PAC Motions MULTI-AXIS MOTION CONTROLLER USER MANUAL

GFK-2448F PACMotion Multi-axis Motion Controller User’s Manual

The PACMotion Multi-axis Motion Controller (PMM) is a high performance, easyto-use servo motion control module that is closely integrated with the
PACSystems RX3i CPU’s logic solving and communications functions. This versatilemotion controller combines the benefits of highly integrated motion and machine
logic with the performance, flexibility and scalability required for advanced machine automation. The open programming environment simplifies motion and
machine logic synchronization without sacrificing real time performance required for high-speed motion applications.
The built-in faceplate I/O of the PMM supports applications with lower I/O counts,while the optional Fiber Terminal Block I/O (FTB) supports larger applications with
extensive distributed user-configurable digital and analog I/O.This chapter provides an overview of PMM and FTB features.

Contents
Section 1: Introduction ………………………………………………..1
1.1 Revisions in this Manual……………………………………………………………………………1
1.2 PACSystems Documentation…………………………………………………………………….2
1.2.1 PACSystems Manuals………………………………………………………………………2
1.2.2 RX3i Manuals…………………………………………………………………………………..2
1.2.3 RX3i Motion Information…………………………………………………………………2
1.2.4 Servo Manuals…………………………………………………………………………………2
1.3 PACMotion Multi-Axis Motion Controller…………………………………………………..3
1.3.1 Servo Types Supported……………………………………………………………………3
1.3.2 PMM335 Features……………………………………………………………………………3
1.3.3 Performance to Improve Machine Productivity……………………………….4
1.3.4 Open and Integrated to Improve Engineering Productivity…………….4
1.3.5 Flexibility and Scalability………………………………………………………………….5
1.4 Fiber Terminal Block I/O……………………………………………………………………………5
1.4.1 FTB Features……………………………………………………………………………………5
1.5 i, HVi, and αHVi Series FSSB Servos ……………………………………………………….6
1.5.1 is and HVis Series Servo Motors…………………………………………………..7
1.5.2 i Series Digital Amplifiers……………………………………………………………….7
1.5.3 HVi and HVis Series Servo Motors……………………………………………….7
1.5.4 HVi and HVis Series Servo Amplifiers…………………………………………..8
Section 2: Getting Started…………………………………………….9
2.1 Motion System Overview ………………………………………………………………………..10
2.1.1 PACMotion Programming – PAC Machine Edition ………………………….10
2.1.2 PMM/RX3i Interface ………………………………………………………………………11
2.1.3 Fiber Terminal Block I/O………………………………………………………………..11
2.1.4 Servo Amplifier and Machine Interfaces………………………………………..13
2.1.5 Human-Machine Interfaces …………………………………………………………..13
2.2 Basic Installation …………………………………………………………………………………….14
2.2.1 PMM Installation……………………………………………………………………………14
2.2.2 FTB Installation ……………………………………………………………………………..17
2.3 Basic Configuration…………………………………………………………………………………22
2.3.1 Connecting the Programmer to the RX3i……………………………………….22
2.3.2 Adding a Motion Controller Module to the Hardware Configuration23
2.3.3 Configuring PMM Settings…………………………………………………………….25
2.3.4 Configuring PMM I/O…………………………………………………………………….26
2.3.5 Configuring Axis Parameters…………………………………………………………27
2.3.6 Motor Type Codes …………………………………………………………………………28
2.3.7 Downloading the Configuration to the RX3i ………………………………….29
2.4 Basic Motion Example – Jogging an Axis …………………………………………………30
2.4.1 Hardware Configuration (HWC)……………………………………………………..30
2.4.2 Terminals Tab………………………………………………………………………………..30
2.5 Using the Synthetic Motor ………………………………………………………………………33
2.6 Axis Power-up and Feedback Device Initialization…………………………………..34
2.7 Basic Motion Example – Axis Initialization ………………………………………………34
2.7.1 Hardware Configuration (HWC)……………………………………………………..34
Section 3: I/O Wiring, Connections and LED Operation ..38
3.1 PMM Faceplate I/O………………………………………………………………………………….38
3.1.1 PMM Faceplate Wiring Diagrams and Pin Assignments…………………40
3.1.2 PMM335 LED Operation ………………………………………………………………..42
3.2 Fiber Terminal Block I/O………………………………………………………………………….43
3.2.1 IC695FTB001 Fiber Terminal Block I/O Specifications ……………………44
3.2.2 Terminal Header and Cable Options ……………………………………………..45
3.2.3 FTB Input Power ……………………………………………………………………………46
3.2.4 FTB Wiring Diagrams and Pin Assignment…………………………………….47
3.2.5 Typical External Differential Encoder Connection for FTB ……………..49
3.2.6 Typical Single-Ended Encoder Connection for FTB…………………………50
3.2.7 FTB LED Operation ………………………………………………………………………..51
3.3 Errors Indicated by LEDs…………………………………………………………………………52
3.3.1 PMM LEDs……………………………………………………………………………………..52
3.3.2 FTB LEDs………………………………………………………………………………………..54
3.4 I/O Circuit Specifications …………………………………………………………………………55
3.4.1 PMM Faceplate I/O Circuits……………………………………………………………55
3.4.2 FTB I/O Circuits ……………………………………………………………………………..58
3.5 FSSB Connections……………………………………………………………………………………65
3.5.1 FSSB Fiber Optic Servo Command Interface Cable ………………………..65
3.6 FTB to PMM Connection………………………………………………………………………….66
3.7 Grounding the PACMotion System………………………………………………………….66
3.7.1 System Grounding Example ………………………………………………………….67
3.7.2 Fiber Terminal Block I/O Shield Ground Connection ……………………..70
3.7.3 I/O Cable Grounding……………………………………………………………………..71
Section 4: Configuration …………………………………………….74
4.1 Connecting the Programmer to the RX3i ………………………………………………..74
4.2 Adding a PMM to the Hardware Configuration……………………………………….75
4.3 Configuring PMM Parameters…………………………………………………………………76
4.3.1 Settings …………………………………………………………………………………………77
4.3.2 PMM Status Data …………………………………………………………………………..80
4.3.3 I/O Function Assignments……………………………………………………………..81
4.3.4 I/O Interrupts………………………………………………………………………………..92
4.3.5 Axis Configuration Data…………………………………………………………………94
4.3.6 Advanced Parameters………………………………………………………………… 137
4.3.7 Power Consumption…………………………………………………………………… 137
4.3.8 Terminals …………………………………………………………………………………… 137
Section 5: PACMotion Function Block Operation………..138
5.1 PACMotion Function and Function Block Types …………………………………… 139
5.2 Behavior of Motion Instructions ………………………………………………………….. 142
5.2.1 Instance Data …………………………………………………………………………….. 142
5.2.2 Immediate Response vs. Deferred Response Function Blocks……. 143
5.2.3 Administrative vs. Motion-Generating Functions and Function Blocks144
5.2.4 Function Block Triggering (Enabled vs. Executed Instructions) ….. 144
5.3 Function and Function Block Parameters…………………………………………….. 154
5.3.1 Permissives, Constants, Variables or Flow used with Motion Function
Blocks ………………………………………………………………………………………… 154
5.3.2 EN Input and ENO Output………………………………………………………….. 155
5.3.3 Input Parameters……………………………………………………………………….. 155
5.3.4 Reference ID Variables……………………………………………………………….. 161
5.3.5 Output Parameters ……………………………………………………………………. 163
5.3.6 In_Out Parameters …………………………………………………………………….. 166
5.4 Data Types and Structures…………………………………………………………………… 166
5.4.1 HWC Parameter Linked Data Types……………………………………………. 166
5.4.2 Enumerated Data Types …………………………………………………………….. 168
5.4.3 CAM Profile Linked Data Types…………………………………………………… 169
5.5 Axis States …………………………………………………………………………………………… 169
5.5.1 Axis State Diagram…………………………………………………………………….. 172
5.6 Synchronized Motion…………………………………………………………………………… 173
Section 6: PACMotion Instruction Set Reference………..174
6.1 MC_AbortTrigger…………………………………………………………………………………. 174
6.1.1 Operands …………………………………………………………………………………… 175
6.2 MC_CamFileRead…………………………………………………………………………………. 176
6.2.1 Operands …………………………………………………………………………………… 177
6.3 MC_CamFileWrite ………………………………………………………………………………… 178
6.3.1 Operands …………………………………………………………………………………… 179
6.4 MC_CamIn …………………………………………………………………………………………… 180
6.4.1 Operands …………………………………………………………………………………… 181
6.4.2 Offset and Scaling………………………………………………………………………. 183
6.4.3 Start Mode Mask………………………………………………………………………… 184
6.5 MC_CamOut ………………………………………………………………………………………… 188
6.5.1 Operands …………………………………………………………………………………… 189
6.6 MC_CamTableDeselect ………………………………………………………………………… 190
6.6.1 Operands …………………………………………………………………………………… 191
6.7 MC_CamTableSelect…………………………………………………………………………….. 192
6.7.1 Operands …………………………………………………………………………………… 193
6.7.2 Periodic (CAM Cycle Execution Mode) ………………………………………… 193
6.8 MC_DelayedStart …………………………………………………………………………………. 194
6.8.1 Operands …………………………………………………………………………………… 195
6.9 MC_DigitalCamSwitch………………………………………………………………………….. 196
6.9.1 Operands …………………………………………………………………………………… 197
6.9.2 Requirements for Switch and Track Option Selections……………….. 198
6.9.3 Enabling Outputs for DCS Control ……………………………………………… 199
6.10 MC_DL_Activate …………………………………………………………………………………… 208
6.10.1Operands …………………………………………………………………………………… 209
6.11 MC_DL_Configure………………………………………………………………………………… 210
6.11.1Operands …………………………………………………………………………………… 211
6.12 MC_DL_Delete ……………………………………………………………………………………… 215
6.12.1Operands …………………………………………………………………………………… 215
6.13 MC_DL_Get ………………………………………………………………………………………….. 216
6.13.1Operands …………………………………………………………………………………… 217
6.13.2Data Logging Example……………………………………………………………….. 217
6.14 MC_GearIn…………………………………………………………………………………………… 227
6.14.1Operands …………………………………………………………………………………… 228
6.14.2MC_GearIn Example…………………………………………………………………… 230
6.15 MC_GearInPos …………………………………………………………………………………….. 232
6.15.1Operands …………………………………………………………………………………… 234
6.16 MC_GearOut………………………………………………………………………………………… 236
6.16.1Operands …………………………………………………………………………………… 237
6.17 MC_Halt……………………………………………………………………………………………….. 238
6.17.1Operands …………………………………………………………………………………… 239
6.18 MC_Home ……………………………………………………………………………………………. 240
6.18.1Operands …………………………………………………………………………………… 241
6.18.2Homing Modes…………………………………………………………………………… 243
6.18.3Home to a Hard Stop …………………………………………………………………. 247
6.19 MC_JogAxis ………………………………………………………………………………………….. 249
6.19.1Operands …………………………………………………………………………………… 250
6.19.2Example: Jog to Software End of Travel with Warning ……………….. 251
6.20 MC_LibraryStatus ………………………………………………………………………………… 256
6.20.1Operands …………………………………………………………………………………… 257
6.21 MC_ModuleReset…………………………………………………………………………………. 258
6.21.1Operands …………………………………………………………………………………… 259
6.22 MC_MoveAbsolute……………………………………………………………………………….. 260
6.22.1Operands …………………………………………………………………………………… 261
6.22.2MC_DIRECTION Data Type …………………………………………………………. 262
6.22.3MC_Move Absolute Example………………………………………………………. 263
6.22.4MC_MoveAbsolute Example with Dwell Operation …………………….. 264
6.23 MC_MoveAdditive………………………………………………………………………………… 265
6.23.1Operands …………………………………………………………………………………… 266
6.23.2Example……………………………………………………………………………………… 267
6.24 MC_MoveRelative ………………………………………………………………………………… 268
6.24.1Operands …………………………………………………………………………………… 269
6.25 MC_MoveSuperimposed ……………………………………………………………………… 270
6.25.1Operands …………………………………………………………………………………… 271
6.26 MC_MoveVelocity ………………………………………………………………………………… 272
6.26.1Operands …………………………………………………………………………………… 273
6.27 MC_Phasing…………………………………………………………………………………………. 274
6.27.1Operands …………………………………………………………………………………… 275
6.28 MC_Power……………………………………………………………………………………………. 276
6.28.1Operands …………………………………………………………………………………… 277
6.28.2MC_Power Input Combinations………………………………………………….. 278
6.28.3Example……………………………………………………………………………………… 278
6.29 MC_ReadActualPosition……………………………………………………………………….. 279
6.29.1Operands …………………………………………………………………………………… 279
6.30 MC_ReadActualVelocity ……………………………………………………………………….. 280
6.30.1Operands …………………………………………………………………………………… 280
6.31 MC_ReadAnalogInput………………………………………………………………………….. 281
6.31.1Operands …………………………………………………………………………………… 282
6.31.2Input Example……………………………………………………………………………. 283
6.32 MC_ReadAnalogOutput……………………………………………………………………….. 284
6.32.1Operands …………………………………………………………………………………… 285
6.33 MC_ReadAxisError……………………………………………………………………………….. 286
6.33.1Operands …………………………………………………………………………………… 286
6.34 MC_ReadBoolParameter ……………………………………………………………………… 287
6.34.1Operands …………………………………………………………………………………… 288
6.34.2Example……………………………………………………………………………………… 288
6.35 MC_ReadBoolParameters ……………………………………………………………………. 289
6.35.1Operands …………………………………………………………………………………… 289
6.35.2Example……………………………………………………………………………………… 290
6.36 MC_ReadDigitalInput…………………………………………………………………………… 291
6.36.1Operands …………………………………………………………………………………… 292
6.36.2Example……………………………………………………………………………………… 292
6.37 MC_ReadDigitalOutput………………………………………………………………………… 294
6.37.1Operands …………………………………………………………………………………… 295
6.38 MC_ReadDwordParameters…………………………………………………………………. 296
6.38.1Operands …………………………………………………………………………………… 297
6.39 MC_ReadEventQueue ………………………………………………………………………….. 298
6.39.1Operands …………………………………………………………………………………… 299
6.39.2Example……………………………………………………………………………………… 299
6.40 MC_ReadParameter …………………………………………………………………………….. 302
6.40.1Operands …………………………………………………………………………………… 302
6.40.2Example……………………………………………………………………………………… 303
6.41 MC_ReadParameters …………………………………………………………………………… 304
6.41.1Operands …………………………………………………………………………………… 305
6.41.2Example……………………………………………………………………………………… 306
6.42 MC_ReadStatus……………………………………………………………………………………. 307
6.42.1Operands …………………………………………………………………………………… 308
6.42.2Axis Status Flags ………………………………………………………………………… 309
6.43 MC_ReadTorqueCommand………………………………………………………………….. 312
6.43.1Operands …………………………………………………………………………………… 312
6.44 MC_Reset …………………………………………………………………………………………….. 313
6.44.1Operands …………………………………………………………………………………… 314
6.45 MC_SetOverride…………………………………………………………………………………… 315
6.45.1Operands …………………………………………………………………………………… 317
6.46 MC_SetPosition……………………………………………………………………………………. 318
6.46.1Synchronous State Operation…………………………………………………….. 319
6.46.2Operands …………………………………………………………………………………… 319
6.47 MC_Stop………………………………………………………………………………………………. 321
6.47.1Operands …………………………………………………………………………………… 322
6.48 MC_SyncStart ………………………………………………………………………………………. 323
6.48.1Operands …………………………………………………………………………………… 324
6.49 MC_TouchProbe…………………………………………………………………………………… 325
6.49.1Operands …………………………………………………………………………………… 326
6.49.2Examples……………………………………………………………………………………. 327
6.50 MC_WriteAnalogOutput ………………………………………………………………………. 332
6.50.1Operands …………………………………………………………………………………… 333
6.50.2Example……………………………………………………………………………………… 334
6.51 MC_WriteBoolParameter……………………………………………………………………… 335
6.51.1Operands …………………………………………………………………………………… 336
6.52 MC_WriteBoolParameters……………………………………………………………………. 337
6.52.1Operands …………………………………………………………………………………… 338
6.53 MC_WriteDigitalOutput ……………………………………………………………………….. 339
6.53.1Operands …………………………………………………………………………………… 340
6.53.2Example……………………………………………………………………………………… 341
6.54 MC_WriteDwordParameters………………………………………………………………… 342
6.54.1Operands …………………………………………………………………………………… 343
6.55 MC_WriteParameter…………………………………………………………………………….. 344
6.55.1Operands …………………………………………………………………………………… 345
6.56 MC_WriteParameters…………………………………………………………………………… 346
6.56.1Operands …………………………………………………………………………………… 347
Section 7: Electronic CAM Programming……………………348
7.1 Overview of PACMotion CAM Profile Development……………………………… 348
7.1.1 Point Limits in CAM Profiles……………………………………………………….. 349
7.2 CAM Types and Modes for the PMM……………………………………………………. 350
7.2.1 CAM Profile Types………………………………………………………………………. 351
7.3 CAM Operation Restrictions by Type and Mode…………………………………… 354
7.4 Smoothing and Curve Fitting……………………………………………………………….. 356
7.5 Calculating Slave Axis Velocity and Acceleration………………………………….. 357
7.6 Synchronized Motion Function Block Status………………………………………… 360
7.6.1 Pending……………………………………………………………………………………… 361
7.6.2 Ramping…………………………………………………………………………………….. 364
7.6.3 InSync………………………………………………………………………………………… 366
7.7 CSV CAM File Format……………………………………………………………………………. 369
7.7.1 File Header Format…………………………………………………………………….. 370
7.7.2 Sector Header Format………………………………………………………………… 370
7.7.3 CSV Sector Body (repeated for each Sector) Format…………………… 370
7.8 Reference Memory Format for CAM Files…………………………………………….. 371
7.8.1 Boolean Parameters…………………………………………………………………… 372
Section 8: Parameters for Monitoring and Control …….373
8.1 Axis Parameter Numbers…………………………………………………………………….. 373
8.1.1 Position Loop Overview……………………………………………………………… 374
8.2 Module Parameter Numbers……………………………………………………………….. 391
8.3 I/O Data Reference Numbers ………………………………………………………………. 397
Section 9: Diagnostics ………………………………………………400
9.1 PMM Error IDs …………………………………………………………………………………….. 400
9.1.1 Accessing Error IDs ……………………………………………………………………. 400
9.1.2 Error ID Format………………………………………………………………………….. 401
9.1.3 Clearing PMM Errors………………………………………………………………….. 401
9.1.4 I/O Fault Table……………………………………………………………………………. 402
9.1.5 Error ID Reference……………………………………………………………………… 402
9.2 CPU Error Codes………………………………………………………………………………….. 461
9.3 FSSB Servo Alarms……………………………………………………………………………….. 467
9.3.1 Digital Servo Alarm Error Codes…………………………………………………. 467
9.3.2 Diagnostics for FSSB Servo Alarms…………………………………………….. 468
9.4 PMM Event Queue……………………………………………………………………………….. 472
9.4.1 Event Queue Details…………………………………………………………………… 472
9.5 Accessing the Ten Most Recent Events………………………………………………… 473
9.5.1 Parameter Errors Caused by Changes in Axis Scaling ………………… 474
9.6 Diagnostic Logic Blocks……………………………………………………………………….. 477
9.6.1 Using DLBs with PACMotion CAM Profiles………………………………….. 478
Appendix A: Touch Probe and Digital CAM Switch Accuracy
Calculations………………………………………………………………..479
A-1 Touch Probe Accuracy …………………………………………………………………………. 479
A-1.1 External Quadrature Encoder…………………………………………………….. 479
A-1.2 Motor Encoder …………………………………………………………………………… 479
A-2 Digital CAM Switch Accuracy ……………………………………………………………….. 483
A-2.1 DCS Accuracy at Constant Velocity……………………………………………… 484
A-2.2 DCS Accuracy During Acceleration……………………………………………… 484
Appendix B: Position Feedback Devices ……………………….489
B-1 Digital Serial Encoders……………………………………………………………… 489
B-1.1 Digital Serial Encoder Resolutions ……………………………………………… 489
B-1.2 Digital Serial Encoder Modes……………………………………………………… 489
B-2 External Quadrature Encoders…………………………………………………………….. 492
B-2.1 Example: Connecting an External Encoder to Axis 5…………………… 493
Appendix C: Tuning Digital and Analog Servo Systems….497
C-1 Validating Axis Direction, Over Travel Switch and Home Switch Inputs.. 497
C-1.1 Validating Motor Direction…………………………………………………………. 498
C-1.2 Validating the Over Travel Limit Switch Inputs…………………………… 499
C-1.3 Validating the Home Switch Input ……………………………………………… 499
C-1.4 FSSB Servo System Start-up Diagnostics ……………………………………. 501
C-2 Forcing Servo Velocity………………………………………………………………………….. 501
C-3 Tuning a FANUC FSSB Servo Drive……………………………………………………….. 502
C-3.1 Tuning Requirements ………………………………………………………………… 502
C-3.2 Advanced FSSB Servo Tuning …………………………………………………….. 513
C-4 Tuning an Analog, Velocity-Controlled Drive ……………………………………….. 523
C-4.1 Wiring and Configuration…………………………………………………………… 523
C-4.2 Validating Axis Configuration and Amplifier Settings…………………. 525
C-5 Tuning an Analog, Torque-Controlled Drive ………………………………………… 526
C-5.1 Wiring and Configuration…………………………………………………………… 526
C-5.2 Verifying Basic Analog Control Functions…………………………………… 529
C-5.3 Tuning the Torque Mode Velocity Loop……………………………………… 530
C-5.4 Position Loop Tuning …………………………………………………………………. 545

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