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D-20

Compensation system status information and diagnostics

Table D.16 – Axis diagnostics (Communication tab)

Error

Description

Configuration mode

Compensation mode

Advanced

Simple

Sensor
Comms
Timeout

No reply from a sensor. One or
more sensors timed out.

WARNING

ERROR

Check sensor connections.

Check

Sensor

screen for errors.

Check individual sensor errors.

Sensor
Comms
Error

Sensor communications error.
Framing, over run, parity or
UART IC error.

WARNING

SUSPEND

ERROR

Check sensor connections.

Check

Sensor

screen for errors.

Check individual sensor errors.

Assert

Reset

line on Auxiliary I/O connector (Error

condition only).

PC Comms
Timeout

Communication from PC
interrupted.

WARNING

Check connection to PC.

PC Comms
Error

Personal Computer
communications error. Framing,
over run, parity or UART IC
error.

WARNING

Check connection to PC.

Fast Serial
Bus Failure

Unrecoverable network error. No
master connected. Includes
timeout errors.

SYSTEM ERROR

System Reset.

Fast Serial
Bus Data
Error

Data corruption on sensor
information passed over fastlink.

ERROR

Assert

Reset

line on Auxiliary I/O connector.

Содержание RCU10

Страница 1: ...Installation and user s guide M 9904 1122 09 A RCU10 quadrature compensation unit...

Страница 2: ...y measures that can be included in machine design However it is the sole responsibilty of the OEM system integrator to specify and integrate measures suitable for the application Symbol definition The...

Страница 3: ...general household waste Please dispose of the used batteries at a designated collection point This will prevent potential negative effects on the environment and human health which could otherwise ari...

Страница 4: ...put see item 3 below If the controller is not capable of detecting open circuit position feedback signals this option must not be enabled 2 The axis must include physical limit switches which when tri...

Страница 5: ...axes should be monitored If the difference in their positions exceeds an expected limit then axis motion must be stopped Note In the case of measures 6 9 the limits need to be selected carefully depe...

Страница 6: ...3 1 Connector positions 2 5 2 3 2 Connector functions 2 6 J1 24 V dc power 2 6 J2 Controller output 2 6 J3 Encoder input 2 6 J4 Reference switch port 2 7 J7 Auxiliary I O 2 8 J8 PC port 2 9 2 4 Veloci...

Страница 7: ...rror testing 5 2 5 2 2 RCU10 error testing 5 3 5 2 3 Testing environment sensors 5 5 5 2 4 Auxiliary I O connector input functions 5 6 5 2 5 Reference mark connector function 5 8 5 2 6 Encoder conside...

Страница 8: ...1 Connector pinout B 11 B 6 2 Wiring requirements B 11 B 7 PC port J8 B 13 B 7 1 Connector pinout B 13 B 7 2 Wiring requirements B 13 B 8 Fastlink port B 14 B 9 Sensors J5 J6 B 14 B 9 1 Connector pino...

Страница 9: ...2 F 1 2 Extended system status monitoring F 2 F 1 2 1 Extended status monitoring F 2 F 1 3 Axis referencing with extended error lines F 4 F 1 4 Controlling workpiece compensation from motion control s...

Страница 10: ...tion of compensation terms G 6 G 2 Air refraction compensation G 9 G 3 Worked example laser compensation G 11 G 3 1 Direction sense setting G 11 G 3 2 Laser dead path LO G 12 G 3 3 Workpiece thermal e...

Страница 11: ...viii Contents This page is intentionally left blank...

Страница 12: ...ctor 1 4 1 3 2 Air refractive index compensation 1 4 1 3 3 Encoder thermal expansion compensation 1 5 1 3 4 Workpiece thermal expansion compensation 1 5 1 3 5 Structure thermal compensation 1 7 1 4 Op...

Страница 13: ...network of sensors and uses advanced digital signal processing to perform real time compensation on the position feedback signals The RCU10 can provide Refractive index compensation for laser encoder...

Страница 14: ...to the motion controller The corrected feedback signals are provided to the motion controller in either RS422 digital A quad B or analogue Sin Cos 1 Vpp formats with a nominal accuracy of 1 ppm refra...

Страница 15: ...ls can be found in Appendix G 1 3 1 Scale factor The RCU10 is capable of performing a fixed scale factor correction to convert the intrinsic encoder resolution into a more useable value e g 633 nm 1 m...

Страница 16: ...for this effect by measuring the temperature of the scale and applying the relevant positional correction This will significantly improve system accuracy when subjected to temperature variation To uti...

Страница 17: ...ts machined in an environment maintained at 20 C 68 F That is to say no matter what temperature the part is machined at it will be the correct size when measured at 20 C 68 F Expansion is a greater pr...

Страница 18: ...la to convert from ppm C to ppm F ppm C multiplied by 5 9 ppm F e g 20 ppm C x 5 9 11 11 ppm F 1 3 5 Structure thermal compensation An additional source of positioning error may be the thermal distort...

Страница 19: ...ging of the material type e g aluminium steel 1 4 2 Compensation buffering When the RCU10 is in this mode it will continue to monitor the encoder input and perform the relevant quadrature scaling Howe...

Страница 20: ...buted to other RCU10s in the network via a high speed serial link Compensation unit part number RCU10 XX XX Similar to the RCU10 PX XX however this assembly does not contain a pressure sensor Note tha...

Страница 21: ...to meet the requirements of the application Communication with the RCU10 units is established through an RS232 or RS485 serial link in some instances this may necessitate the use of a USB to RS232 co...

Страница 22: ...nstallation process detailed information has been placed within the appendices Reference to these appendices is made where appropriate Figure 1 5 Installation flow diagram System design Section 2 Defi...

Страница 23: ...1 12 System overview This page is intentionally left blank...

Страница 24: ...Controller output 2 6 J3 Encoder input 2 6 J4 Reference switch port 2 7 J7 Auxiliary I O 2 8 J8 PC port 2 9 2 4 Velocity resolution bandwidth considerations 2 9 2 4 1 Encoder input frequency 2 10 2 4...

Страница 25: ...digital quadrature in differential RS422 format or analogue Sine Cosine quadrature in 1 Vpp format is capable of recognising an error condition by one of the following methods RS422 differential erro...

Страница 26: ...0 sensors are factory programmed with an address that is the same as the serial number of the sensor engraved on the sensor body Each sensor port can supply power to a maximum of four sensors which me...

Страница 27: ...wn in Figure 2 3 making a maximum of eight sensors per RCU10 There is a limit of 32 sensors per multi axis system Additionally of these 32 sensors only 24 may be distributed Distributed sensors are th...

Страница 28: ...to Appendix B CAUTION Do not connect anything other than Renishaw environmental sensors to the sensor ports 2 3 1 Connector positions Figure 2 4 Front panel layout Figure 2 5 Top panel layout Not curr...

Страница 29: ...analogue incremental sine cosine format 1 Vpp differential sine and cosine line driver outputs using the configuration software The output resolution of the RCU10 system may be selected from a number...

Страница 30: ...input can accept a range of actuator types that have solid state high side or low side 5 V logic signal or mechanical switch output formats The reference process is triggered by the current s rising e...

Страница 31: ...V or 24 V Connect to 5 V 1 or 24 V 11 as required Note This must also be selected to match the RCU10 configuration 5 Seek reference I Enables search for reference mark input LOW 15 Reset I Resets the...

Страница 32: ...m Renishaw Alternatively custom cables may be made by the user connector kits are available Please see Appendix B for connector pinouts and standard cable specifications Notes New PCs are increasingly...

Страница 33: ...ast 25 greater than the encoder output quadrature rate 2 4 2 Output frequency Determine the RCU10 output controller input resolution Calculate the maximum output frequency as follows Output frequency...

Страница 34: ...oder input resolution nm RCU10 output resolution sinusoid period m 20 25 40 50 100 316 5 00 m s 158 3 164 m s 3 164 m s 3 164 m s 79 1 1 582 m s 1 582 m s 1 582 m s 1 582 m s 39 6 0 791 m s 0 791 m s...

Страница 35: ...f the reference switch To overcome this the RCU10 includes a circuit that re phases the position signals so that the reference mark output occurs synchronised and in a repeatable position Digital inte...

Страница 36: ...ude of sine and cosine are equal The re synchronisation process ensures a reference output starts nominally 256 output counts later than the reference input and is valid at 320 1 Figure 2 8 Analogue i...

Страница 37: ...ssued In this case it is advisable that the reference position is located outside the normal working zone of the axis Linking Reset permanently to 0 V will cause the RCU10 to automatically reset the e...

Страница 38: ...n be used to enable a reference cycle In this mode of operation taking the Seek Reference line low enables the reference mark input line into the RCU10 At all other times i e with Seek Reference high...

Страница 39: ...2 16 System design...

Страница 40: ...y to port the pressure sensor aperture to the outside environment such that the correct air pressure is measured This can be done by using 4 mm O D plastic tubing which will simply push fit into the a...

Страница 41: ...or should be positioned in a dry location in air next to the laser beam An armoured cable option is available for applications where there is a danger of the cable being stressed or cut The sensor is...

Страница 42: ...e contamination It is common for material temperature sensors to be mounted in variable locations on a machine area being removed and replaced as required An armoured cable option is available for app...

Страница 43: ...ingle RCU10 sensor port One cable is attached to the RCU10 and the sensors are plugged into the distribution box at a remote location The box may be mounted vertically or horizontally using either set...

Страница 44: ...identification Contained in this section 3 1 Defining kit numbers 3 2 3 2 Kit numbers and part identification 3 3 3 2 1 RCU10 kit numbers laser encoder based systems 3 3 3 2 2 RCU10 kit numbers non la...

Страница 45: ...eparately if required N Total number of axes in system Range 1 6 N Number of air sensors required Range 0 6 It is assumed that if an air sensor is required at least one axis will be using refractive i...

Страница 46: ...U10 55AFZ RCU10 66AGZ RCU10 PX XX RCU10 compensation unit with pressure sensor 1 1 1 1 1 1 RCU10 XX XX RCU10 compensation unit 0 1 2 3 4 5 RCU10 AT XX Air temperature sensor 1 2 3 4 5 6 RCU10 MT XX Ma...

Страница 47: ...0 XX XX RCU10 compensation unit 1 2 3 4 5 6 RCU10 MT XX Material temperature sensor 1 1 1 1 1 1 RCU10 TC X5 Sensor cable 1 1 1 1 1 1 RCU10 CS XX RCU10 CS software 1 1 1 1 1 1 A 9904 1455 RCU10 connect...

Страница 48: ...and part identification 3 5 3 3 Additional components and part identification Part number Component description A 8014 0670 Serial USB adaptor RCU10 DB XX Sensor distribution box RCU10 AC X5 Armoured...

Страница 49: ...3 6 Kit configuration and part identification This page is intentionally left blank...

Страница 50: ...0 address set up 4 2 4 1 3 Electrical installation 4 4 4 1 4 RCU CS settings 4 4 4 2 System configuration 4 5 4 2 1 System configuration 4 6 4 2 2 Sensor network configuration 4 7 4 2 3 Compensation s...

Страница 51: ...detailed in section 2 At this stage the high speed serial link cables and controller output cables should be disconnected The remaining cables J3 Encoder input J4 Reference switch port J5 and J6 Senso...

Страница 52: ...NOTE Each unit must have a unique address before connection as part of a network for example a six axis system must have RCU10s addressed as 1 2 3 4 5 and 6 It is important to ensure that compensator...

Страница 53: ...ectly Ensure the configuration PC is connected to an RCU10 unit it may be connected to any RCU10 in a multi axis system Press the Receive button on the RCU CS screen to establish communications The RC...

Страница 54: ...either Metric or Imperial when using imperial distance measurements values are entered and displayed in decimal format Three options are available Inches Millimetres or Metres 4 2 System configuration...

Страница 55: ...s not applied to any extra length Error Monitoring Error Line Only standard error mode in which the RCU10 produces an Error output for any system error Error Suspend and Warning Lines extended error m...

Страница 56: ...figurator has the option to apply limits to the air and material temperature sensor readings minimum maximum and also the rate of change If the limits are exceeded an error warning is asserted which c...

Страница 57: ...system configuration window Configuration is split into five main sections Encoder Input Compensation Output To Controller Limits and Misc It is recommended that you follow this order during configur...

Страница 58: ...e 4 4 Configuration window Compensation tab Encoder Input Encoder Type Selects the type of encoder used from a pre defined list RLE Axis 1 RLE Axis 2 HS10 or Linear Tape and Glass Wavelength Pitch Eac...

Страница 59: ...thermal expansion compensation algorithm Structure Thermal Selects the machine structure thermal expansion compensation algorithm Output to Controller Signal Format Selects the format of the feedback...

Страница 60: ...movement when Rate certain functions are operated e g deactivating workpiece compensation at distance compensation buffering Misc Inhibit Compensation When selected the RCU10 will only power up into M...

Страница 61: ...hat the direction sense is carefully considered Failure to do this may cause opposite ends of the cross member to move in opposite directions possibly causing damage to the machine 3 To maintain the i...

Страница 62: ...s before continuing on to the next table validate current tab will validate all parameter tables not just the one visible To move to the next table for the axis press the right arrow key by the Displa...

Страница 63: ...ture sensor to be used in the compensation algorithm Common for all parameter tables in one RCU10 axis Expansion Coefficient Define the coefficient of expansion for the scale substrate to be used in t...

Страница 64: ...sary to transmit it from the PC into the RCU10 units The RCU10 units will then store the configuration in non volatile memory so it is retained even if the RCU10s are switched off To transmit the conf...

Страница 65: ...RCU10 system may be returned to configuration mode at any time if it is required to make changes to the parameters or configuration The RCU10 does not provide valid feedback signals when in configurat...

Страница 66: ...nostic information Step through the Configuration Compensation Communication and Sensors tabs to find the source of the problem which will be depicted by a RED indicator Having identified the source o...

Страница 67: ...4 18 System installation This page is intentionally left blank...

Страница 68: ...g 5 2 5 2 2 RCU10 error testing 5 2 5 2 3 Testing environment sensors 5 5 5 2 4 Auxiliary I O connector input functions 5 6 5 2 5 Reference mark connector function 5 8 5 2 6 Encoder considerations 5 9...

Страница 69: ...ored by the controller and if it is asserted on any axis the machine control MUST stop all axes of motion 2 It is the responsibility of the system integrator to ensure in the event of a failure of any...

Страница 70: ...ure With reference to the wiring diagrams in Appendix B connect the encoder output cables to the encoder input connection on the relevant RCU10 unit Clear the initial error asserted at start up by sen...

Страница 71: ...laced between the head and the scale Check on the machine control that the Error line is active Remove the source of the error condition and send a Reset signal to the RCU10 to clear the error Check o...

Страница 72: ...nger than one second and the RCU10 has been referenced then the Suspend and Error lines will also be asserted to indicate the failure of a compensation algorithm These can be cleared by issuing a Rese...

Страница 73: ...e the error conditions as described in sections 5 2 1 5 2 2 and 5 2 3 Ensure that the controller recognises the input and responds as detailed in Table 5 1 Table 5 1 Auxiliary I O connector functions...

Страница 74: ...n advanced mode to indicate when the machine may not be accurately positioned The controller can use the signal to suspend machining and hence prevent inaccurate parts Suspend is also asserted tempora...

Страница 75: ...tting 5 2 5 Reference mark connector function The reference mark function must be tested at this stage to ensure that it is behaving correctly Ensure that the drives are inactive and that they will no...

Страница 76: ...er system is a little more difficult because it makes the process of ensuring that the resolution and direction of count are correct for feedback purposes more difficult It will be necessary to move t...

Страница 77: ...s should be checked on both the RCU10 compensation display and the controller s dummy axis If the movement is not what you expected continue to section 5 2 8 Repeat for all axes Method 2 single encode...

Страница 78: ...an encoder and compensation system is installed on to an existing machine a retrofit or a machine that has already had its motors tuned according to a rotary encoder then a different tuning set up is...

Страница 79: ...irm the correct operation of the machine home or reference cycle once the system is correctly homed compensated feedback can begin Perform a normal machine home operation if possible setting the feed...

Страница 80: ...n 6 Operation Contained in this section 6 1 Standard operation 6 2 6 2 RCU CS status during operation 6 2 6 2 1 Compensation display 6 3 6 2 2 Sensor display 6 4 6 2 3 Diagnostics display 6 5 6 3 Gene...

Страница 81: ...tering compensation mode 6 2 RCU CS status during operation RCU CS software is not required for normal operation however it may be used to display information about the RCU10 s status To use RCU CS so...

Страница 82: ...the individual axis required from the displayed tabs in this window this summary information may be displayed in a clearer single screen shown in Figure 6 3 Figure 6 3 Axis compensation screen Note Fo...

Страница 83: ...d in the RCU10 network It displays operational and communication status as well as a real time display of the reported readings If the system is functioning correctly all readouts should be green Lase...

Страница 84: ...led description of the fault condition double click the axis name to open up the individual axis s diagnostic screen Figure 6 6 Axis diagnostics screen selection This screen details most of the functi...

Страница 85: ...or details of battery replacement The customer must not change the battery Typical battery life is ten years At end of life the RCU10 must be disposed of in accordance with local regulations The use o...

Страница 86: ...Appendix A RCU10 system specifications Contained in this appendix A 1 RCU10 system performance A 2 A 2 Component performance A 4 A 2 1 Compensation unit A 4 A 2 2 Air sensor A 5 A 2 3 Material sensor...

Страница 87: ...ctive index compensation only This assumes a working environment that falls within Temperature range 0 C to 40 C Pressure range 650 mB to 1150 mB Relativity humidity RH entered within 20 2 ppm with 10...

Страница 88: ...contains a digital filter which is used to remove noise spikes from the incoming signals This filter is only operational for input sample clocks of 10 MHz and below NOTE RCU10 performance specificatio...

Страница 89: ...V 2 V Current 0 25 A Maximum power 6 W with 8 sensors connected The 24 V power supply should be single fault tolerant certified to EN IEC 60950 1 Operating environment Pressure Normal atmospheric 650...

Страница 90: ...3 Material sensor Accuracy 0 1 C k 2 Measurement range 0 C 55 C Update rate 1 Hz A 2 4 Pressure sensor Accuracy 2 mbar k 2 Measurement range 650 mbar to 1150 mbar Operating temperature 0 C 60 C Updat...

Страница 91: ...A 6 RCU10 system specifications This page is intentionally left blank...

Страница 92: ...equirements B 5 B 3 2 Analogue feedback signals B 6 B 3 2 1 Connector pinout B 6 B 3 2 2 Wiring requirements B 7 B 4 Encoder input J3 B 8 B 4 1 Connector pinout B 8 B 4 2 Wiring requirements B 9 B 5 R...

Страница 93: ...pecified for the cable connector All pinouts are shown from the connector wiring side RCU10 front panel B 2 24 V dc power J1 B 2 1 Connector pinout 4 way binder 680 series female The connector is view...

Страница 94: ...2 V and 26 V and has reverse and overvoltage protection The supply is reverse voltage protected and if the supply is taken above its normal operating range will be protected by means of an inline ther...

Страница 95: ...1 9 0 V sense line see Note 1 10 11 Error error output RS422 12 Z reference output RS422 13 B Quad RS422 14 A Quad RS422 15 Inner screen see Note 2 Shell Case Note 1 Pins 2 7 8 and 9 are provided as...

Страница 96: ...ture and reference pairs may be ac terminated with a series combination of 100 to120 resistor and 1 nF capacitor For cable lengths less than 1 m a smaller 100 pF capacitor is recommended The Error lin...

Страница 97: ...ference output 1 V analogue 13 Sine 1 V analogue see Note 1 14 Cos 1 V analogue see Note 1 15 INSCR inner screen see Note 3 Shell Case Note 1 Under error conditions the quadrature signal level will dr...

Страница 98: ...he differential pairs This should be applied to the quadrature and reference lines only When correctly terminated the amplitude of the differential Sine and Cosine signals is specified to be 1 V 5 pea...

Страница 99: ...nse 9 Do not connect Do not connect 0 V Sense 10 Do not connect Do not connect Do not connect 11 Error Beam blocked Error 12 Z Beam low Z 13 B quad B quad B quad 14 A quad A quad A quad 15 Do not conn...

Страница 100: ...error line differential pair is ac terminated with a series 120 resistor and 10 nF capacitor In addition the line is pulled active in the event of a disconnection to either signal All the encoder port...

Страница 101: ...ference switch port interface e g Belden 9925 The interface is isolated and consists of four terminals the power and its return and the signal and its return To make the reference activate the interfa...

Страница 102: ...ctor 24 V 10 O Warning open collector 24 V 11 O 24 V output 12 I Parameter table select 1 13 I Parameter table select 2 14 I Buffer enable 15 I Reset Shell Case B 6 2 Wiring requirements The operating...

Страница 103: ...idual current In this situation it is recommended that the user fits external pull ups of 2K2 in parallel to each signal Figure B 3 Auxiliary I O port circuit NOTE For HS20 applications the RCU10 syst...

Страница 104: ...2 cables should be constructed using multi conductor cable with an overall shield e g Belden 9925 If the interface is longer than 10 m it is recommended that the RS485 interface be used instead of the...

Страница 105: ...rmination Run the configuration software and select termination on the two end units only Remove and re apply power or reset the system to activate the termination NOTE The configuration software only...

Страница 106: ...an inline thermal fuse if activated then power must be removed from the RCU10 unit so that it can reset The Data and Data lines are protected from short circuit to each other and to either supply line...

Страница 107: ...n 88102 are shown below For a single run Belden 88102 has 24AWG cores that give a resistance of 76 per km which means a maximum single run of 400 m see Figure B 5 A common network with three equally s...

Страница 108: ...this appendix C 1 RCU CS C 2 C 1 1 Overview C 2 C 1 2 Access levels C 2 C 1 3 Operating modes C 3 C 1 4 Configuration data C 4 C 2 RCU CS installation C 5 C 2 1 System requirements C 5 C 2 2 Installat...

Страница 109: ...ation of the system No changes can be made to the system configuration or the current operating mode This level is intended for the base level end user Access at this level does not require a password...

Страница 110: ...not be enabled In this mode the RCU10 error output signal 24 V error is asserted so that the controller can disable motion Compensation This is the normal operating mode once configuration has been co...

Страница 111: ...the system This data is stored only in the relevant RCU10 unit and comprises all the settings and data in the Compensation and Parameters tabs of the configuration screen detailed in sections 4 2 3 a...

Страница 112: ...ons 40 MB free hard drive space minimum Windows 7 and Windows 8 32 bit or 64 bit 800 x 600 screen resolution minimum 1024 x 768 preferred DVD ROM At least one free serial port either RS232 or USB used...

Страница 113: ...he latest version of RCU CS This program will install the RCU CS software and associated files in the default folder C Program Files Renishaw RCU CS if using a Windows 64 bit PC then C Program Files x...

Страница 114: ...the RCU CS is shown in Figure C 2 Any commands that require user input will be marked in bold Figure C 2 RCU10 status display Button bar Menu bar Status bar Serial port status RCU10 connection status...

Страница 115: ...to the software at a different access level Exit the RCU CS software package Open the configuration dialogue to allow system configuration In compensation mode it will display the configuration stored...

Страница 116: ...cified Set the RCU10 network system time to the PC s current time Configure the units used by the RCU CS software for information display see section 4 1 4 for details Serial port configuration System...

Страница 117: ...play the real time RCU10 network compensation status screen Sensors Display the real time RCU10 network sensor status screen Diagnostics Display the real time RCU10 diagnostics status screen Data Log...

Страница 118: ...n screens D 4 D 3 1 Compensation system screen D 4 D 3 2 Compensation axis screen D 8 D 3 3 Sensor data screen D 9 D 3 3 1 Individual View status screen D 10 D 3 4 Diagnostics D 13 D 3 4 1 System stat...

Страница 119: ...to contact Renishaw for further support D 1 1 Process overview There should be a sequential approach to diagnosing problems on the RCU10 compensation system Refer to the RCU CS diagnostics screens Ide...

Страница 120: ...signal is asserted and the condition that caused the error has disappeared Suspend conditions indicate states where the compensator has not fully completed the compensation adjustment such as waiting...

Страница 121: ...der Count size depends upon the selected encoder input resolution and amount of movement since referencing the axis Single counts OC Output count Fully compensated output count from the RCU10 Count si...

Страница 122: ...ctor Axis is in a normal operational state None required AMBER Warning line is active low on the Auxiliary I O connector Check compensation process for errors or sensor errors in Diagnostics window EC...

Страница 123: ...nector Errors will register in error log and on error line for one second before auto resetting Take Reset line inactive high on Auxiliary I O connector if using basic or extended operation No action...

Страница 124: ...Enable line on the Auxiliary I O connector is active low Compensation buffering is enabled To deactivate take Compensation Buffer Enable line inactive high on the Auxiliary I O connector SW Seek work...

Страница 125: ...mm m Wavelength Compensated Axis position with air refractive index compensation applied Greyed out in encoder compensation mode in mm m Diff bottom Difference between wavelength compensated and fully...

Страница 126: ...overview of the entire sensor network as well as offering individual sensor status information It is accessible by pressing Sensors on the button bar Figure D 3 Sensor data screen Table D 7 Sensor da...

Страница 127: ...connection The RCU unit that the sensor is physically connected to Integer 1 6 Sensor Type Sensor type One of three variants air temperature sensor material temperature sensor and air pressure sensor...

Страница 128: ...alibrated specification None required RED Sensor data is out of calibration Return sensor to Renishaw for recalibration Not Ready OFF Sensor is operating normally None required RED Sensor s operationa...

Страница 129: ...is configured correctly Check sensor is wired correctly Replace sensor Comms Error OFF Compensator is communicating with the sensor correctly None required RED Communications error Parity overrun or...

Страница 130: ...equired RED RCU communication error As there are no communications relevant data cannot be displayed Check network communications and connections Status GREEN Axis is operating correctly None required...

Страница 131: ...ne on Auxiliary I O connector is asserted or Error in simple error reporting mode Check individual tabs in axis diagnostics screen to locate cause Warning GREEN Axis is functioning without a suspend s...

Страница 132: ...ional configuration and start up errors that can occur inside the RCU10 NOTE In the following tables System Reset refers to a power cycle of the RCU10 unit This enables the unit to start up again perf...

Страница 133: ...onfiguration data targeted at FPGA is invalid SYSTEM ERROR System Reset Check configuration and re send to unit Sensor Configuration Invalid Sensor configuration is invalid Configuration data targeted...

Страница 134: ...information and diagnostics D 17 D 3 4 4 Axis diagnostics Compensation tab This screen details the errors that can occur to prevent the RCU10 compensating correctly Figure D 9 Axis diagnostics Compens...

Страница 135: ...has failed or is in error SUSPEND ERROR Check Sensors diagnostic tab for errors Check Sensors screen for errors Assert Reset line on Auxiliary I O connector Workpiece Comp Failure Workpiece compensat...

Страница 136: ...agnostics D 19 D 3 4 5 Axis diagnostics Communication tab This screen details the systems communication status This may be the sensor communications RCU10 network communications or PC communications F...

Страница 137: ...ARNING SUSPEND ERROR Check sensor connections Check Sensor screen for errors Check individual sensor errors Assert Reset line on Auxiliary I O connector Error condition only PC Comms Timeout Communica...

Страница 138: ...Compensation system status information and diagnostics D 21 D 3 4 6 Axis diagnostics Sensors tab Compensation mode Figure D 11 Axis diagnostics Sensors tab...

Страница 139: ...heck Sensor screen for errors Check individual sensor errors Assert Reset line on Auxiliary I O connector Error condition only Structure Sensor Failure Allocated material temperature sensor has failed...

Страница 140: ...est 1 Linear compensation air refractive index or encoder scale compensation E 3 E 1 3 Test 2 Workpiece thermal expansion compensation E 4 E 1 4 Test 3 Workpiece thermal expansion at higher temperatur...

Страница 141: ...s required Renishaw XC 80 environmental compensation unit Renishaw XC 80 air temperature sensor Renishaw XC 80 material temperature sensor Each set of tests should be conducted for each axis before mo...

Страница 142: ...XC 80 by setting the expansion coefficient to zero in the LaserXL software Ensure that the RCU10 controlling the axis under test has been referenced This will automatically activate air refractive ind...

Страница 143: ...active index compensation in the RCU10 Move the axis under test to a position near the axis reference position Datum the XL 80 inputting an offset if required to allow the XL 80 and RCU10 to display t...

Страница 144: ...rature sensor artificially to a constant temperature Repeat the ISO230 2 accuracy check as previously outlined The accuracy and repeatability figures should be unchanged from test 2 NOTE The XL 80 cal...

Страница 145: ...out the test monitor the XL 80 reading As the temperature changes there should be no change in the axis position as indicated by the XL 80 reading E 1 6 Test 5 Static workpiece temperature change at d...

Страница 146: ...e movement use the following formula Distance distance from workpiece reference X change in temperature X EC where EC expansion coefficient Example With an offset of 2500 mm a coefficient of expansion...

Страница 147: ...E 8 Commissioning tests This page is intentionally left blank...

Страница 148: ...pending workpiece compensation F 6 F 1 4 5 Multiple fixturing with workpiece compensation F 6 F 1 5 Parameter table selection F 7 F 1 6 Compensation buffering F 8 F 1 7 Configuration of advanced featu...

Страница 149: ...Error output line There is also an extended mode of error handling termed Advanced which allows a greater level of monitoring of the RCU10 status by the machine control When the extended mode is selec...

Страница 150: ...nance Suspend Sensor rate of change exceeded Sensor reading out of range Following error Accuracy detected Axis not yet referenced homed Sensor failure Compensation failure Parameter table select fail...

Страница 151: ...ferencing with extended error lines The axis referencing sequence for applications that use Error Suspend and Warning lines is shown in Figure F 1 Figure F 1 Axis referencing sequence using extended e...

Страница 152: ...ine Workpiece compensation temperature freeze is used to do this This function can also be implemented as machine M codes M92 Suspend workpiece temperature sensor reading M93 Resume workpiece temperat...

Страница 153: ...antly Low M92 The material temperature is held at the last reading F 1 4 5 Multiple fixturing with workpiece compensation If because of multiple fixturing the machine now moves to the next part with w...

Страница 154: ...tem Configurator level as detailed in sections 4 2 4 and F 1 7 1 and then selected during operation by the machine control or a simple switch The number of parameter tables available depends on how th...

Страница 155: ...selected each axis has a number of selectable tables of parameters which may be switched during machine operation By making the appropriate hardware selection the parameter tables may be selected on...

Страница 156: ...that is available Repeat this for each axis In this case Expansion coefficient 1 will be set for one material and Expansion coefficient 2 will be set for another etc 4 In operation the appropriate mat...

Страница 157: ...e two parameter tables are used to switch between two working positions on a machine Axes X1 X2 and Y use laser encoders and axes Z W and A use linear tape scales Workpiece compensation is used only o...

Страница 158: ...sition a different method of enabling workpiece compensation is to be used It is configured to enable workpiece compensation at the same point as the machine home reference position An offset is enter...

Страница 159: ...e used F 2 1 1 Saving the configuration It is advisable to save the finished configuration to a file that may be kept as a back up of the system configuration This may then be used in the event of a f...

Страница 160: ...on data is displayed in the configuration window If the contents of the file are correct press OK to overwrite the PC data If the contents are deemed incorrect press Cancel and the data will be discar...

Страница 161: ...PC communication port The default setting for the PC communication with the RCU10s is COM 1 If an alternative COM port is to be used this can be done as follows From the Tools menu select the Serial P...

Страница 162: ...ess level Select Configure Passwords from the Tools menu The following screen will appear Select the password to change and enter the new password into both fields Click OK when complete Make a note o...

Страница 163: ...he File menu RCU CS will return to the main log in screen allowing the user to select the access level required F 2 1 6 Rebooting the RCU By selecting Re boot RCU from the Tools menu the user may re s...

Страница 164: ...t the mode the unit s must start up into True will boot the RCU10 s into configuration mode False will boot the RCU10 s into compensation mode NOTE If any of the units have Inhibit Compensation Mode s...

Страница 165: ...The data is recorded at the rate at which it is received from the RCU10 network This is approximately 17 20 readings per second The number of records created depends upon the number of display screens...

Страница 166: ...he Data Log button on the button bar or select Data Log from the Tools menu Select Disabled from the drop down list Press Save to transfer the data log results to a file Define a file name for the dat...

Страница 167: ...s provided primarily for Renishaw diagnostics purposes To activate the error log it must be configured in the global system settings Ensure that the RCU10 network is in configuration mode Press the Co...

Страница 168: ...Select All to enable the logging of all errors Press OK to continue and transmit the configuration as normal Each individual unit will now log all errors during operation To access the error log selec...

Страница 169: ...d capability The screen will show a list of up to the last 32 errors logged in all the RCU10s in the network To look at individual errors double click the error to display the full details of that err...

Страница 170: ...n to call up the screen below Saving data The error log may be saved for records or analysis Select Save from the Log menu in the error log window This will allow the data to be stored in a delimited...

Страница 171: ...0x800 HS10 signal low warning 0x1000 Reserved 0x2000 Air temperature sensor failure 0x4000 Workpiece material temperature sensor failure 0x8000 Reserved 0x10000 UARTB error 0x20000 Air compensation fa...

Страница 172: ...Extended capability F 25 F 2 3 1 Error log descriptions The dialog below shows all the errors that can be recognised by the system...

Страница 173: ...nput Error The encoder is producing an error This also freezes the compensation process internal counters ERROR ERROR Gantry Axis Failure Not implemented Air Temp Snsr Failure Allocated air temperatur...

Страница 174: ...s active ERROR ERROR SMat Temp Snsr Failure Allocated material temperature sensor has failed All four encoder errors fail together when zoning is not available SUSPEND ERROR RTC and NVRAM Failure Real...

Страница 175: ...F 28 Extended capability This page is intentionally left blank...

Страница 176: ...ation terms G 3 G 1 2 Laser compensation G 5 G 1 2 1 Definition of position terms G 5 G 1 2 2 Definition of compensation terms G 6 G 2 Air refraction compensation G 9 G 3 Worked example laser compensa...

Страница 177: ...he axis encoder measured in m IQR20 Nominal encoder Input Quadrature Resolution at 20 C taken from encoder manufacturer s datasheet and expressed in m IQCer Input Quadrature Count since the encoder wa...

Страница 178: ...ds EO should be entered as a negative value if the axis would have to travel in a negative reverse direction to move from the encoder expansion point to the encoder s reference point e Encoder s linea...

Страница 179: ...piece expansion origin and the cutting tool tip or processing point when workpiece expansion compensation is going to be enabled WO is measured parallel to the axis of motion and expressed in metres W...

Страница 180: ...ength in air at 20 C 101 325 Pa 50 RH 450ppm CO2 expressed in nm Refer to section G 2 IQCer Input Quadrature Count since the laser encoder was referenced The input quadrature direction sense must be s...

Страница 181: ...a 50 RH 450ppm CO2 Refer to section G 2 Laser dead path wavelength compensation m LO 10 6 c r 1 This is the additional compensation for the effects of changes in the refractive index of air on the las...

Страница 182: ...o section G 2 r Laser wavelength in air at instant the laser encoder is referenced Refer to section G 2 The use of r instead of ntp ensures the axis doesn t jump as it is referenced Machine structure...

Страница 183: ...piece expansion origin and the cutting tool tip or processing point when workpiece expansion compensation is going to be enabled WO is measured parallel to the axis of motion and expressed in metres W...

Страница 184: ...is expressed in nm For dry air at a temperature of t C and a pressure of p Pa the refractivity ntp 1 is given by ntp 1 p ns 1 1 p 60 1 0 972 t x 10 10 96 095 43 1 0 003 661 t The refractivity of wate...

Страница 185: ...e the reference values from which all the other values have been derived by using the Edlen equations above to go from left to right in the table or by dividing by successive powers of two to go down...

Страница 186: ...axis at the axis reference position For simplicity of installation workpiece thermal expansion compensation is also enabled at this position Figure G 3 Worked example The text describes how the laser...

Страница 187: ...rse direction in order to move the tool tip from the point at which workpiece compensation is enabled to the workpiece expansion origin G 3 4 Machine structure thermal expansion compensation Tsc S The...

Страница 188: ...sed to measure how much the spindle moves relative to the table surface as the column temperature varies Note This test must be performed with the machine in closed loop mode holding a constant positi...

Страница 189: ...G 14 Reference This page is intentionally left blank...

Страница 190: ...ords H 1 Appendix H Test records Contained in this appendix H 1 Installation and configuration checklist H 2 H 2 Installation details H 3 H 3 Sensor record test sheet H 5 H 4 Parameter table record sh...

Страница 191: ...set up 4 1 2 Electrical installation 4 1 3 RCU CS settings 4 1 4 Configure system tab 4 2 1 Configure sensor tab 4 2 2 Configure compensation tab including all sub tabs for each axis 4 2 3 Configured...

Страница 192: ...type Encoder serial no RCU model RCU serial no Axis length example X1 RLE Ax1 H11092 RCU10 P H11802 1000 mm Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 No of parameter tables 1 2 3 4 Error indication E...

Страница 193: ...H 4 Test records This page is intentionally left blank Cut here Cut here...

Страница 194: ...Test records H 5 H 3 Sensor record test sheet Sensor type Serial number Location function Connected to RCU axis number Example Air temperature V12345 X axis laser 1 Air pressure Cut here Cut here...

Страница 195: ...H 6 Test records This page is intentionally left blank Cut here Cut here...

Страница 196: ...Axis Units select Air dead path 1 mm m inch Workpiece temperature sensor 1 Serial Workpiece expansion coefficient 1 ppm C ppm F Workpiece origin offset mm m inch Actuation method Structure thermal com...

Страница 197: ...Air dead path 2 mm m inch Workpiece temperature sensor 2 Serial Workpiece expansion coefficient 2 ppm C ppm F Workpiece origin offset mm m inch Actuation method Structure thermal compensation tempera...

Страница 198: ...Air dead path 3 mm m inch Workpiece temperature sensor 3 Serial Workpiece expansion coefficient 3 ppm C ppm F Workpiece origin offset mm m inch Actuation method Structure thermal compensation tempera...

Страница 199: ...Air dead path 4 mm m inch Workpiece temperature sensor 4 Serial Workpiece expansion coefficient 4 ppm C ppm F Workpiece origin offset mm m inch Actuation method Structure thermal compensation tempera...

Страница 200: ...gure D 11 D 21 Axis referencing sequence using extended error lines Error Suspend and Warning Figure F 1 F 4 Button bar Figure C 8 C 10 Compensation axis screen Figure D 2 D 8 Compensation system scre...

Страница 201: ...re 1 1 1 2 Reference mark actuator connection Figure 2 6 2 7 RS422 differential line driver outputs Figure 2 1 2 2 Sensor data screen Figure D 3 D 9 Sensor data screen sensor information Table D 8 D 1...

Страница 202: ...n under Edge Gloucestershire GL12 8JR United Kingdom T 44 0 1453 524524 F 44 0 1453 524901 E uk renishaw com www renishaw com For worldwide contact details please visit our main website at www renisha...

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