Jupiter Motion Drive

Transcription

1 Jupiter Motion Drive Model JMD-FS Manual for Fly-SYNC Application

2 Revision notes: Revision Date Modification V2.0 Mar. 20 Add revision notes V2.0 Mar. 20 Add figure, show Trigger & DI-9 for Fly-CATCH V2.0 Add figure, show Trigger without DI-9 for Fly-Shear V2.0 Mar.24 Change name, of Pr.483 & Pr.484 Change description of Pr.308 & Pr.310 Add Pr.412 Add Pr.431 & Pr.432

3 Contents: 1. Introduction 1.1 Typical Fly-Shear description Typical mechanical structure Typical Fly-Shear curve Phases of the Fly-Shear operation Pre-Starting-Length calculation 1.2 Generalized Fly-SYNC description Typical Fly-SYNC curve Ramp time of Fly-SYNC curve Maximum Travel Length SP2P functions after Fly-SYNC FLY-SHEAR then go-home FLY-CATCH then STOP FLY-CATCH then Go to Point-X (Absolute mode) FLY-CATCH then Go to Point-X (Increment mode) 2. Additional Features 3. Parameters 4. Special Input & Output functions 4.1 Special Input DIx () for Fly-SYNC 4.2 Special Output DOx () for Fly-SYNC 5. Examples 5.1 Fly-Cut for plastic cosmetic tube 5.2 Fly-Shear for Card Board Tube cutting application 5.3 Fly-Catch from a moving Golf-Painting line (Fly Loading/Unloading) 5.4 Intermittent Label print application

4 1. Introduction This document describes the embedded Fly-SYNC (model JMD-FS) function of Jupiter servo controller/drive unit. The Fly-SYNC motion function is actually a single axis, automatic motion profile generator, which was specially designed and embedded into the Jupiter servo drive unit. This functional block is dedicated for all applications that involve the servo system concerning Linear-Synchronal motion control on the Fly. Unlike conventional stand-alone motion controllers that generate single Vcmd *1 (or Pcmd *2 ) to command the servo motor drive unit, the Jupiter s embedded Fly-SYNC function block will generate all Pcmd, Vcmd and Acmd *3 commands simultaneously in order to enhance the dynamic response of the servo control loop. The description starts from the general Fly-Shear application and extend to generalized concept of the Jupiter s Fly-SYNC functional block. Assuming that the users are already familiar with the operation of SP2P *4 function embedded in Jupiter servo drive, only Fly-SYNC related parameters and I/O functions are described. At the end of this document, some applications are included, in order to provide best comprehensive examples for our faithful customers. Notes: *1: Vcmd = Velocity command *2: Pcmd = Position command *3: Acmd = Acceleration command *4: SP2P stands for Smart Point-to-Point function

5 1.1 Description of a typical Fly-Shear system Typical mechanical structure Fly-Cut, Fly-Shear, Fly-Saw or Fly-Catch, customers may choose different names for different applications, If the servo motor controls the mechanism in linear motion (not Rotary), then, it means the same control philosophy. Here, for simplicity, we use the name Fly-Shear as the discussion topic. The following figure is a simplified machine structure of Fly-Shear application for a Non-Stop pipe production line. The machine is designed for cutting the pipe on the fly. Typical machine structure of a Fly Shear The machine is composed of the following components: Cut/Shear Mechanism to cut or shear the material into desired length. Under standby mode, the Cutter is located at its upper position in order to allow the Carriage move freely without intervention. Only when the Carriage speed is synchronized with the input material (SYNC status=1), the Cutter may execute Cutting operation. After Cutting operation completes, this mechanism will issue a CUT-End signal to Jupiter servo controller. Carriage and Ball Screw Carriage is driven by a ball screw is a moving platform used to carry and guide the Cut/Shear mechanics into linear motion along with the production line. Prior to start the Fly-Shear operation, the Carriage may execute Home-Search and Home-Shift (both are SP2P embedded functions) operation in order to meet different production requirements. In addition, limit switches at both end should be considered in order to prevent the accidentally over travel condition. The Carriage s maximum travel distance is an important message. This

6 message is recorded at the end of each cutting cycle by the Jupiter controller. Measure Roll with Encoder The Encoder output signal (designated as X/Y clock pulse) is fed to Jupiter servo controller for measuring the Line-speed and Input-length of the material in production line. Servo Motor The motor is Powered by Jupiter servo controller to drive the Ball Screw Jupiter Servo controller The servo controller Jupiter JMD-FS Drive is embedded with Fly-SYNC function specially designed for this application. Other control elements, like HMI, PLC, etc Typical Fly-Shear curve The following picture captured by Soft-Scope is a typical waveform that shows a complete Fly-Shear system s operation cycle. Descriptions of the typical Fly-Shear Speed & Status curves: Analog trace -1: Red line stands for servo motor speed in rpm, designated as RPM(A/B). Analog trace -2: Green line stands for the material s production line speed in rpm, which is designated as RPM (X/Y). Though line speed should be expressed in Meter/Minute, however, for the convenience of direct comparison, the line speed in Soft-Scope is normalized to equivalent rpm with respect to the servo motor speed. There is a coefficient parameter for converting the input X/Y clock pulses into length that can be expressed in Metric number: Pr.308 INPUT side PPM (Pulses Per Meter) And, another coefficient parameter for converting the Metric-length into equivalent A/B clock pulses of the servo motor: Pr.310 MOTOR side PPM (Pulses Per Meter) By use of the above two coefficients, the Line-Speed signal captured from Measuring-Roll-Encoder is then easily normalized to RPM(X/Y) for direct

7 comparison with the speed of servo motor RPM(A/B). Analog trace -3: Blue line represents the servo motor s Position-Feedback, in clock pulses. Analog trace -4: Black line stands for Position-Tracking-Error, which is a measure of deviation between Position-Feedback and Theoretical Position-Command (not shown). Digital trace -1: In this example, SYNC status output is assigned to DO-04 of Jupiter controller. When SYNC status is high, means the linear speed of the carriage driven by servo motor is now synchronizing with the line speed of incoming material. During the SYNC period, the Cutter mechanism can be actuated to start the Cutting process. This is called Cutting-On-the-Fly, because the cutting process does not need to stop the material which is flying on the production line. Digital trace -2: In this example, DI-02 is assigned as the function SYNC-Exit (Cut-End). The SYNC-Exit signal is used to terminate the SYNC period. This figure shows the SYNC period extends 200ms before it was terminated by SYNC-Exit from DI-02 input. Note: For how long the SYNC period should extend is actually determined by the material characteristic and the Cutter mechanism itself. It should be guaranteed that, after the end of cutting process, the Cutting mechanism must issue a SYNC-Exit signal to Jupiter controller, in order to terminate the SYNC period and to stop the servo motor.

8 1.1.3 Phases of the Fly-Shear operation Home search operation must be executed prior to start the Fly-Shear Operational. It is a standard operation of SP2P, which will not be discussed here. Following describes the typical Fly-Shear phases: Phase I: Standby phase The Jupiter monitors the input Line-Speed, and counts total input X/Y clock pulses. When total input length is far less than Desired Cut-Off Length, the servo motor must remain at its home position. RPM (X/Y) = 600 rpm, From beginning to the end, the measured line speed is maintained at 600 rpm indicating a Non-Stop production line is in production. RPM (A/B) = 0 rpm, Servo motor is standby at desired Home position. Position-Feedback = 0 pulses, Servo motor is standby at desired Home position. Position-Error = 0 pulses, No deviation with respect to theoretical desired position Phase II: Servo Motor ramp up The Jupiter continues to monitor the input Line-Speed, and counts total input X/Y clock pulses. When Desired Cut-Off Length is almost reached *1 (or IMCUT *2 is requested), the Jupiter will command the motor to ramp up toward the line speed RPM(X/Y). RPM (X/Y) = 600 rpm, RPM (A/B) = 0~600 rpm, According to S-curved Ramp Time setting (Pr.412), the Servo motor ramps up toward the measured line speed RPM (X/Y). In this example, RPM(X/Y)=600rpm and Pr.412=200ms/Krpm, then, Time of Phase II equals to 120ms = 600rpm * 200ms/Krpm. Position-Feedback = 0 ~ Pre-Starting-Length (6000 pulses in this example), At the end of the acceleration period of Phase-II, servo motor will reach the measured line speed, and in the mean time, the travel length equals to the Pre-Starting-Length, which in this example, equals to 6000 pulses. 6000(pulses) = 10000(pulses/rev) * 600rpm * 120ms / 2 Note: the motor encoder =10000 pulses per rotation Position-Error = error pulses during acceleration, Though the position error in this phase is not so important, however, control to keep the error small will help minimize the error when entering to Phase-III. *1: Almost Reached Depending on the measured line speed RPM (X/Y) and the desired Ramp-Rate, the Jupiter calculates on real-time basis to find a best Pre-Starting-Length. This Pre-Starting-Length is necessary in order to guarantee the perfect and smooth match for both Speed and Position Synchronicity Refer to section *2: IMCUT It stands for Immediate-Cut-off, or called Waste-Cut-off. It means the operator

9 demand to cut off the material immediately despite the desired length is reached or not. Usually, this command will be issued at the beginning of the Fly-Shear operation, or a material defect is detected. Phase III: Synchronal period The Jupiter continues to monitor the input Line-Speed, and counts total input X/Y clock pulses. Within this period, the Carriage speed and position is in perfect synchronicity with the input material. RPM (X/Y) = 600 rpm, RPM (A/B) = RPM(X/Y) = 600 rpm, Position-Feedback = (Total Input-Length) (Desired Cut-Off Length) Note: not considering the tracking error Position-Error = measured error pulses during synchronizing period, Through the use of Soft-Scope, the actual controllable error can be easily monitored and verified. Modify the parameters in PID block, user can minimize the tracking error in order to get best performance and accuracy of the Fly-Shear system. SYNC status digital output User must select a digital output port and assign it to serve as SYNC status output function. During this phase, SYNC output always true during this phase. This signal is used to enable the cutting mechanism to start cutting process. In this example, for convenience, the time tag reference is set at the starting point of SYNC output signal. The SYNC period continues for 200ms, until the SYNC-Exit signal triggers the Jupiter controller. SYNC-Exit digital input User must select a digital input port and assign it to serve as SYNC-Exit input function. In this phase, unless the SYNC-Exit signal triggers the Jupiter controller, the system will stay in SYNC status indefinitely. In general, the SYNC-Exit signal is generated from the cutting mechanism after the cutting process was completed. Within practical limitation, the SYNC-Exit should be generated as fast as possible. Because the Carriage s travel distance can be minimized, results to the reduction of the machine size and system cost. The travel length of the Carriage during SYNC period (Phase-III) can be calculated directly and intuitively, Travel Length in Phase-III = RPM (A/B) * (SYNC time) * (Pulses/rev) In this example, that is 10(rev/sec) * 200(ms) * = pulses In addition to the length already traveled in Phase-II, the total travel distance at the end of phase-iii equals to = pulses. Please check this out from the example curves shown above. Phase IV: End of Synchronal period, ramp down to stop The ramp down curve always follows the predefined Ramp Rate parameter defined in Pr.412. RPM (X/Y) = 600 rpm, RPM (A/B) = 600 rpm ramp down to stop

10 The Travel Length during Phase-IV is similar to Phase-II. In this case, it is 6000 pulses. Then, it is easy to verify the Position-Feedback at the end of Phase-IV equals to = pulses. The Carriage s Maximum Travel Distance is defined to be the position at the end of Phase-IV. This value is recorded and updated for each Fly-Shear cycle. Again, please check this out from the example curves shown above. Phase V: Servo Return to Home/Standby Point (typical SP2P function) After the servo motor had ramped down to completely stop, the Jupiter drive will record the Maximum Travel Distance for future reference, and in the mean time, this distance is immediately used as the command data length for executing Smart-Point-to-Point return to Home Position. From the example curves shown above, please confirm the Position-Feedback is zero at the end of Phase-V. After the servo motor returns to its Home Position, a full Fly-Shear cycle is completed; Then, control phase will jump to Standby phase, ready to start again. Note: Four selectable profiles can be selected for the SP2P s go back home operation. Each selected profile is characterized by four parameters: Ramp up & Ramp-Down rate, expressed in ms/krpm S-curve time in ms Peak Speed Desired Travel Length Bear in mind that the Ramp-Rates (Pr.358/362/366/370) defined for SP2P are different from the Ramp-Rate (Pr.412) defined for Fly-Shear. Refer to detailed description of Smart-Point-to-Point application.

11 1.1.4 Pre-Starting-Length calculation By simple physics, the travel length of fixed rate acceleration objects is Length = End-Velocity * Ramp-Time / 2 In Jupiter s definition, Pr.412 is defined as Ramp Rate, expressed in ms/krpm, which must be described as The time required to accelerate the motor from 0 to 1000rpm, or The time required to decelerate the motor from 1000rpm to stop. In our example, the End-Velocity is 600rpm; and the Ramp Rate = 200ms/Krpm. Therefore, we can calculate: The actual Ramp-Time = 600rpm * 200ms/Krpm = 120ms The Travel Length = 600rpm * 120ms /2 = 10rps * 0.12s = 0.6 rev As the motor encoder used in this example is 10000pulses/rev, Then the Travel Length in Phase-II and Phase-IV = 0.6*10000 = 6000pulses

12 1.2 Generalized Fly-SYNC description The generalized Fly-SYNC operation is also composed of two independent operations: SYNC function Phase-I: Standby Same as standard Fly-Shear Phase-II: Ramp Up Discuss the factors that affects the Ramp Up curve Phase-III: SYNC period Discuss different waveform that is affected by the SYNC period Phase-IV: Ramp Down Discuss the factors that affects the Ramp down curve SP2P function,(choose different P2P functions after the Fly-SYNC operation. SYNC then Go-Home (=Fly-Shear) SYNC then STOP May accept next Fly-SYNC cycle. SYNC then Go to Point-X (Absolute mode) SYNC then Go to Point-X (Incremental mode)

13 1.2.1 Typical Fly-SYNC curve The following figure captured by Soft-Scope is a basic Fly-SYNC operational curves. In this curve, the Phase-II period is initiated by a Catch (or Mark) sensor that triggers the dedicated input port DI-09. *1 *1: Compare the difference that the Phase-II of standard Fly-Shear is automatically initiated by the Pre-Starting-Length is reached (section & 1.1.4), and the ramp time in Phase-II & Phase-IV are the same Ramp up time of Fly-SYNC curve In addition, another difference is the ramp up time of Phase-II. In this case, it is affected by Pr.408, Catch-Trigger Position (mm). This parameter defines that when DI-09 is triggered, the Carriage speed will start ramp up toward RPM(X/Y) immediately; and, will catch up the coming point (of material) specified by the Pr.408. The following figures shows the ramp up time is shortened when Pr.408 changes from 200mm to 50mm. Next figure shows the ramp up time is also affected by different Line-Speed RPM(X/Y). In this example, Pr.408=200mm, RPM(X/Y) changes from 600rpm to 300rpm.

14 Also note from the above figures, the ramp down time of Phase-IV changes according to the Line Speed of the production line Maximum Travel Length Here is another figure for showing the effect of Phase-III. The time in SYNC period is extended from 200ms to 250ms. Review again, from the all above figures, it shows the Maximum Travel Length of Carriage is affected by Phase-II, Phase-III, Phase IV, and RPM(X/Y) the Line speed. In brief, the Maximum Travel Length can be calculated by: = RPM(X/Y) * ( T-III + ( T-II + T-IV )/2 ) * (Pulses/rev)

15 1.2.4 SP2P functions after Fly-SYNC The Fly-SYNC is also named as Fly-CATCH/Fly-SHEAR in Servo-Win. The Fly-SYNC can be viewed as special operation modes of the Smart Point to Point application. After user selects a Point-X (by assigned digital inputs), the Jupiter will check the mode parameters (Pr.388~Pr.403), then, selected operation will be initiated. Possible operations are: FLY-SHEAR then go home FLY-CATCH then STOP FLY-CATCH then Go to Point-X (Absolute mode) FLY-CATCH then Go to Point-X (Increment mode) FLY-SHEAR then go home In this mode, the length value set in parameters Pr.274~Pr.304 are considered as the Desired Cut Off Length. Refer to section 1.1 for Detail operation is described in previous sections FLY-CATCH then STOP In this mode, the length value set in parameter Pr.274~Pr.304 is ignored. After the Fly-SYNC operation completes, the Jupiter controller will terminate the process and ready to accept next SP2P process. Refer to the figures shown in section 1.2.1

16 FLY-CATCH then Go to Point-X (Absolute mode) In this mode, the length value set in parameter Pr.274~Pr.304 represents an absolute target Point-X. When Fly-SYNC was initiated, the Jupiter controller will memorize all the information for the selected Point-X, then, execute Fly-SYNC operation similar to the Fly-CATCH then STOP operation described in After the first part of Fly-SYNC (then STOP) operation has been completed; the Jupiter controller will recall all the memorized information of Point-X, and issue the second part SP2P command. Though the target position of Point-X is known, however, the STOP Point (Maximum-Travel-Length) is randomly unknown. Therefore the Travel-Length for second part SP2P must be calculated by: Desired-Travel-Length = (Selected Point-X) (Maximum-Travel-Length) If the STOP point is less than the desired Point-X, then, the motor continues to go forward in second part of SP2P. Else, if the STOP point exceeds the desired Point-X, then, the motor will move backward automatically. The following figures show the differences. Basic settings are: Pr.310= pulses/meter Pr.388=3, Pr.274=300mm Fly-Catch then Go to Point-300mm (Absolute mode) From the left side curve, the SYNC period is 200ms, STOP point is less than 300mm. Therefore, the motor continues to go forward. From the right hand side curve, the SYNC period is 220ms, STOP point exceeds 300mm. Therefore, the motor go backward automatically FLY-CATCH then Go to Point-X (Increment mode) The operation is very similar to the Go to Point-X (Absolute Mode). Only one extra process is added before the Fly-CATCH process starts. The extra process is : Assign present position as HOME position After the HOME position is reassigned, the following operations are exactly the same as described in section

17 2. Additional Features The JMD-FS model of Jupiter servo drive unit itself includes all the functions described above. Without the need of complex programming for conventional Motion controller plus PLC and servo drive, Only with these embedded functions in Jupiter drive, the system engineers can easily achieve the sophisticated Fly-SYNC control system. Benefit highlights for the Jupiter JMD-FS drive: Employ the use of delicacy Servo-Win software, Powerful Soft-Scope with real-time 0.1ms high resolution Dual 32bits DSP (TI 2812) master and co-processor design Auto unit conversion function, setting/reading data by metric number High Resolution up to um 10Khz (100us) sampling & calculation interval for Pcmd, Vcmd and Acmd loop Up to 1-Mhz, isolated High Speed input clock rate Versatile Fly-Shear mode, Fixed-Length, DIx-Immediate, or Catch/Mark Trigger Direct Compatibility with SP2P functions. Home Search Home DOG Go to Point-X Incremental Mode Go to Point-X Absolute mode Multiple Mode Mixture Up to sixteen programmable Point-X Multiple velocity profiles selectable Embedded Simulation function, allows stand-alone pre-testing On-Line fine adjustment for perfect synchronicity. Enhanced monitoring functions Protection functions

18 3. Parameters In this chapter, only those parameters which relate to the Fly-SYNC function will be discussed. 3.1 Home Parameters Pr.269 Search HOME Mode select R/W Word By DIx(32), the Jupiter can control the servo to search a dedicated point as future HOME reference. When necessary, DIx(33) is used as DOG Switch input port. This parameter choose one among varieties of selections: Pr.270 HOME Offset R/W Word 0 mm This parameter can define an Offset Position after DOG Switch is searched. 3.2 Fly-CATCH Parameters Pr.408 CATCH Trigger Position R/W LWord 50 mm 0 max This parameter is used together with a CATCH sensor. The sensor signal must connect to the dedicated input port DI-09. Usually, set this parameter equals to the distance between HOME & the sensor.

19 3.3 Point-X Description Parameters Complete SP2P motion operation includes Operation mode Target position or length or distance Velocity Profile Speed Limit Ramp rate S-Curve Pr.388 Pr.389 Operation Mode Select for Point-0 (POSxSW=0000) Operation Mode Select for Point-1 (POSxSW=0001) Pr.388~Pr.403, Operation Mode Select for Point-0~15 (POSxSW=0000~1111) Pr.402 Pr.403 Operation Mode Select for Point-14 (POSxSW=1110) Operation Mode Select for Point-15 (POSxSW=1111) R/W Word For any Point-X, choose an equivalent parameter for defining the Fly-Shear or Fly-Catch mode = 2, Fly-CATCH then STOP = 3, Fly-CATCH then Go-to-Point-X, Absolute mode = 4, Fly-CATCH then Go-to-Point-X, Incremental mode = 8, Fly-SHEAR then Go-to-HOME position = other Smart-Point-to-Point function Pr.274 Pr.276 Position/Length/Distance Set-0 (POSxSW=0000) Position/Length/Distance Set-1 (POSxSW=0001) Pr.274~Pr.304, Position/Length/Distance Set-0~15 (POSxSW=0000~1111) Pr.303 Pr.304 Position/Length/Distance Set-14 (POSxSW=1110) Position/Length/Distance Set-15 (POSxSW=1111) R/W LWord 0 mm -Max +Max

20 These are long-word parameters used to define a desired target before initiating the SP2P function When used in absolute position mode, this parameter stands for the target position. When used in incremental mode, this parameter stands for the relative length or distance. Pr.372 Pr.373 Profile Select for Point-0 (POSxSW=0000) Profile Select for Point-1 (POSxSW=0001) Pr.372~Pr.387, Profile Select for Point-0~15 (POSxSW=0000~1111) Pr.386 Pr.387 Profile Select for Point-14 (POSxSW=1110) Profile Select for Point-15 (POSxSW=1111) R/W Word For any Point-X, choose an equivalent parameter for defining the velocity profile. Four selections are allowed: =0, Profile-A, defined by Pr.357~359 =1, Profile-B, defined by Pr.361~363 =2, Profile-C, defined by Pr.365~367 =3, Profile-D, defined by Pr.369~371

21 3.4 Conversion Parameters Pr.308 INPUT side PPM (Clock Pulses Per Meter) R/W LWord Cks/Meter 0 max This parameter is used to define the resolution of the input encoder. Only for Fly-Shear or Fly-SYNC operation. Not used in general SP2P. Pr.310 MOTOR side PPM (Clock Pulses Per Meter) R/W Lword Cks/Meter 0 max This parameter is defines the resolution of the motor encoder. Used to convert metric length unit into motor pulse counts. 3.5 Simulation Parameters Pr.312 INPUT Line-Speed Simulation Set R/W Word 0 Meter/min This parameter is used for simulation purpose. Controlled by DIx(84) or DIx(85), the setting value can be used as virtual Line Speed input for simulation Pr.414 Delay-Time for Fly-SYNC Timer R/W Word 100 ms A special On-Delay-Timer is designed for the Fly-SYNC function. This timer will be enabled when the SYNC status =1. This parameter is used to set the Delay-Time period. When the SYNC Status=1, DOx(64): CATCH-SYNC =1 immediately, and the Delay-Timer starts, after the set Delay-Time, the DOx(65): SYNC-Delay =1, This Delay-Timer is useful, especially in simulation mode. It can be used to simulate the SYNC-Exit (or Cut-End) input.

22 3.6 SP2P Profile Parameters Pr.357 Pr.361 Pr.365 Pr.369 Profile-A, Top Speed Setting Profile-B, Top Speed Setting Profile-C, Top Speed Setting Profile-D, Top Speed Setting R/W Word 0 rpm When generating velocity profile, this parameter is used as a limit of maximum possible speed. Pr.358 Pr.362 Pr.366 Pr.370 Profile-A, Acc/Dec Ramp Rate Profile-B, Acc/Dec Ramp Rate Profile-C, Acc/Dec Ramp Rate Profile-D, Acc/Dec Ramp Rate R/W Word 10 ms/krpm When generating velocity profile, this parameter is used to define the ramp rate. Pr.359 Pr.363 Pr.367 Pr.371 Profile-A, S-Curve Time Profile-B, S-Curve Time Profile-C, S-Curve Time Profile-D, S-Curve Time R/W Word 1 ms When generating velocity profile, this parameter is used to define the S-Curve for minimizing the jerk.

23 3.7 Protection Parameters Pr.404 Travel Limit in Forward direction R/W LWord mm -max +max This parameter is used to define the travel limit in forward direction. The position/length set value is defined with reference to HOME position. When position exceeds this limit, a DOx(66) function (OVER_TRAVEL) may be assigned to serve as a warning signal. Pr.406 Travel Limit in Reverse direction R/W LWord mm -max +max This parameter is used to define the travel limit in reverse direction. The position/length set value is defined with reference to HOME position. When position exceeds this limit, a DOx(66) function (OVER_TRAVEL) may be assigned to serve as a warning signal.

24 3.8 Monitoring Parameters Pr.411 Calculated Productivity for Monitoring M Word 0 SPM 0 max This parameter is used to show the productivity of the production line expressed in SPM (Sheet Per Minute). SPM = (Line-Speed) / (Desired-Cut-Off-Length) Pr.416 Machine (Carriage) Position M Lword 0 mm 0 max This parameter shows the actual position of the machine with respect to HOME position. Pr.418 Actual Cut-Off-Length M Lword 0 mm 0 max This parameter shows the actual Cut-Off-Length of this Fly-Shear cycle. Pr.434 Monitor Input Feed-Length M Lword 0 mm 0 max This parameter shows input Feed-Length. Pr.438 Maximum Travel Distance, Sync-Then-Stop position M Lword 0 mm 0 max For each Fly-SYNC cycle, this parameter records the position of SYNC-Then-STOP point, which is equal to the Maximum-Travel-Distance of this cycle..

25 3.9 Auto Calibration Parameters Pr.483 Fly-Sync Tracking-Error (measured), for Fly-Shear Auto-Calibration R/W Word 0 mm Pr.483 and Pr.484 are specially designed for Auto-Calibration purpose. Pr.483 is used to set the Delta-Error-Length after Fly-Shear cycle. It is used in cooperative with a digital input function DIx(141)=Input-PPM Update. In case when synchronal error occurs, this function allows the user to modify the Pr.308 on line. First, observe the result of the Cut-Off-Product, 1. Set Delta-Length-Error in Pr.483, and 2. Set Full-Length-Reference in Pr.484, Then, activate DIx(141), Jupiter controller will calculate a new value for Pr.308, and modify Pr.308 automatically. In this way, the Synchronicity can be kept easily without stopping the production line. Note: The modification value in Pr.308 is not stored in EAROM. Pr.308 will be restored to its original value after next power on. Pr.483 is stored in non-volatile RAM memory. And, Pr.483 will be cleared to zero after modification completed. The modification factor = Pr.483/Pr.484 Pr.484 Fly-Sync Tracking-Range (setting), for Fly-Shear Auto-Calibration R/W LWord 1000 mm 0 max Pr.483 and Pr.484 are specially designed for Auto-Calibration purpose. Pr.484 is used to set the Full-Length-Referenc. This is used in cooperative with a digital input function DIx(141)=Input-PPM Update. In case when synchronal error occurs, this function allows the user to modify the Pr.308 on line. Refer to Pr.483 for further discussion.

26 4 Special Digital Input & Output Functions In this chapter, only those Fly-SYNC related I/O functions are discussed. 4.1 Digital Input Functions Function no. DI-09(4) DIx(5) Fly-Catch Trigger/Sensor Input Description Refer to Pr.408. This function is effective only for input port DI-09. Do not set this function to other input ports. Fly-SYNC Exit (or CUT-End) Request Jupiter controller exit the SYNC mode. DIx(17/16/15/14) POSxSW(3/2/1/0), These four inputs are combined to select Point-X, where X=0~15 DIx(18) DIx(30) DIx(31) DIx(32) DIx(33) DIx(84) DIx(85) DIx(102) DIx(140) DIx(141) SP2P Trigger Used to initiate the SP2P function for Point-X JOG Forward (for SP2P mode) JOG Reverse (for SP2P mode) HOME Search Start HOME DOG Switch Master Clock of Line Speed Control Input (Type-1) ON : Line-Speed is measured from X/Y input clocks OFF : Line-Speed is Simulated by Pr.312 setting Do not assign DIx(84) when DIx(85) was chosen already. Master Clock of Line Speed Control Input (Type-2) ON : Line-Speed is Simulated by Pr.312 setting OFF : Line-Speed is measured from X/Y input clocks Do not assign DIx(85) when DIx(84) was chosen already. SERVO-ON IMCUT, Immediate-CUT or Waste-CUT Update/Modify Pr.308 (Auto-Calibration the Input-side-PPM)

27 4.2 Digital Input Functions Function no. DOx(62) DOx(64) DOx(65) DOx(66) DOx(67) DOx(32) SP2P RUNNING Status Description Indicating the SP2P function is in execution SYNC Status Indicating the system is in synchronization. Catch-Delay-Timer Output SYNC Time exceeds Pr.414 OVER-TRAVEL Indicating the running motor had exceeded the Travel-Limits. Refer to Pr.404 * Pr.406 SP2P READY Status Indicating previous SP2P function is completed, Ready for accepting next SP2P cycle. HOME Search OK Indicating the Home Search function has completed

28 5. EXAMPLES 5.1 Fly-Cut for plastic cosmetic tube The machine shown in Figure 5.2a is a High-Speed Cosmetic tube Cut-Off machine. There will be an Plastic-Tube-Extruder machine installed at right hand side of the Cut-Off assembly. In the center-right of the picture, it is Tractor-Unit used to pull the tube into the Cutter-Mechanism located at center-left. In the mean time, the Line-Speed is measured by an encoder mounted on the tractor. The Cutter-Mechanism shown in the picture, includes Shearing Cutter Blade Induction motor for turning the Cutter blade Carriage (on the slide guide) for carrying both The Cutter-Mechanism is driven by Ball Screw and Servo motor underneath the table. And of cause, there exists a Jupiter motion drive JMD-FS installed for governing the control of the whole Fly-Shear system control. Fig. 5.1a Fig. 5.1b Figure 5.2b is a typical curve captured by field engineer while testing the machine. In the curve, it shows: Speed command Speed response Current consumption Tracking Error Using the powerful analytical tool, the system engineer can easily identify the problem and solve it efficiently.

29 5.2 Fly-Shear for Card Board Tube cutting application Figure 5.2a is taken from the front end of the Spiral-Wound Card board Tube. At the end of the card board tube production line, a Fly-Shear Cutting-Mechanism is absolute necessary to cut the tube into small pieces each with precise length. Though the Cutting-mechanism is different, the basic control algorithm is similar to that described in section 5.1 for plastic tube. Figure 5.2b shows the finished product. Fig. 5.2a Fig. 5.2b For this application, it involves the following functions: HOME Search (only once after Power-On) Standby Fly-Shear to Measured-Length ( for shorter length about 2 Meters) or, Fly-Catch/Mark Shear ( for longer tube about 10 Meters) or, IMCUT (=Waste-Cut) when defected-tube is detected Go back to Home Position and standby Moreover, easiest Auto-Calibration function is readily designed, enabling the operator to on-line calibrate the system s Synchronicity.

30 5.3 Fly-Catch from a moving Golf-Painting line (Fly Loading/Unloading) The following figures are taken from an advanced Golf-Ball Painting line. Fig. 5.3a Fig. 5.3b Fig. 5.3c Fig. 5.3d Fig, 5.3a shows the Loading/Unloading Station using the embedded Fly-Catch function. Fig. 5.3b is the HOME position of the Catcher-Mechanism. Fig. 5.3c is the target position (Point-X) to unload the Golf-Ball. Fig. 5.3d shows the Catching on the Fly operation. This application involves: 1. HOME Search (only once after Power-On) 2. Standby 3. Fly-Catch then Stop 4. Go to Point-X 5. Go to Home Position, (then jump to standby mode)

31 5.4 Intermittent Label print application Figure 5.4.a is a typical Intermittent Label Print machine. Its print roll has a fixed diameter, however, the desired label length (print area) is usually smaller than the roller circumference (refer to fig. 5.4.b). Fig. 5.4.a Fig. 5.4.b In this kind of application, we can use Fly-SYNC then Go to Point-X incremental Mode. The curve shown below. The SYNC area = Print Area = SYNC time * Line-Speed (RPM(X/Y)) Total Area under RPM(X/Y) equals Print-Roll Circumference. Area under Vcmd equals to Label Pitch (including Label gap) Note the Forward/Backward operation.