fixed and rotating coils
of wire to generate an electronic signal that represents shaft position. The resolver is
usually coupled to a machine shaft at a 1:1 ratio so that one resolver shaft rotation cor-
responds to one machine cycle. Resolvers have no brushes, contacts, or any frictional
moving parts to wear out.
Based on the resolver signal, the PS-6144 Programmable Limit Switch turns electrical
circuits, or “Outputs,” on and off, simulating the mechanical roller limit switch. Because
the combination PS-6144/resolver system is completely electronic and has no frictional
parts, it offers several advantages over mechanical cam switches:
• Long service life with no parts to wear out.
• “On” and “off” points can be adjusted instantly from the keypad; there are no cams to
rotate or replace.
• Adjustment is possible with the machine running or stopped.
• Programmable logic allows complex switching functions that are impossible with
mechanical cams.
• Operation at speeds up to 3000 RPM.