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Theory of Operation

P/N  400274-01  Revision A7

19

Maximum Master Velocity

For every set of Master and Follower cycle parameters, the user must

limit the maximum velocity of the Master so that the maximum velocity

of the Follower is not exceeded. This is critical for product lengths

shorter than the Follower Cycle Length.

(

)

Maximum Master Velocity 

MAV

FVS  /  MVS * 2  -  WR

=

Where:

MAV

 = Maximum Allowable Velocity of the Follower from the Limits

screen.

WR

 = Working Ratio.

FVS

 = Follower Variable Segment =

Follower Cycle Length - Working Segment.

MVS

 = Master Variable Segment =

Master Cycle Length - (Working Segment / Working Ratio).

Note:

The above equation reflects ideal conditions and the user must
reduce the calculated Maximum Master Velocity due to the
effects of inertia, friction, encoder slippage, sensor, mechanical
issues to allow enough velocity headroom for any motion
corrections. Usually, this velocity reduction needs to be
approximately 20 percent.

V

Peak

V

Working Ratio

Velocity

Time

T

Peak

T

Working Segment End

V

Peak

 - 

V

Working Ratio

T

Peak

 - 

T

Working Segment End

Follower Acceleration =

VARIABLE
SEGMENT

WORKING
SEGMENT

WORKING
SEGMENT

0

Figure 12

Variable Segment Acceleration

At the Maximum Master Velocity, V

Peak

 = MAV.

WARNING!

When sizing a system, keep in mind the velocity and acceleration of
the Follower during the variable segment for the shortest product
length because the Follower acceleration and deceleration rates are
not controlled by PCX Limits.

Summary of Contents for PCM-22

Page 1: ...he right to change the design or operation of the equipment described herein and any associated motion products without notice EMERSON Motion Control also assumes no responsibility for any errors that may appear in this document Information in this document is the property of EMERSON Motion Control and is subject to change without notice P N 400274 01 Rev A2 Date December 7 1998 1998 EMERSON Motio...

Page 2: ...ntrol is a registered trademark of EMERSON ELECTRIC Printed in U S A December 1998 Revision A2 This document has been prepared to conform to the current release version of the PCM 22 Rotary Knife Controller Because of our extensive developments and our desire to further improve and enhance the product inconsistencies may exist between the product and documentation in some instances Call your custo...

Page 3: ...ort 612 474 8833 E Mail service emersonemc com EMERSON Motion Control s products are backed by a team of professionals who will service your installation wherever it may be Our customer service center in Minneapolis Minnesota is ready to help you solve those occasional problems over the telephone Our customer service center is available 24 hours a day for emergency service to help speed any proble...

Page 4: ...manual s 2 The model and serial number s of your PCM s 3 The result using Terminal Mode of ID 0ID zero ID if axis ID s are used 4 The result using Terminal Mode of ID1 0ID1 zero ID1 if axis ID s are used 5 A description of the symptom s or issue s observed including any fault status codes displayed on the LED Diagnostic Display 6 Copies of the current uploaded program s that are in each of your PC...

Page 5: ...2 Master Cycle Not Defined By Sensor Mode 12 Resetting the Master Cycle Processing 13 How the Master Cycle is Defined 13 Automatically Resetting the Master Processing 13 Manually Resetting the Master Processing 14 Starting A Follower Cycle 15 Homes and the Follower Zero Position 16 Indexes and the Follower Zero Position 16 Cycle Inter Relationships 17 Operational Timing 18 Maximum Master Velocity ...

Page 6: ... Correction Deadband 48 Length Change Increment 48 Master Cycle Number 48 Batch Count 48 Cycle Count 49 Working Segment Width 49 Offset Phase Fine Increment 51 Offset Phase Coarse Increment 51 Input Functions 52 Description of Input Functions 53 Typical Input Assignments 57 Output Functions 58 Description Of Output Functions 58 Recommended Output Assignments 62 Programming 63 Additional programmin...

Page 7: ... Units 92 FM9 Master Length Variation In Sync Counts 92 FM10 Follower Length Variation In Resolver Counts 93 FM11 Master Axis Velocity 93 FM12 Average Master Length In User Units 93 FM13 Average Follower Length In User Units 93 FM14 Computed Starting Master Distance In Master Steps 93 FN1 Follower Cycles Per Follower Sensor 94 KC4 Total Cycle Count 94 MF Master Cycle Flags 94 ML11 Current Master L...

Page 8: ......

Page 9: ...ground information needed to setup and configure the PCM 22 FX amplifier combination using PCX 7 x software Description The PCM 22 Rotary Knife Controller is an application module that attaches to any EMERSON Motion Control FX positioning servo drive The PCM 22 enables a FX drive to automatically calculate and create motion profiles using sensor information and or user defined parameters The PCM 2...

Page 10: ...ion sensor the PCM 22 can automatically adjust parameters based on sensor information about that axis It will within user defined limits automatically compensate for length changes and detected mechanical inaccuracies For example If the distance between registration sensor inputs on the Follower axis indicate that the length is 8 25 inches and not 8 30 inches as entered using PCX The PCM 22 will a...

Page 11: ... can be changed automatically without stopping Two internal counters for each cycle product cycle counter and product batch counter 100 programs with a maximum of 512 steps total for all programs 16 Master axis and 16 Follower axis motion profile definitions 98 user assignable I O functions 64 indexes 2 homes Expands I O line capacity of FX drive with an additional eight optically isolated input l...

Page 12: ...e input required for all Master cycles following When the Master axis has moved the user entered Master Cycle Length it has moved the distance between two Master zero positions WORKING SEGMENT RO TAT I O N MASTER PHASE DISTANCE CIRCUMFERENCE OF ROTARY KNIFE EQUALS FOLLOWER LENGTH ZERO FOLLOWER SENSOR WORKING OFFSET ZERO MASTER SENSOR PRODUCT MOVEMENT MASTER LENGTH PHASE CYCLE POINT Figure 2 Typica...

Page 13: ...ally when the Follower is in contact with the product The Follower moves at the Working Ratio velocity relative to the Master velocity during this distance See Figures 4 5 and Cycle Inter Relationships Maximum Product Velocity and Variable Segment Note The Master Length also has a Working Segment It is not directly user adjustable it is computed from the Follower Cycles Working Segment divided by ...

Page 14: ...F WORKING SEGMENT G CYCLE DROPOUT POSITION G C D A F E DIRECTION OF FOLLOWER ROTATION Figure 5 Circular View of Follower Terminology Relationships Variable Segment This is a computed parameter It is the Follower Cycle Length minus the Working Segment This is where all cycle adjustments occur See Figures 4 5 6 and Cycle Inter Relationships WARNING When designing a PCM 22 system the peak acceleratio...

Page 15: ...y during the Working Segment For example If the Follower is to move the same speed as the Master during the Working Segment then the Working Ratio would be 1 00000 This is common in many applications If the Follower is to move 5 percent faster than the Master velocity during the Working Segment then the Working Ratio would be 1 05000 The range is from 0 to 9 99999 FOLLOWER LENGTH ONE TO ONE RELATI...

Page 16: ...e 7 Phase Relationship Between Master and Follower Cycle Lengths The PCM 22 maintains the phase relationship by automatically making adjustments based on sensor inputs and applying user defined parameters Figures 3 4 and 6 show a phase relationship of zero Average Length The PCM 22 uses continuous averaging when an axis is defined by sensor Continuous averaging provides increased stability by inco...

Page 17: ...least 24 cycles to completely adjust for the new length See Follower Length Correction Limit and Master Length Correction Limit Therefore the lower the average the faster length errors are corrected However too low a value adversely affect the drive s ability to quickly correct for phase errors by causing overcompensation and instability See Maximizing Profile Performance and Theory of Operation T...

Page 18: ...PCM 22 Rotary Knife Controller 10 EMERSON Motion Control ...

Page 19: ...llower axis motion profile will be made for product differences or encoder slippage If the Follower axis is not in phase synchronization with the Master axis the PCM 22 computes a correction which is applied in the next Follower cycle The Follower axis will speed up or slow down depending on what is required for the length or phase correction If both the Follower and the Master axes are in phase s...

Page 20: ...ed to see if it is between the Master Length Upper Limit and the Master Length Lower Limit This measured distance is factored into the Average Master Length starting from the user entered Master Cycle Length Any necessary corrections will be made to the next Follower axis motion profile See Average Length Master Cycles screen and Operational Timing FX AMPLIFIER WITH PCM 22 REGISTRATION MARKS FOLLO...

Page 21: ... is received the Master Cycle Length will be defined and the Master Cycle Defined output function will activate Master Cycle Not Defined By Sensor Mode When the first Zero Master Cycle input is received the product is at the initial Master zero position The Master Cycle Length will be defined at this point and the Master Cycle Defined output function will activate This will be the only Zero Master...

Page 22: ... Resetting the Master Processing Manually Resetting the Master Cycle Processing is particularly useful for troubleshooting product handling slippage or registration issues The PCM 22 provides two ways for resetting the Master processing manually by Writing the MF serial command Reset Master input function 115 These methods allow the user to reset the Master processing as the application requires T...

Page 23: ...ke the second product position it will check the third and so on until the PCM 22 finds a product position that will allow the Follower axis to reach the product s Working Ratio velocity at the beginning of its Working Segment The Follower axis is not moving while it is determining which product position to try for See Figure 9 and Master Phase Distance ZERO MASTER SENSOR MASTER PHASE DISTANCE ZER...

Page 24: ...se variations when the Follower is executing its first several cycles and learning its length the fastest It is not recommended but it is possible once the home is completed to move to a different location which will be the Follower zero position It is from this point that the Follower cycle will start If this is not the actual Follower zero position and the Follower cycle is defined by sensor the...

Page 25: ...ne half of the Working Segment This means that the follower sensor must not be inside the Working Segment The above Cycle Inter Relationship cross checks are performed against the following cycle parameters every time a cycle is started and every time one of these parameters is changed while the Follower is in cycle Working Segment Working Offset Follower Cycle Length Master Length Lower Limit If ...

Page 26: ...EGMENT WORKING SEGMENT ZERO MASTER POSITION MACHINE CYCLE WORKING RATIO VELOCITY CYCLE POINT CYCLE POINT Figure 11 PCM 22 Motion Profile In both cases all motion profile changes user requested changes learned length and or phase variations occurring before the Cycle Point will be applied when the PCM 22 calculates the next Working Segment location When the Follower reaches the end of the current W...

Page 27: ...e equation reflects ideal conditions and the user must reduce the calculated Maximum Master Velocity due to the effects of inertia friction encoder slippage sensor mechanical issues to allow enough velocity headroom for any motion corrections Usually this velocity reduction needs to be approximately 20 percent VPeak VWorking Ratio Velocity Time TPeak TWorking Segment End VPeak VWorking Ratio TPeak...

Page 28: ...This determines how consistently the sensor can be activated by the target For a target larger than the sensor moving at a constant velocity the sensor should be selected be selected so the following equation is true Response Time Width of target Velocity of target As the target becomes smaller approaching the size of the sensors detection field at a constant velocity the sensor should be selected...

Page 29: ...inimize the effects of product slippage and to allow the PCM 22 to correct for any phase variation on that product See Operational Timing Follower Sensor A Follower sensor must be used if the Follower Cycle Length is not an exact number of motor steps i e no fractions of steps If the Follower Length is not an exact number of steps the Follower can drift out of position due to rounding The precisio...

Page 30: ... R T of 1000 Hz 0 001 seconds The acceleration and response time effects on sensor accuracy are shown in the following table Working Segment Velocity W S V Follower Acceleration F A See Figure 12 Time Factor T F W S V F A Sensor Accuracy T F 1 W S V R T 10 in sec 0 in sec2 0 sec 0 010 in 10 in sec 10 in sec2 1 sec 0 020 in 10 in sec 20 in sec2 2 sec 0 030 in ...

Page 31: ...minals numbered 13 20 are inputs and the last four pairs of terminals numbered 21 24 are outputs The outputs are capable of sinking or sourcing 200 mA You must limit the output current to 200 mA per output or less I O Wiring Input Wiring Inputs require an external voltage source for operation This voltage source must be in the range of 10 5 to 30 VDC The negative lead of the external power supply ...

Page 32: ...EXAMPLE C SINKING OUTPUT WITH INDUCTIVE LOAD DIODE SUPPRESSOR PCM MODULE INPUTS OUTPUTS LOA D EXTERNAL POWER SUPPLY 10 5 to 30 VDC EXTERNAL POWER SUPPLY 10 5 to 30 VDC EXTERNAL POWER SUPPLY 10 5 to 30 VDC EXTERNAL POWER SUPPLY 10 5 to 30 VDC FX DRIVE WITH AN PCM APPLICATION MODULE 48 PIN CONNECTOR Figure 13 Installing the PCM Module WARNING Do not install or remove the PCM module when there is pow...

Page 33: ...e The Master Axis screen is where you identify the signal source of the Master axis and set up synchronization parameters The next step is to define the motion parameters in the Define Motion screen The first three menu selections Jog Homes and Indexes are explained in the Software Setup and Operation section of the 230V 460V FX Drives Setup and Programming Operator s Manual or 525 Programmable Mo...

Page 34: ...ster Axis Drive Setup Jog Homes Limits Input Functions Output Functions Indexes Master Cycles Follower Cycles Suspend Figure 14 PCX Hierarchy Diagram 1 Initialize Memory Operations Entire Memory Program Data Index Data Input Output Data Gain Setup Analog Setup Limit Setup Cycle Infeed Data Figure 15 PCX Hierarchy Diagram 2 ...

Page 35: ...when running Cycle Profiles Signal Source Encoder Count Per Revolution User Distance Per Revolution Signal Polarity Signal Interpretation Sync Output Signal from In addition to running Cycle Profiles the PCM 22 also has the ability to run synchronized Indexes and Homes This is what the remaining parameters on this screen are used for The Master Axis screen is found by selecting Drive Setup Drive C...

Page 36: ... and the Follower Zero Position and Homes and the Follower Zero Position The Homes and Indexes screens are found by selecting Drive Setup then Define Motion from the PCX menu 7 Cycle Profile Programs Create a program using the Y Execute Cycle Profile programming function The program typically contains motion statements before and after the Y Execute Follower Cycle statement ...

Page 37: ...ofiles the PCM 22 also has the ability to run synchronized Homes Indexes and Jogs The remaining parameters on this screen are listed below and used for these synchronized operations Master Maximum Velocity Sync Velocity User Units Sync Velocity Scaling External Mode Override Encoder selection should be based on the accuracy desired for the application For example If your encoder delivers 12 000 co...

Page 38: ...PCM 22 Rotary Knife Controller 30 EMERSON Motion Control WARNING The maximum Master axis frequency into the PCM 22 module must not exceed 210 kHz 210 000 steps second ...

Page 39: ...axis positional information When Drive is selected the Follower axis PCM 22 is receiving its synchronization source from a FX DX upstream drive the Counts Per Revolution becomes 4096 counts per revolution If you select Drive for your signal source the Encoder Counts Per Revolution parameter will not appear shown below Figure 16 Master Axis Screen for an Upstream Drive If your Master axis is an Enc...

Page 40: ...PCM 22 Rotary Knife Controller 32 EMERSON Motion Control Figure 17 Master Axis Screen for an Encoder ...

Page 41: ...tion Controller Installation and Operation manual as appropriate The minimum value is 1 and maximum value is 65 535 Signal Polarity This feature defines the direction of the synchronization source that corresponds to a positive Master axis position change Clockwise is indicated with a counterclockwise is indicated with a CW and CCW motion of the Master axis is defined while facing the encoder shaf...

Page 42: ...or example the Master stops then inadvertently backs up due to conveyer slack etc Mode 5 COMP The Follower axis will only react to synchronization pulses when the Master axis runs in the CCW direction The drive counts the pulses received in the CW direction and ignores that exact number of CCW pulses before Follower motion in the CCW direction occurs This feature compensates for Master axis motion...

Page 43: ...CM Drive The Signal Source of the next FX drive and PCM 22 in the synchronization chain must be set to Drive in order to operate with this signal Encoder pulses are passed to all amplifiers in the synchronization signal chain How you answer this question has no effect on the integrity of the encoder signal External Mode Override External mode override works in conjunction with input function 38 to...

Page 44: ...s immediate velocity without ramping in your FX drive If the Master axis accelerates very quickly your FX drive Follower axis will try to follow just as quickly Too fast an acceleration by the Master axis could result in F Following Error faults for the Follower axis Bipolar Sync Ratio Motor This parameter is the relationship of the Follower axis position to the Master axis position For example If...

Page 45: ...om the PCX menu Note The Master Cycle must be defined before a Follower Cycle may start See Resetting the Master Cycle Processing for details on Master Cycle definition Master Cycle Number This parameter identifies the Master Cycle currently being defined Up to 16 different Master cycles can be defined 0 to 15 Any Master Cycle can be used with any Follower cycle Master Cycle Length The Master Cycl...

Page 46: ...gt th h i is s c co on ns si id de er re ed d i in nv va al li id d a an nd d i is s r re ep pl la ac ce ed d b by y t th he e M Ma as st te er r L Le en ng gt th h U Up pp pe er r L Li im mi it t v va al lu ue e w wh hi ic ch h w wi il ll l b be e a av ve er ra ag ge ed d T Th he e C Cy yc cl le e L Li im mi it t R Re ea ac ch he ed d o ou ut tp pu ut t f fu un nc ct ti io on n 4 41 1 i is s a ac...

Page 47: ...ed from the previous input indicates a length less than the Master Length Lower Limit the sensor input is considered invalid and is replaced by the Master Length Lower Limit value which will be averaged The Extra Master Sensor output function 47 and Cycle Limit Reached output function 41 is activated until a valid sensor input is received See Figure 20 Master Sensor Valid Zone and the CQ serial co...

Page 48: ...tively while in cycle Master Cycle Defined By Sensor This parameter determines if the product position is defined by a sensor input Yes or if not defined by a sensor No Master Cycle Defined By Sensor No If No is entered the Master Cycle Length entered using PCX will be executed The Zero Master Cycle input must be activated once to define the Master zero position Once the Master zero position has b...

Page 49: ... input signal which occurs 10 mm before or after the expected Zero Master Cycle sensor input will be ignored Master Length Correction Limit The Master Length Correction Limit is used to reduce the amount of Master Length Variation corrected during each Master cycle When an input is received from the Zero Master Cycle sensor input and a difference is found to exist between the Current Average Maste...

Page 50: ...m example above shows a flat product such as paper or plastic that moves through a set of pinch rollers which feeds back Master axis positional information to the PCM 22 using an encoder The Master registration sensor allows the PCM 22 to reference the registration marks on the product in relation to the Cycle Point Similarly the Follower sensor provides reference information for the Follower axis...

Page 51: ...le of motion Follower Length Correction Limit This parameter only applies if the Follower cycle is defined by sensor The Follower Length Correction Limit is used to reduce the amount of Follower Length Variation corrected during each Follower cycle When an input is received from the Zero Follower Cycle sensor input and a difference is found to exist between the current average Follower length and ...

Page 52: ...s s 3 3 W Wh he en n t th he e F Fo ol ll lo ow we er r c cy yc cl le e i is s D De ef fi in ne ed d B By y a a R Re eg gi is st tr ra at ti io on n S Se en ns so or r i if f t th he e d di is st ta an nc ce e t tr ra av ve el le ed d s si in nc ce e t th he e l la as st t Z Ze er ro o F Fo ol ll lo ow we er r C Cy yc cl le e s se en ns so or r i in np pu ut t e ex xc ce ee ed ds s t th he e F Fo ...

Page 53: ...er r c cy yc cl le e i is s D De ef fi in ne ed d B By y a a R Re eg gi is st tr ra at ti io on n S Se en ns so or r i if f t th he e d di is st ta an nc ce e t tr ra av ve el le ed d s si in nc ce e t th he e l la as st t Z Ze er ro o F Fo ol ll lo ow we er r C Cy yc cl le e s se en ns so or r i in np pu ut t i is s l le es ss s t th ha an n t th he e F Fo ol ll lo ow we er r L Le en ng gt th h L...

Page 54: ...t a Zero Follower Cycle sensor input signal is considered valid This is useful in applications where the follower sensor may detect something other than the target on the Follower axis such as another portion of the machine The amplifier will ignore all inputs except those which appear within the Follower Sensor Valid Zone See Figure 24 and the CQ serial command Note The Follower Sensor Valid Zone...

Page 55: ...ing Master or Follower cycle The Phase Correction Limit is used to limit the rate at which phase variations are corrected for in the next cycle and allow for smoother operation It is similar to a gain and is used to slow the rate of correction for Follower phase variations and allow smoother operation Small amounts of Follower phase variation are normal Phase Variation Measured Length Average Leng...

Page 56: ...ly are toggled The Length Change Increment is also the value used when Working Segment Increase or Working Segment Decrease input functions 70 and 71 respectively are toggled This parameter is only valid when the Follower cycle is not defined by a registration sensor Master Cycle Number Designates which Master Cycle this Follower Cycle will be associated with Each Follower Cycle requires a Master ...

Page 57: ...83 648 See the FF and KC4 serial commands Working Segment Width This is also called the Working Segment This parameter is the distance that the Follower moves at the Working Ratio The position of this segment is centered around the Cycle Point which is determined by the Working Offset See Figure 27 WORKING SEGMENT RO TAT I O N MASTER PHASE DISTANCE CIRCUMFERENCE OF ROTARY KNIFE EQUALS FOLLOWER LEN...

Page 58: ...move 1 5 percent faster than the material during the Working Segment to increase the efficiency of the cut then the Working Ratio would be 1 01500 See Cycle Inter Relationships and Figures 6 and 27 Working Offset This parameter sets the distance from the Cycle Point to the Follower zero position When the Follower cycle is started the Follower is assumed to be at the Follower zero position If the F...

Page 59: ...rement input functions 68 69 72 and 73 respectively are toggled while the Phase Fine Inc Select input function 77 is active Offset Phase Coarse Increment This parameter is the amount of adjustment which occurs in the next cycle when the Working Offset Increment Working Offset Decrement or Master Phase Increment Master Phase Decrement input functions 68 69 72 and 73 respectively are toggled while t...

Page 60: ...00310 00 or 525 Programmable Motion Controller Installation and Operation Manual P N 400276 01 as appropriate The input functions which are specific to the PCM 22 are discussed in this section Figure 28 Input Functions Screen To assign an input function use the up down arrows to move the cursor to the desired input function type in the desired line number and then press Enter The left hand window ...

Page 61: ...nput must be assigned to one of the high speed input lines 1 or 2 and not the same input line as the Zero Master Cycle 2 Do not assign filtering to this function 49 Cycle Drop Out When this input function is activated before the Cycle Point the Follower will complete the current Working Segment then decelerate at a calculated rate until it s stopped at the Cycle Drop Out Position If the Master axi...

Page 62: ...ps It is not functional if the Follower cycle is Defined By a Registration Sensor See Cycle Inter Relationships Follower Cycles screen and the PH4 serial command 67 Follower Length Decrement This edge triggered input function decrements the Follower Cycle Length by the Length Change Increment value each time an input signal is received It is checked against the Follower Length Lower Limit and the ...

Page 63: ...4 serial command 73 Master Phase Decrement This edge triggered input function decrements the Master Phase Distance by the Offset Phase Coarse Increment or Offset Phase Fine Increment value as appropriate each time an input signal is received It is only functional when in a cycle See the Master Cycles screen the Follower Cycles screen and PH4 serial command 74 Reset Cycle Counter This input is used...

Page 64: ...ts screen will be used after the completion of the Working Segment This input is a latching type function This means that the input need only be pulsed once It is cleared when the cycle is exited WARNING The next motion statement following the Y Execute Follower Cycle statement should not be an Absolute Index because the Follower axis might reverse direction When used in conjunction with the Cycle...

Page 65: ...ial command 119 Working Ratio Decrement This edge triggered input is used to decrement the Working Ratio by the Working Ratio Change Increment value It is only functional when in a cycle It must be assigned using the IF serial command It is uploaded and downloaded by PCX See the TC5 serial command Typical Input Assignments The following input assignments handle most customer needs Input Function N...

Page 66: ...pt multiple output assignments on any output line Most of the output functions are discussed in the 230V FX Drives Setup and Programming Operator s Manual P N 400282 00 460V FX Drives Setup and Programming Operator s Manual P N 400310 00 or 525 Programmable Motion Controller Installation and Operation Manual P N 400276 01 as appropriate The output functions which are specific to the PCM 22 are dis...

Page 67: ...cycle 24 In Phase Activates when the total phase variation is between Phase Distance Error Limit and Phase Distance Error Limit It will not activate until the Follower has completed its phase correction It is the compliment of the Phase Distance Error Limit output function 44 It may be active in a cycle and is always deactivated outside of a cycle When the Follower cycle is starting it will be ina...

Page 68: ...en the Cycle Count number set in the Follower Cycles screen is reached It may stay active after the cycle has ended This output function may be deactivated by activating the Reset Cycle Counter input function 74 or by changing the value of the Cycle Count which will clear the current Cycle Count See the FF and KC4 serial commands 43 Batch Count Reached Active when the Batch Count number set in the...

Page 69: ...be temporarily changed The output will be latched active even if the situation was controlled It is up to the user to decide how to handle this error condition when a cycle is executing The CQ serial command will have flags set indicating where the problem is Other than user changes the primary causes of this would be too small of a Working Segment for the Follower velocity required encoder slippa...

Page 70: ...lid Zone issue 10 41 Cycle Limit Reached 47 Extra Master Sensor There is an issue in progress usually the last user adjustment exceeded a limit Check CQ serial command for reason If the Master Cycle is defined by sensor see Lower Master Length Limits 11 25 Master Sensor Missing Only active in a cycle if the Master Cycle is defined by sensor Possible sensor failure or Master Sensor Valid Zone issue...

Page 71: ... refer to your FX Drives manual for a complete description of the programming capabilities available Additional programming functions The PCM 22 has additional programming capabilities available Each program function has a designated single or double letter function code that is used when creating a program This section describes the unique PCM 22 functions Please refer to your FX Drives manual fo...

Page 72: ...er the Y Execute Follower Cycle function code will be executed unless the Cycle Exit input function 116 is activated If a stop motion command is issued the program will end Example program Typically the first step in the program moves the Follower axis to some valid start point or home The Home function is executed prior to the Y Execute Follower Cycle function code to establish a Follower zero po...

Page 73: ...ld be fed to the stop motion input of the material feed master axis The exiting Follower axis velocity will automatically become the starting velocity of the next motion command a real time incremental Index in this example See Cycle Exit ...

Page 74: ...PCM 22 Rotary Knife Controller 66 EMERSON Motion Control ...

Page 75: ...ter registration product sensor on the conveyor belt Master axis and a follower proximity sensor on the knife axis Follower axis Operation As the leading edge of the printed image is sensed the distance from the last image is computed This allows the PCM 22 to compute a correction necessary to compensate for any phase or length variation on the next cycle When the product reaches the correct posit...

Page 76: ...conveyor belt a master registration product sensor on the conveyor belt Master axis and a follower proximity sensor on the seal cut head Follower axis Operation As the leading edge of the registration mark is sensed the distance from the last registration mark is computed This allows the PCM 22 to compute a correction necessary to compensate for any phase or length variation on the next cycle When...

Page 77: ...t Follower axis a product seal position sensor Master axis and the rolling die position sensor 2nd Follower axis Operation When the desired amount of material has passed the first PCM 22 will have positioned the seal bar at the correct position relative to the last seal The seal functions as a registration mark for the rolling die operation When the seal reaches the correct position for punching t...

Page 78: ...rocess Master axis and a follower proximity sensor on the vacuum pick up take away assembly Follower axis Operation The PCM 22s Working Segment is positioned so as the mold is opening it matches the speed of the mold The vacuum pick up lifts the part from the mold and gets it clear before the mold closes again As the Working Segment occurs to pick up the product from the mold the product that was ...

Page 79: ...a proximity follower sensor for the imprint Follower axis Operation The union of the reciprocating eccentric imprint mechanism with the PCM 22 Rotary Knife Controller allows the motion profile to be changed VARIABLE SEGMENT CALCULATED BY THE PCM FOLLOWER VELOCITY MASTER CYCLE FOLLOWER CYCLE WORKING SEGMENT WORKING SEGMENT ZERO MASTER POSITION MACHINE CYCLE WORKING RATIO VELOCITY CYCLE POINT CYCLE ...

Page 80: ...PCM 22 Rotary Knife Controller 72 EMERSON Motion Control A flexible system capable of precise placement and control over an imprint ...

Page 81: ...ut slipping or vibrating This adjustment process is done in two stages 1 The Average Master and Average Follower Length Variations are minimized 2 The Master and Follower Phase Variations are minimized The process will take the longest the first time and successive profile styles will only need minor adjustments to account for profile variation Following is a detailed explanation of how to perform...

Page 82: ...e instructions for MON EXE are in the README TXT file A sample script file PCM22 MON for MON EXE has been provided to be used when performing the procedures described in Minimizing Length Variation and Minimizing Phase Variation MON EXE PCM22 MON and README TXT files are located on the PCX diskette They may also may be obtained from the EMERSON Motion Control BBS or the Internet web page Minimizin...

Page 83: ... After several passes you should see a trend towards stability when querying ML11 and FL11 that will verify that the lengths are becoming more regular This will be easy to see if you are using MON EXE Notes If the length variations do not stabilize to an acceptable level or if the either Master or Follower Length Correction Limit is below 35 percent something is wrong mechanically with the system ...

Page 84: ...g for you during the adjustments and allow user to more effectively monitor the machines performance 1 Query FM7 and FM8 Add them to obtain the total phase variation 2 Query FL11 and ML11 the average Follower and Master Lengths respectively The average lengths should stabilize further as the adjustment process continues 3 For the system to track as tightly as possible you need to reduce the Phase ...

Page 85: ...e Performance P N 400274 01 Revision A7 77 3 Perform the process for Minimizing Length Variation again 4 Adjust the Working Segment wider or narrower by 5 percent 5 Adjust the EG gain by increments of 0x10 upwards first ...

Page 86: ...unless there are large Follower Length or sensor position changes due to a machine or product change Note The value of FM7 plus FM8 is tested against the Phase Distance Error Limit and Phase Distance Error Limit to activate the In Phase output An alternate way of minimizing phase variation is to monitor the In Phase output function 24 and adjust Phase Correction Limit slowly while reducing the Pha...

Page 87: ...P N 400274 01 Revision A7 79 ...

Page 88: ...is to setup several Master Cycle definitions and have each called from identical Follower cycle definitions Each Master Cycle definition would cover a smaller product range Each Follower cycle could then be called from separate programs This may be accomplished with program select lines 2 Setup several smaller product ranges in separate Master Cycle definitions and only use one Follower cycle defi...

Page 89: ...ee Cycle Inter Relationships Symptom The Follower is in cycle with P on the display but no motion is occurring Cause 1 Check to make sure that the drive is receiving sync pulses from the encoder or up stream drive and that the sync polarity and compensation are correct See Master Axis Note The synchronization source must count in a positive direction for proper operation 2 The Master cycle is not ...

Page 90: ...lower length variations are primarily differences between the individual Follower lengths which can be controlled by adjusting the Follower Length Correction Limit or Follower Sensor Averaging If the Follower distance per revolution does not match the gear ratio then it will first be perceived as length variation and then as phase variation once the Follower Upper Lower Length Limit is reached 5 I...

Page 91: ...ues Symptom The Follower motion is jumpy or coarse Possible Causes A The PCM 22 is synchronized with the encoder Master position Any slippage or bounce of the encoder to the product will be reflected in the position and motion of the Follower Chain sprocket coupling to the encoder such as should not be used B The number of sync steps per Master Length is much less than the number of resolver steps...

Page 92: ...s 6 Products are being skipped i e no Follower cycle occurs 7 A constant Master Phase Variation FM7 equal to the difference in what was measured between Master sensor inputs ML1 8 ML11 or FM12 and one of the Master Length Limits 8 A constant Follower Phase Variation FM8 equal to the difference in what was measured between Follower sensor inputs FL1 8 FL11 or FM13 and one of the Follower Length Lim...

Page 93: ...ve inputs 2 Electrical noise can be picked up on the sensor leads and cause false triggering Follower Axis 1 Make sure you are getting the Follower sensor input when you are supposed to by widening the Follower Sensor Valid Zone This can be checked by querying serial command IO0 IO zero while monitoring the position of the Follower axis and the Follower Sensor Missing output function 2 Make sure t...

Page 94: ...he active inputs Follower Axis 1 Make sure you are not getting extra Follower sensors when you are not supposed to by narrowing the Follower Sensor Valid Zone This can be checked by querying IO0 IO zero serial command while monitoring the position of the Follower axis as appropriate 2 Make sure that the Follower Length Lower Limit is within the Follower Sensor Valid Zone and Follower Length Lower ...

Page 95: ...he LED display on the front of the drive is lit Symptoms Drive displays a H J or P but motor does not move and the motor shaft has no torque in either direction Possible Causes The FX drive is inhibited by Inhibit Drive input function 12 or by the BR serial command The Hold input function 3 is active Symptom Drive will not Suspend Possible Causes It is already suspended The FX drive can only be su...

Page 96: ...dditive These eight flags will cause the Cycle Limit Reached output function 41 to activate The Cycle Error output function 66 will activate if one of these conditions exist when the cycle is exited Ratio Limit 0x01 Not able to make ratio change at the current Master velocity The Working Ratio will be changed temporarily to get through the problem i e the Master Length or Working Ratio is changing...

Page 97: ...ing the Follower zero position The following four flags will cause the Cycle Error output function 66 to activate and stay on until the cycle is stopped and restarted They usually indicate a mechanical failure sensor failure or invalid profile in the corresponding system Master Profile Error 0x100 Profile data for the next Master cycle indicates a serious problem will occur or is in progress The a...

Page 98: ...ips See Working Segment and Cycle Inter Relationships Example 2 CQ 84 The user tried to adjust the Working Segment larger than the Cycle Inter Relationships will allow Adjusting the Master Phase Distance Example CQ 40 The Master Phase Distance requested is less than zero Sensor Issues and Length Limits Example 1 CQ 810 The Master Sensor is missing See Missing Sensors Example 2 CQ 20 If the Followe...

Page 99: ...g mode is disabled FF 21 Adding 0x20 to the current value will enable Force Reset Master Processing before starting on cycle 5 Follower Cycle Defined By Sensor 0x01 This command specifies if this Follower cycle definition is defined by sensor It is available from PCX on the Follower Cycles screen Disable Cycle Counter Reset 0x08 This command allows the user to disable clearing the Cycle Counter wh...

Page 100: ...It is only supported in Master defined by sensor mode and is query only See Maximizing Profile Performance FM8 Follower Phase Variation In User Units This is the amount Follower Phase Variation in user units from the measured distance between sensors to the average length This should be used in conjunction with FM7 The sum of FM7 and FM8 is the total phase variation for that cycle This command is ...

Page 101: ...ngth field in PCX for executing Master Cycle definition The command is query only See ML11 FM13 Average Follower Length In User Units This is the same value as FL11 average Follower Cycle Length but in user units instead of resolver steps This value can be used to verify the Follower Cycle Length field when the Follower cycle is defined by sensor in PCX for executing Follower cycle definition The ...

Page 102: ...Follower FN1 1 cycle 2 and PCX returns the current Follower Cycles Per Follower Sensor for Follower cycle 2 FN1 3 Change the Follower Cycles Per Follower Sensor to 3 on Follower cycle 2 KC4 Total Cycle Count This command returns the total number of Followers cycles executed since the Master processing was last reset See Follower Flags MF Master Cycle Flags The Master Cycle Flags are a bit map in h...

Page 103: ...n Master defined by sensor mode The default setting for the Disable Reset of Master Cycle 0 flag is off ML11 Current Master Length In Master Steps This is the executing Master Length or product length in Master steps This value the same as FM12 The command is query only PH4 Minimum Master Velocity For I O Profile Adjustments This parameter disables I O profile adjustments below a certain Master sp...

Page 104: ... Cycles Screen Screen Parameter Serial Command Master Cycle Number CY Master Cycle Length ML0 Master Length Upper Limit ML9 Master Length Lower Limit ML10 Master Phase Distance TA Master Cycle Defined by Sensor MF Cycle Length Averaging MS Master Sensor Valid Zone MZ Master Length Correction Limit PH3 ...

Page 105: ...wer Cycles Per Master Cycle FN0 Follower Sensor Averaging PA Phase Correction Limit PH1 Phase Distance Error Limit PP Phase Distance Error Limit PN Phase Correction Deadband PH0 Length Change Increment TC2 Master Cycle Number FT Batch Count KC3 Cycle Count KC2 Working Segment Width FM0 Working Ratio FM2 Working Offset FM1 Upper Working Segment Limit Width FM3 Lower Working Segment Limit Width FM4 ...

Page 106: ... the channels has 1000 2500 and 3000 lines respectively The inputs are A A complement B and B complement Quadrature encoding of these two signals produces a signal whose frequency is 4 times the line count One revolution of the sync encoder produces the equivalent of 4000 10 000 and 12 000 counts steps per revolution respectively Figure 31 SCS 2 3 and 4 Encoder Mechanical Electrical Information ...

Page 107: ... cable is provided in different lengths MSC 015 15 feet MSC 025 25 feet MSC 050 50 feet Drive to Drive Cables For some applications another digital drive could be the Master signal source This is the purpose of the second connector on the PCM The first axis can provide the synchronization signal for the second axis The SSC XXX cable is a symmetrical cable and its ends can be interchanged Figure 33...

Page 108: ...Differential Gain 74 E EG 74 Encoder 29 30 31 32 33 80 95 Error Gain 74 Extra Master Sensor 36 37 42 58 81 82 83 Extra Sensor 83 F FE 34 79 FF 14 88 91 94 FL0 17 41 52 81 94 FL10 43 52 94 FL11 9 72 73 74 90 FL1 8 81 82 83 FL9 41 42 52 94 FM0 17 19 47 74 87 94 FM1 17 48 52 86 94 FM10 72 73 77 90 FM11 90 FM12 9 35 80 90 92 FM13 9 80 90 FM14 90 FM2 19 48 55 92 94 FM3 48 94 FM4 48 94 FM5 48 94 FM6 48 ...

Page 109: ...3 17 38 93 Master Position Not Defined By Sensor 12 13 36 37 38 42 43 Master Sensor Distance 15 38 51 53 58 79 86 Master Sensor Missing 36 42 57 82 Master Velocity 15 19 36 37 42 85 90 92 Maximum Master Velocity 19 36 37 42 MF 13 14 17 91 93 Missing Sensor Issues 82 ML0 35 86 90 ML10 12 17 37 58 87 93 ML11 90 92 ML9 12 36 42 43 93 O Offset Phase Coarse Increment 49 94 Offset Phase Fine Increment 4...

Page 110: ...Offset 5 17 45 48 52 85 86 94 Working Offset Decrement 52 Working Offset Increment 52 Working Ratio 5 7 15 19 48 55 86 92 94 Working Ratio Change Increment 55 92 Working Ratio Decrement 55 92 Working Ratio Increment 55 Working Ratio Limit 48 Working Segment Working Segment 5 7 17 18 19 37 44 46 47 52 53 74 85 87 91 94 Working Segment Decrease 46 49 53 Working Segment Increase 46 49 53 Working Segm...

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