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Mitsubishi Electric RD77MS2 User Manual

Melsec iq-r simple motion module.
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MELSEC iQ-R Simple Motion Module
User's Manual (Advanced Synchronous Control)
RD77MS2
RD77MS4
RD77MS8
RD77MS16

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Table of Contents

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   Summary of Contents for Mitsubishi Electric RD77MS2

  • Page 1 MELSEC iQ-R Simple Motion Module User's Manual (Advanced Synchronous Control) RD77MS2 RD77MS4 RD77MS8 RD77MS16...
  • Page 3: Safety Precautions

    SAFETY PRECAUTIONS (Read these precautions before using this product.) Before using this product, please read this manual and the relevant manuals carefully and pay full attention to safety to handle the product correctly. The precautions given in this manual are concerned with this product only. Refer to the user’s manual of the CPU module to use for a description of the PLC system safety precautions.
  • Page 4 WARNING ● When connecting an external device with a CPU module or intelligent function module to modify data of a running programmable controller, configure an interlock circuit in the program to ensure that the entire system will always operate safely. For other forms of control (such as program modification, parameter change, forced output, or operating status change) of a running programmable controller, read the relevant manuals carefully and ensure that the operation is safe before proceeding.
  • Page 5 [Design Precautions] CAUTION ● Do not install the control lines or communication cables together with the main circuit lines or power cables. Keep a distance of 100 mm or more between them. Failure to do so may result in malfunction due to noise.
  • Page 6 [Installation Precautions] WARNING ● Shut off the external power supply (all phases) used in the system before mounting or removing the module. Failure to do so may result in electric shock or cause the module to fail or malfunction. [Installation Precautions] CAUTION ●...
  • Page 7 [Wiring Precautions] CAUTION ● Individually ground the FG and LG terminals of the programmable controller with a ground resistance of 100 ohm or less. Failure to do so may result in electric shock or malfunction. ● Use applicable solderless terminals and tighten them within the specified torque range. If any spade solderless terminal is used, it may be disconnected when the terminal screw comes loose, resulting in failure.
  • Page 8 [Startup and Maintenance Precautions] WARNING ● Do not touch any terminal while power is on. Doing so will cause electric shock or malfunction. ● Correctly connect the battery connector. Do not charge, disassemble, heat, short-circuit, solder, or throw the battery into the fire. Also, do not expose it to liquid or strong shock. Doing so may cause the battery to generate heat, explode, ignite, or leak, resulting in injury or fire.
  • Page 9 CAUTION ● Startup and maintenance of a control panel must be performed by qualified maintenance personnel with knowledge of protection against electric shock. Lock the control panel so that only qualified maintenance personnel can operate it. ● Before handling the module, touch a conducting object such as a grounded metal to discharge the static electricity from the human body.
  • Page 10 [Transportation Precautions] CAUTION ● When transporting lithium batteries, follow the transportation regulations. For details on the regulated models, refer to the MELSEC iQ-R Module Configuration Manual. ● The halogens (such as fluorine, chlorine, bromine, and iodine), which are contained in a fumigant used for disinfection and pest control of wood packaging materials, may cause failure of the product.
  • Page 11: Conditions Of Use For The Product

    Please make sure that the end users read this manual. Relevant products RD77MS2, RD77MS4, RD77MS8, RD77MS16 In this manual, buffer memories are classified using the following symbols. Each area name can represent the buffer memories corresponding to each axis.
  • Page 12: Compliance With Emc And Low Voltage Directives

    COMPLIANCE WITH EMC AND LOW VOLTAGE DIRECTIVES Method of ensuring compliance To ensure that Mitsubishi programmable controllers maintain EMC and Low Voltage Directives when incorporated into other machinery or equipment, certain measures may be necessary. Please refer to one of the following manuals. MELSEC iQ-R Module Configuration Manual Safety Guidelines (This manual is included with the base unit.) The CE mark on the side of the programmable controller indicates compliance with EMC and Low Voltage Directives.
  • Page 13: Table Of Contents

    CONTENTS SAFETY PRECAUTIONS ..............1 CONDITIONS OF USE FOR THE PRODUCT .
  • Page 14 Smoothing method for clutch..............82 Use example of clutch .
  • Page 15: Relevant Manuals

    RELEVANT MANUALS Manual name [manual number] Description Available form MELSEC iQ-R Simple Motion Module User's Manual Functions and programming for the synchronous control of the Print book (Advanced Synchronous Control) Simple Motion module e-Manual [IB-0300249] (This manual) EPUB MELSEC iQ-R Simple Motion Module User's Manual Functions, input/output signals, buffer memories, parameter Print book (Application)
  • Page 16: Terms

    High speed synchronous communication network between RD77MS and servo amplifier. SSCNET SSCNET(/H) Generic term for SSCNET/H, SSCNET. Servo network 2-axis module Generic term for RD77MS2. 4-axis module Generic term for RD77MS4. 8-axis module Generic term for RD77MS8. 16-axis module Generic term for RD77MS16.
  • Page 17: Chapter 1 Outline Of Synchronous Control

    OUTLINE OF SYNCHRONOUS CONTROL The outline, specifications and the operation method of synchronous control using the Simple Motion module are explained in this chapter. This chapter helps to understand what can be done using the positioning system and which procedure to use for a specific purpose.
  • Page 18 List of synchronous control module The module is used in synchronous control as follows. Synchronous parameter Main shaft module Input axis module Main shaft Composite main Main shaft (main input axis) shaft gear gear Synchronous encoder axis parameter Synchronous encoder axis Main shaft clutch Servo input axis...
  • Page 19 ■Output axis Classification Name Parts Function description Maximum number of usable Reference Number per module Numbe r per 2-axis 4-axis 8-axis 16-axis axis module module module module Page 61 Main shaft Main shaft • The input axis on the main module main input side of the main shaft module.
  • Page 20: Performance Specifications

    Performance Specifications Performance specifications Item Number of settable axes 2-axis module 4-axis module 8-axis module 16-axis module Input axis Servo input axis 2 axes/module 4 axes/module 8 axes/module 16 axes/module Synchronous encoder 4 axes/module axis Composite main shaft gear 1/output axis Main shaft main input axis 1 axis/output axis Main shaft sub input axis...
  • Page 21 ■Stroke ratio data format Cam resolution Maximum number of cam registration Cam storage area Cam open area 1024 2048 4096 8192 16384 32768 ■Coordinate data format Coordinate number Maximum number of cam registration Cam storage area Cam open area 1024 2048 4096 8192...
  • Page 22: Operation Method Of Synchronous Control

    Operation Method of Synchronous Control Synchronous control execution procedure The synchronous control is executed using the following procedure. Preparation STEP 1 One of the following two methods can be used. Set the following parameters. • Common parameters ([Pr.24], [Pr.82], [Pr.89], <Method 1>...
  • Page 23: Starting/ending For Synchronous Control

    Precautions • Mechanical elements such as limit switches are considered as already installed. • Parameter settings for positioning control apply for all axes with the Simple Motion module. • Be sure to execute the home position return when the home position return request flag is ON. Starting/ending for synchronous control Set the parameters for synchronous control for each output axis to start synchronous control.
  • Page 24 Starting history The starting history is updated when starting synchronous control. "9020: Synchronous control operation" is stored in "[Md.4] Start No.". Status when starting synchronous control The following bits in "[Md.31] Status" are turned OFF when starting synchronous control in the same way as for the positioning control start.
  • Page 25: Stop Operation Of Output Axis

    Stop operation of output axis If the following causes occur in stopping the output axis during synchronous control, synchronous control is completed after stops processing for the output axis (BUSY signal is OFF, axis operation status is standby). Synchronous alignment must be executed for the output axis to restart the synchronous control. (Page 90 Output Axis Module) Stop cause Stop process...
  • Page 26: Chapter 2 Input Axis Module

    INPUT AXIS MODULE The settings for the parameter and monitor data for the input axis module that used with synchronous control are explained in this chapter. Refer to the following manual of the Simple Motion module that is used for details on the connection and control for the servo amplifier and the synchronous encoder that used for input axis module.
  • Page 27 If "1: Feed current value" or "2: Real current value" is set in "[Pr.300] Servo input axis type", set "1: Update feed current value" in "[Pr.21] Feed current value during speed control" to start the speed position change control. If "0: Do not update feed current value" or "2: Clear feed current value to zero" is set in [Pr.21], the error "Speed-position switching control start in servo input axis not possible"...
  • Page 28: Servo Input Axis Parameters

    Servo input axis parameters n: Axis No. - 1 Setting item Setting details Setting value Default value Buffer memory address [Pr.300] • Set the current value type to be ■Set in decimal. 32800+10n Servo input axis type generated of the input value for the 0: Invalid servo input axis.
  • Page 29 [Pr.301] Servo input axis smoothing time constant Set the averaging time to execute a smoothing process for the input movement amount from the servo input axis. The smoothing process can moderate speed fluctuation, when the "Real current value" or "Feedback value" is used as input values.
  • Page 30 [Pr.304] Servo input axis rotation direction restriction Set this parameter to restrict the input movement amount for the servo input axis to one direction. This helps to avoid reverse operation caused by machine vibration, etc. when "Real current value" or "Feedback value" is used as input values.
  • Page 31: Servo Input Axis Monitor Data

    Servo input axis monitor data n: Axis No. - 1 Monitor item Storage details Monitor value Buffer memory address [Md.300] • The current value for the servo input axis ■Monitoring is carried out in decimal. 33120+10n Servo input axis current value is stored.
  • Page 32 [Md.303] Servo input axis rotation direction restriction amount While the rotation direction is restricted for a servo input axis, the accumulation for input movement amount in the opposite direction of the enabled direction is stored in servo input axis position units (Page 25 Servo input axis position units) as follows.
  • Page 33: Synchronous Encoder Axis

    Synchronous Encoder Axis Overview of synchronous encoder axis The synchronous encoder is used to drive the input axis based on input pulse from a synchronous encoder that is connected externally. The status of a synchronous encoder axis can also be monitored after the system's power supply turns ON. [Pr.24] Manual pulse generator/Incremental synchronous encoder...
  • Page 34 Synchronous encoder axis type The following 3 types of synchronous encoders can be used for the synchronous encoder axis. Refer to the following for the setting method for each synchronous encoder axis. Page 34 Setting method for synchronous encoder Synchronous encoder axis type Details Incremental synchronous encoder The incremental synchronous encoder that is connected to the manual pulse generator/incremental synchronous...
  • Page 35 ■Synchronous encoder axis speed units Setting value of "[Pr.321] Synchronous encoder axis Synchronous encoder Range unit setting" axis speed unit Control unit Speed time unit Number of decimal places for speed 0: mm 0: second [s] mm/s -2147483648 to 2147483647 [mm/s] ...
  • Page 36: Setting Method For Synchronous Encoder

    Setting method for synchronous encoder Incremental synchronous encoder ■Setting method Connect the synchronous encoder to the "Manual pulse generator/Incremental synchronous encoder input" of the Simple Motion module. Set the input method for the incremental synchronous encoder signal using the following parameters. (It may be common to use the same set up for the manual pulse generator input.) •...
  • Page 37 Synchronous encoder via servo amplifier There are restrictions in the function that can be used by the version of the servo amplifier MR-J4-_B-RJ. Refer to the following for details. SSCNET/H Interface AC Servo MR-J4-_B(-RJ) MR-J4-_B4(-RJ) MR-J4-_B1(-RJ) Servo Amplifier Instruction Manual ■Setting method Used to use a serial absolute synchronous encoder connected to CN2L of the servo amplifier MR-J4-_B-RJ as a synchronous encoder axis.
  • Page 38 ■Setting example The following shows an example for setting a serial absolute synchronous encoder Q171ENC-W8 using MR-J4-_B-RJ as synchronous encoder axis 1 of the Simple Motion module. RD77MS RD77MS4 MR-J4-_B-RJ Q171ENC-W8 (4194304 pulses/rev) Axis 1 Axis 2 Axis 3 Synchronous encoder axis 1 Set the parameters as below.
  • Page 39 Synchronous encoder via CPU (Synchronous encoder via CPU module) ■Setting method Used to operate a gray code encoder that is connected to the input module of the CPU module as a synchronous encoder axis. By setting "201: Synchronous encoder via CPU" in "[Pr.320] Synchronous encoder axis type", the synchronous encoder is controlled by the encoder value which is the input value of "[Cd.325] Input value for synchronous encoder via CPU".
  • Page 40: Synchronous Encoder Axis Parameters

    Synchronous encoder axis parameters j: Synchronous encoder axis No. - 1 Setting item Setting details Setting value Default Buffer value memory address [Pr.320] • Set the synchronous encoder axis ■Set in decimal. 34720+20j Synchronous encoder axis type to be used. 0: Invalid type Fetch cycle: At power supply ON...
  • Page 41 [Pr.320] Synchronous encoder axis type Set the synchronous encoder type to be generated of the input value for the synchronous encoder axis. Setting value Details 0: Invalid Synchronous encoder axis is invalid. 1: Incremental synchronous encoder Generate the input value based on the incremental synchronous encoder input. 101 to 116: Synchronous encoder via servo Generate the input value based on the synchronous encoder input via servo amplifier connected to the amplifier...
  • Page 42 ■Setting example of the unit conversion and the length per cycle. The following shows an example a rotary encoder is connected which resolution is 4000 [pulse/rev] to the motor axis side on the rotation table that drives by 1/5 pulley system, and the control unit is degree. •...
  • Page 43 [Pr.326] Synchronous encoder axis phase compensation advance time Set the time to advance or delay the phase (input response) of the synchronous encoder axis. Refer to the following for the delay time inherent to the system using the synchronous encoder axis. Page 104 Phase Compensation Function Setting value Details...
  • Page 44 [Pr.328] Synchronous encoder axis rotation direction restriction Set this parameter to restrict the input movement amount for the synchronous encoder axis to one direction. This helps to avoid reverse operation caused by machine vibration, etc. when "Real current value" or "Feedback value" is used as input values.
  • Page 45: Synchronous Encoder Axis Control Data

    Synchronous encoder axis control data j: Synchronous encoder axis No. - 1 Setting item Setting details Setting value Default Buffer value memory address [Cd.320] • If set to "1", the synchronous encoder axis control is ■Set in decimal. 35040+10j Synchronous encoder axis started.
  • Page 46 [Cd.320] Synchronous encoder axis control start If set to "1", the synchronous encoder axis control is started. [Md.320] Synchronous encoder axis current value [Cd.320] Synchronous encoder axis control start [Cd.321] Synchronous encoder axis 0: Current value change control method [Cd.322] Synchronous encoder axis current value setting address If set to "101 to 116", the synchronous encoder axis control starts based on the high-speed input request [DI] for the specified servo amplifier axis.
  • Page 47 [Cd.322] Synchronous encoder axis current value setting address Set a new current value in synchronous encoder axis position units to apply to the current value change for the synchronous encoder axis (Page 32 Synchronous encoder axis position units). [Cd.323] Synchronous encoder axis error reset If set to "1", "[Md.326] Synchronous encoder axis error No."...
  • Page 48: Synchronous Encoder Axis Monitor Data

    Synchronous encoder axis monitor data j: Synchronous encoder axis No. - 1 Monitor item Storage details Monitor value Buffer memory address [Md.320] • The current value for the synchronous encoder axis ■Monitoring is carried out in decimal. 35200+20j Synchronous encoder axis is stored.
  • Page 49 [Md.323] Synchronous encoder axis phase compensation amount The phase compensation amount for a synchronous encoder axis is stored in the synchronous encoder axis position units (Page 32 Synchronous encoder axis position units). The phase compensation amount for a synchronous encoder axis is the value after smoothing processing and phase compensation processing.
  • Page 50: Chapter 3 Cam Function

    CAM FUNCTION The details on cam data and operation for cam function in output axis (cam axis) are explained in this chapter. The cam function controls output axis by creating cam data that corresponds to the operation. The functions to operate cam data include "Cam data operation function", "Cam auto-generation function", and "Cam position calculation function".
  • Page 51 Cam data ■Stroke ratio data format The stroke ratio data format is defined in equal divisions for one cam cycle based on the cam resolution, and configured with stroke ratio data from points within the cam resolution. Refer to the following for setting methods for cam data. Page 54 Create Cam Data Setting item Setting details...
  • Page 52 ■Coordinate data format The coordinate data format is defined in coordinates of more than 2 points for one cam cycle. The coordinate data is represented as "(Input value, Output value)". Input value: Cam axis current value per cycle Output value: Stroke position from cam reference position With this format, "[Pr.441] Cam stroke amount"...
  • Page 53 Output value: Y [Output axis position units] Generated line Generated line segment from segment from ) and (X ) and (X 2147483647 Input value: X (Cam reference position) -2147483648 Cam axis length per cycle [Cam axis cycle units] CAUTION • If the cam data is set incorrectly, such as simply setting a target value and command speed similar to positioning control, the position and speed command to the servo amplifier increases, and may cause machine interface and servo alarms such as "AL.31"...
  • Page 54 Cam reference position The cam reference position is calculated as shown below. ■Stroke ratio data format Cam reference position = The preceding cam reference position + (Cam stroke amount  Stroke ratio at the last point) ■Coordinate data format Cam reference position = The preceding cam reference position + Output value corresponding to "Input value = Cam axis length per cycle"...
  • Page 55 Cam data starting point This setting is only valid for cam data using the stroke ratio data format. The cam data point corresponding to "Cam axis current value per cycle = 0" can be set as the cam data starting point. The default value of the cam data starting point is 0.
  • Page 56: Create Cam Data

    Create Cam Data Memory configuration of cam data Cam data is arranged in the following 2 areas. Memory configuration Storage item Details Remark Cam storage area Cam data Data is written by the following • Data is preserved even when operations.
  • Page 57 Cam data operation with an engineering tool Cam data can be modified while viewing the waveform with the engineering tool. The cam data is written/read/verified to the cam storage area with the engineering tool, however it cannot be executed to the cam open area.
  • Page 58: Cam Data Operation Function

    Cam data operation function This function is used to write/read cam data via buffer memory with the cam operation control data. The amount of data for each operation is 4096 points with the stroke ratio data format, and 2048 points with the coordinate data format. If it is more than that, the operation should be executed separately.
  • Page 59 [Cd.600] Cam data operation request Set the following commands to write/read cam data. Setting value Details 1: Read The cam is read from the cam open area and stored to the buffer memory. 2: Write (Cam storage area) The cam data is written to the cam storage area and the cam open area from the buffer memory. 3: Write (Cam open area) The cam data is written to the cam open area from the buffer memory.
  • Page 60 [Cd.605] Cam resolution/coordinate number Set/load the cam resolution/the coordinate number. Operation Details Reading The cam resolution/the coordinate number of the set cam data is read. Writing Set the cam resolution with the following values when using the stroke ratio data format. 256/512/1024/2048/4096/8192/16384/32768 Set the coordinate number within the range from 2 to 16384 when using the coordinate data format.
  • Page 61: Cam Auto-generation Function

    Cam auto-generation function The cam auto-generation function is used to generate cam data automatically for specific purposes based on parameter settings. With this function, cam data is generated in the cam open area. It is possible to generate up to 1 Mbyte including the regular cam data. (Example: 256 cam data (with the stroke ratio format, resolution is 1024) can be automatically generated.) The processing time of cam auto-generation takes longer if the data point is larger.
  • Page 62 [Cd.610] Cam auto-generation type Set the type of cam auto-generation. Setting value Details Cam for rotary cutter [Cd.611] Cam auto-generation data Set the cam auto-generation data corresponding to "[Cd.610] Cam auto-generation type". ■For a rotary cutter The cam data starting point for a rotary cutter is 0. Buffer memory address Item Setting value...
  • Page 63: Chapter 4 Synchronous Control

    SYNCHRONOUS CONTROL The parameters and monitor data for synchronous control such as "Main shaft module", "Speed change gear module", and "Output axis module" are explained in this chapter. Configure the required settings according to the control and application requirements for each module. Main Shaft Module Overview of main shaft module For the main shaft module, the input value is generated as a composite value from two input axes (the main and sub input...
  • Page 64: Main Shaft Parameters

    Main shaft parameters n: Axis No. - 1 Setting item Setting details Setting value Default value Buffer memory address [Pr.400] • Set the input axis No. on the main input side for the ■Set in decimal. 36400+200n Main input axis No. main shaft.
  • Page 65 [Pr.402] Composite main shaft gear Set the composite method for input values from the main and sub input axes. The setting values for each axis are shown as follows. Setting value Details 0: No input The input value from the input axis is calculated as 0. 1: Input+ The input value from the input axis is calculated as it is.
  • Page 66: Main Shaft Clutch Parameters

    Main shaft clutch parameters n: Axis No. - 1 Setting item Setting details Setting value Default Buffer value memory address [Pr.405] • Set the control method for the clutch. ■Set in hexadecimal. 0000H 36408+200n Main shaft clutch Fetch cycle: Operation cycle H _ _ _ _ control setting ON control mode...
  • Page 67 Setting item Setting details Setting value Default Buffer value memory address [Pr.413] • For smoothing with a slippage method, set the slippage ■Set in decimal. 36420+200n Slippage amount at amount at clutch ON. 0 to 2147483647 36421+200n main shaft clutch Fetch cycle: At turning clutch ON.
  • Page 68 ■High speed input request signal Set the high speed input request signal No. for the ON control mode (1) and the OFF control mode (2) when using the setting "5: High speed input request". Signal No. Setting value Signal No. Setting value Signal No.
  • Page 69 [Pr.409] Main shaft clutch OFF address Set the clutch OFF address when address mode is configured for the OFF control mode of the main shaft clutch. When the reference address is the current value per cycle after main shaft gear, the setting address is converted for control within the range from 0 to (Cam axis length per cycle - 1).
  • Page 70: Main Shaft Clutch Control Data

    [Pr.414] Slippage amount at main shaft clutch OFF Set the slippage amount at clutch OFF when the slippage method is set in "[Pr.411] Main shaft clutch smoothing method". The slippage amount is set in units based on the current value selected in "[Pr.406] Main shaft clutch reference address setting".
  • Page 71: Auxiliary Shaft Module

    Auxiliary Shaft Module Overview of auxiliary shaft module For the auxiliary shaft module, the input value is generated from the auxiliary shaft. The input value can be converted by the auxiliary shaft gear that provides the deceleration ratio and the rotation direction for the machine system, etc. Refer to the followings for details on setting for the auxiliary shaft module.
  • Page 72 [Pr.418] Auxiliary shaft axis No. Set the input axis No. for the auxiliary shaft. Setting value Details 0: Invalid The input value is always 0. 1 to 16: Servo input axis Set the servo input axis (axis 1 to axis 16). When the servo input axis is not set in the system setting, the input value is always 0.
  • Page 73: Auxiliary Shaft Clutch Parameters

    Auxiliary shaft clutch parameters n: Axis No. - 1 Setting item Setting details Setting value Default Buffer value memory address [Pr.422] • Set the control method for the clutch. ■Set in hexadecimal. 0000H 36436+200n Auxiliary shaft Fetch cycle: Operation cycle H _ _ _ _ clutch control ON control mode...
  • Page 74 Setting item Setting details Setting value Default Buffer value memory address [Pr.430] • For smoothing with a slippage method, set the slippage ■Set in decimal. 36448+200n Slippage amount at amount at clutch ON. 0 to 2147483647 36449+200n auxiliary shaft clutch Fetch cycle: At turning clutch ON.
  • Page 75 ■High speed input request signal Set the high speed input request signal No. for the ON control mode (1) and the OFF control mode (2) when using the setting "5: High speed input request" Signal No. Setting value Signal No. Setting value Signal No.
  • Page 76 [Pr.425] Movement amount before auxiliary shaft clutch ON Set the movement amount of the reference address with a signed value between the clutch ON condition completing and the clutch closing. Setting value Details 1 to 2147483647 (Positive value) Used when the reference address is increasing in direction. No movement amount (The clutch is immediately turned ON with the clutch ON condition completing.) -2147483648 to -1 (Negative value) Used when the reference address is decreasing in direction.
  • Page 77 [Pr.428] Auxiliary shaft clutch smoothing method Set the smoothing method for clutch ON/OFF. Refer to the following. Page 82 Smoothing method for clutch Setting value Details 0: Direct No smoothing. 1: Time constant method Smoothing with an exponential curve based on the time constant setting. (Exponent) 2: Time constant method (Linear) Smoothing with linear acceleration/deceleration based on the time constant setting.
  • Page 78: Auxiliary Shaft Clutch Control Data

    Auxiliary shaft clutch control data n: Axis No. - 1 Setting item Setting details Setting value Default value Buffer memory address [Cd.403] • Set the clutch command ON/OFF. ■Set in decimal. 44083+20n Auxiliary shaft Fetch cycle: Operation cycle 0: Auxiliary shaft clutch clutch command command OFF 1: Auxiliary shaft clutch...
  • Page 79: Clutch

    Clutch Overview of clutch The clutch is used to transmit/disengage command pulses from the main/auxiliary shaft input side to the output axis module through turning the clutch ON/OFF, which controls the operation/stop of the servomotor. A clutch can be configured for the main and auxiliary shafts. Control method for clutch Set the ON and OFF control methods separately in "[Pr.405] Main shaft clutch control setting"...
  • Page 80 ■Clutch command ON/OFF The clutch is turned ON/OFF by the operation of clutch command ON/OFF. (Setting in the OFF control mode are not applicable in the clutch command ON/OFF mode.) Clutch command Clutch ON/OFF status Current value before clutch Movement amount after clutch Item Main shaft clutch Auxiliary shaft clutch...
  • Page 81 ■Address mode The clutch is turned ON when the reference address reaches "Clutch ON address". The movement amount after passing through the ON address is calculated as the output movement amount of the clutch based on the reference address passing through, thereby controlling the clutch with an accurate movement amount. Clutch ON/OFF status Clutch ON address Current value specified in...
  • Page 82 OFF control mode ■OFF control invalid Clutch OFF control is not used. This setting is applicable only for execution with clutch ON control. ■One-shot OFF The clutch is turned OFF after moving the distance "Movement amount before clutch OFF" (One-shot operation) after the clutch command turn ON.
  • Page 83 ■Address mode The clutch is turned OFF when the reference address reaches "Clutch OFF address". The movement amount before passing through the OFF address is calculated as the output movement amount of the clutch based on the reference address passing through, thereby controlling the clutch with an accurate movement amount. Clutch ON/OFF status Clutch OFF address Current value specified in...
  • Page 84: Smoothing Method For Clutch

    Smoothing method for clutch Set the clutch smoothing method in "[Pr.411] Main shaft clutch smoothing method" and "[Pr.428] Auxiliary shaft clutch smoothing method". The 2 types of clutch smoothing include the following. • Time constant method smoothing • Slippage method smoothing When not using clutch smoothing, set "0: Direct"...
  • Page 85 ■Time constant method linear acceleration/deceleration smoothing Set "2: Time constant method (Linear)" in the clutch smoothing method. Clutch ON/OFF status Clutch smoothing status Speed before clutch processing Speed after clutch smoothing Clutch smoothing time constant Slippage method smoothing Smoothing is processed with the value in slippage at clutch ON when the clutch turns ON, and with slippage at clutch OFF when the clutch turns OFF.
  • Page 86 ■Slippage method linear acceleration/deceleration smoothing Set "4: Slippage method (Linear)" or "5: Slippage method (Linear: Input value follow up)" in the clutch smoothing method. The differences between "4: Slippage method (Linear)" and "5: Slippage method (Linear: Input value follow up)" are shown below.
  • Page 87 ["5: Slippage method (Linear: Input value follow up)" is set.] The clutch smoothing status ON section is fixed. Clutch ON/OFF status ON section is fixed. Clutch smoothing status Input speed (Speed before clutch processing) Output speed (Speed after clutch processing) Slippage amount at clutch OFF Slippage amount at clutch ON •...
  • Page 88 ■Operation at input speed deceleration during slippage method smoothing When the speed before clutch processing decreases, the speed after clutch smoothing is controlled without exceeding the speed before clutch processing. If slippage amount remains when the speed before clutch processing becomes 0, the smoothing process will be continued. Then, the clutch smoothing process will be executed with the remaining slippage amount when the speed before clutch processing gets faster than the speed after clutch smoothing.
  • Page 89: Use Example Of Clutch

    Use example of clutch The following machine shows an example using clutch control for a flying shear cutting system that synchronizes off a start signal from a sensor input. Sensor input (High speed input Main shaft gear request [DI]) Main shaft main Main shaft clutch input axis (Synchronous...
  • Page 90: Speed Change Gear Module

    Speed Change Gear Module Overview of speed change gear module A speed change gear module is used to change the input speed from the main shaft/auxiliary shaft/composite auxiliary shaft gear during operation. When not using a speed change gear module, set "0: No speed change gear" in "[Pr.434] Speed change gear".
  • Page 91: Speed Change Gear Parameters

    Speed change gear parameters n: Axis No. - 1 Setting item Setting details Setting value Default value Buffer memory address [Pr.434] • Set the arrangement for the speed change gear. ■Set in decimal. 36460+200n Speed change gear Fetch cycle: At start of synchronous control 0: No speed change gear 1: Main shaft side 2: Auxiliary shaft side...
  • Page 92: Output Axis Module

    Output Axis Module Overview of output axis module For the output axis module, the cam axis current value per cycle is calculated based on the input value (the output value from a speed change gear), and is converted based on the set cam data. The feed current value which is a command is output to the servo amplifier.
  • Page 93 Units for the output axis The position units for the output axis are shown below based on the setting "[Pr.1] Unit setting". Setting value of "[Pr.1] Unit setting" Output axis position unit Range  10 0: mm -214748.3648 to 214748.3647 [mm] ( ...
  • Page 94: Output Axis Parameters

    Output axis parameters n: Axis No. - 1 Setting item Setting details Setting value Default Buffer value memory address [Pr.438] • Set the units for the cam axis length per cycle. ■Set in hexadecimal. 0000H 36470+200n Cam axis cycle • There is no influence on the control for the parameter H _ _ _ _ unit setting for monitor display.
  • Page 95 [Pr.438] Cam axis cycle unit setting Set the command units for the cam axis input per cycle to be used for cam control. These units are used for setting the cam axis length per cycle and the cam axis current value per cycle. There is no influence on the control for the parameter for monitor display.
  • Page 96 [Pr.440] Cam No. Set the cam No. for cam control. Cam No.0 is preset in the Simple Motion module, and it operates as a linear cam for 100% of its stroke ratio along the cam axis length per cycle. The cam No. can be changed during synchronous control. The value set in "[Pr.440] Cam No."...
  • Page 97 [Pr.445] Cam axis phase compensation time constant Set the time constant to affect the phase compensation amount for the first order delay. 63 [%] of the phase compensation amount is reflected in the time constant setting. [Pr.444] Cam axis phase Current value per cycle after phase compensation compensation advance time Current value per cycle before phase compensation...
  • Page 98: Synchronous Control Change Function

    Synchronous Control Change Function Overview of synchronous control change function This function can change the cam reference position, the cam axis current value per cycle and the current value per cycle after the main/auxiliary shaft gear during the synchronous control. The following 5 methods exist for the synchronous control change function.
  • Page 99 [Cd.407] Synchronous control change command Set the synchronous control change command. Setting value Details Reference Page 97 Cam reference position movement Cam reference position movement Page 97 Change cam axis current value per cycle Change cam axis current value per cycle Page 98 Change current value per cycle after main shaft gear Change current value per cycle after main shaft gear Page 98 Change current value per cycle after auxiliary shaft gear...
  • Page 100 ■Change current value per cycle after main shaft gear The current value per cycle after main shaft gear is changed to the value set in "[Cd.408] Synchronous control change value". This operation is completed within one operation cycle. Clutch control is not executed if the current value per cycle after main shaft gear (the value before being changed and after being changed) has already passed through the ON/OFF address in address mode.
  • Page 101 [Cd.409] Synchronous control reflection time Set the reflection time for synchronous control change processing as follows. [Cd.407] Synchronous control Setting details for "[Cd.409] Synchronous control reflection time change command 0: Cam reference position movement The time to reflect the movement amount to the cam reference position. 1: Change cam axis current value per Setting not required.
  • Page 102: Synchronous Control Monitor Data

    Synchronous Control Monitor Data Synchronous control monitor data is updated only during synchronous control. The monitor values ([Md.400], [Md.401], [Md.402], [Md.407], [Md.408], and [Md.409]) from the last synchronous control session are restored the next time the system's power supply turns ON. Restarting operation status from the last synchronous control session is possible through returning to the last position via positioning control (Page 106 SYNCHRONOUS CONTROL INITIAL POSITION).
  • Page 103 Monitor item Storage details Monitor value Buffer memory address [Md.420] • The ON/OFF status of main shaft clutch is stored. ■Monitoring is carried out in decimal display. 42828+40n Main shaft clutch ON/OFF Refresh cycle: Operation cycle (During synchronous 0: Clutch OFF status status control only) 1: Clutch ON status...
  • Page 104 [Md.401] Current value per cycle after main shaft gear The input movement amount after the main shaft gear is stored within the range from 0 to (Cam axis length per cycle - 1). The unit is in cam axis cycle units (Page 91 Units for the output axis). The value is restored according to "[Pr.460] Setting method of current value per cycle after main shaft gear"...
  • Page 105 [Md.421] Main shaft clutch smoothing status The smoothing status of the clutch is stored. The status is updated by the clutch smoothing method as follows. Method Details Time constant method The status is always "1: On clutch smoothing" during the clutch ON status. The status will be "0: Not on clutch smoothing"...
  • Page 106: Phase Compensation Function

    Phase Compensation Function In synchronous control, delays in progresses, etc. cause the phase to deviate at the output axis motor shaft end with respect to the input axis (servo input axis or synchronous encoder axis). The phase compensation function compensates in this case so that the phase does not deviate.
  • Page 107: Output Axis Sub Functions

    Output Axis Sub Functions The following shows which sub functions apply for the output axis in synchronous control. : Valid, : Invalid Sub function Output Details axis  Backlash compensation function The same control as other methods.  Electronic gear function ...
  • Page 108: Chapter 5 Synchronous Control Initial Position

    SYNCHRONOUS CONTROL INITIAL POSITION The initial position for synchronous control is explained in this chapter. Configure these settings for situations that require initial position alignment for synchronous control. Synchronous Control Initial Position The following synchronous control monitor data can be aligned to a set position when starting synchronous control, as the initial position for synchronous control.
  • Page 109 Current value after composite main shaft gear at synchronous control start The current value after composite main shaft gear is restored as follows according to the main input axis operation executed before starting synchronous control. Operation of main input axis Servo input axis Synchronous encoder axis (Before synchronous control...
  • Page 110 Current value per cycle after main/auxiliary shaft gear at synchronous control start The current value per cycle after main shaft gear/current value per cycle after auxiliary shaft gear is restored as follows according to the main input axis/auxiliary shaft operation executed before starting synchronous control. Operation of main input axis / Servo input axis Synchronous encoder axis...
  • Page 111 Cam axis position at synchronous control start The cam axis position is composed of the relationship of 3 positions "Cam axis current value per cycle", "Cam reference position" and "Cam axis feed current value". One of positions can be restored by defining 2 positions when starting synchronous control.
  • Page 112: Synchronous Control Initial Position Parameters

    Synchronous Control Initial Position Parameters n: Axis No. - 1 Setting item Setting details Setting value Default Buffer value memory address [Pr.460] • Select the setting method for the current value per ■Set in decimal. 36500+200n Setting method of cycle after main shaft gear. 0: Previous value current value per Fetch cycle: At start of synchronous control...
  • Page 113 [Pr.461] Setting method of current value per cycle after auxiliary shaft gear Select the setting method of "[Md.402] Current value per cycle after auxiliary shaft gear" when starting synchronous control. Setting value Details 0: Previous value The current value per cycle after auxiliary shaft gear from the last synchronous control session is stored. 1: Initial setting value of current value per cycle The value set in "[Pr.466] Current value per cycle after auxiliary shaft gear (Initial setting)"...
  • Page 114 [Pr.466] Current value per cycle after auxiliary shaft gear (Initial setting) Set the initial setting value of the current value per cycle after auxiliary shaft gear when "[Pr.461] Setting method of current value per cycle after auxiliary shaft gear" is set to "1: Current value per cycle after auxiliary shaft gear (Initial setting)". The unit settings are in cam axis cycle units (Page 91 Units for the output axis).
  • Page 115: Cam Axis Position Restoration Method

    Cam Axis Position Restoration Method Cam axis current value per cycle restoration If "[Pr.462] Cam axis position restoration object" is set to "0: Cam axis current value per cycle restoration" when starting synchronous control, the cam axis current value per cycle is restored based on the cam reference position and the cam axis feed current value.
  • Page 116 Cam axis current value per cycle restoration operation ■With a two-way cam pattern operation • Search from "Cam axis current value per cycle = 0". (Cam data starting point = 0) Cam axis current value per cycle Search from "Cam axis current value per cycle=0". Cam axis feed current value (Feed current value) Restore to the first feed current value that matches.
  • Page 117 • Search from a value in the middle of the cam axis current value per cycle. (Cam data starting point = 0) [Pr.468] Cam axis current value per cycle (Initial setting) Cam axis current value per cycle Cam axis feed current value (Feed current value) New cam reference position Cam reference position...
  • Page 118: Cam Reference Position Restoration

    Cam reference position restoration If "[Pr.462] Cam axis position restoration object" is set to "1: cam reference position restoration" when starting synchronous control, the cam reference position is restored based on the cam axis current value per cycle and the cam axis feed current value.
  • Page 119: Cam Axis Feed Current Value Restoration

    Cam axis feed current value restoration If "[Pr.462] Cam axis position restoration object" is set to "2: cam feed current value restoration" when starting synchronous control, the cam axis feed current value is restored based on the cam axis current value per cycle and the cam reference position.
  • Page 120: Synchronous Control Analysis Mode

    Synchronous Control Analysis Mode With synchronous control analysis mode, parameters are only analyzed for synchronous control when there is a command to start synchronous control. This mode is used to confirm the synchronous positions of the output axes in order to align axes with position control before starting synchronous control.
  • Page 121 Example The following shows a procedure of aligning the synchronous position of an output axis that references the input axis. Set the following values in the synchronous control initial position parameters. Setting item Setting value [Pr.460] Setting method of current value per cycle after main shaft gear 2: Calculate from input axis [Pr.462] Cam axis position restoration object 2: Cam axis feed current value restoration...
  • Page 122: Cam Position Calculation Function

    Cam Position Calculation Function The cam position is calculated by the program with this function. This function can be used to calculate the cam position for the synchronous control initial position before starting synchronous control. Example The following shows the procedure for synchronous position alignment, in a synchronous system where cam axes 2 and 3 are synchronized with the cam axis current value per cycle of axis 1.
  • Page 123 [Cd.612] Cam position calculation request Set the following commands to calculate the cam position. Setting value Details Cam axis feed current value calculation request Cam axis current value per cycle calculation request The result is stored in "[Md.600] Cam position calculation result" and the setting value is reset to "0" automatically after completion of cam position calculation.
  • Page 124: Cam Position Calculation Monitor Data

    Cam position calculation monitor data Monitor item Storage details Monitor value Buffer memory address [Md.600] • The result of the cam position calculation ■Monitoring is carried out in decimal. 53800 Cam position calculation result is stored. • When calculating the cam axis feed 53801 Refresh cycle: At cam position calculation current value:...
  • Page 125 Search for the cam axis current value per cycle When calculating the cam axis current value per cycle using cam data, the position corresponding to "[Cd.618] Cam position calculation: Cam axis feed current value" is searched using cam data based on the position specified by "[Cd.617] Cam position calculation: Cam axis current value per cycle".
  • Page 126 • If the corresponding position is not found until the last point of the cam data, searches from the 0th point of the cam data. • Searches until between the 127th point and the 128th point in order of the cam data between the 0th point and the 1st point and between the 1st point and the 2nd point.
  • Page 127 When "[Cd.617] Cam position calculation: Cam axis current value per cycle" is corresponding to the 1st point of cam data Search order At the 2nd point Search starting point At the 3rd point At the 1st point At the 5th point [Cd.617] Cam position At the 0th point calculation: Cam axis...
  • Page 128 (3) The range from the last point of cam data to the cam axis length per cycle When "the last point of cam data  [Cd.617] Cam position calculation: Cam axis current value per cycle < cam axis length per cycle", the position corresponding to "[Cd.618] Cam position calculation: Cam axis feed current value"...
  • Page 129: Method To Restart Synchronous Control

    Method to Restart Synchronous Control The relationship of the synchronous position for synchronous control is always saved in the Simple Motion module. Synchronous control can be restarted without returning all axes to their starting points by restoring the synchronized relationship through the synchronous control initial position parameters (Page 110 Synchronous Control Initial Position Parameters).
  • Page 130: Appendices

    APPENDICES Appendix 1 List of Buffer Memory Addresses (for Synchronous Control) The following shows the relation between the buffer memory addresses and the various items. n: Axis No. - 1 j: Synchronous encoder axis No. - 1 Memory area item Buffer memory address...
  • Page 131 Memory area item Buffer memory address Synchronous Auxiliary shaft [Pr.418] Auxiliary shaft axis No. 36430+200n parameter [Pr.419] Composite auxiliary shaft gear 36431+200n [Pr.420] Auxiliary shaft gear: Numerator 36432+200n 36433+200n [Pr.421] Auxiliary shaft gear: Denominator 36434+200n 36435+200n [Pr.422] Auxiliary shaft clutch control setting 36436+200n [Pr.423] Auxiliary shaft clutch reference address setting...
  • Page 132 Memory area item Buffer memory address Servo input axis monitor data [Md.300] Servo input axis current value 33120+10n 33121+10n [Md.301] Servo input axis speed 33122+10n 33123+10n [Md.302] Servo input axis phase compensation amount 33124+10n 33125+10n [Md.303] Servo input axis rotation direction restriction amount 33126+10n 33127+10n Synchronous encoder axis monitor data...
  • Page 133 Memory area item Buffer memory address Synchronous encoder axis control data [Cd.320] Synchronous encoder axis control start 35040+10j [Cd.321] Synchronous encoder axis control method 35041+10j [Cd.322] Synchronous encoder axis current value setting address 35042+10j 35043+10j [Cd.323] Synchronous encoder axis error reset 35044+10j [Cd.324] Connection command of synchronous encoder via CPU...
  • Page 134 *1 The item details on the cam auto-generation are shown below. Parameters for generating rotary cutter. Details Buffer memory address Cam resolution 53204 Sheet length 53206 53207 Sheet synchronous width 53208 53209 Synchronous axis length 53210 53211 Synchronization starting point 53212 53213 Synchronous section acceleration...
  • Page 135: Appendix 2 Sample Program Of Synchronous Control

    Appendix 2 Sample Program of Synchronous Control The following shows a sample program of executing synchronous control on the axis 1 with the axis 4 as an input axis. (The axis 4 is configured as the virtual servo amplifier.) Set MR-J4(W)-B on the axis 1 and the virtual servo amplifier on the axis 4 in the system setting. Set the axis 4 as the servo input axis in the input axis parameter.
  • Page 136 Create the cam data (cam No.1). Set the synchronous parameter of the axis 1. APPENDICES APPENDIX Appendix 2 Sample Program of Synchronous Control...
  • Page 137 Create the program to start synchronous control. The sample program when head I/O number of the Simple Motion module is set to 00H is shown below. APPENDICES APPENDIX Appendix 2 Sample Program of Synchronous Control...
  • Page 138 Classification Label name Description Module label RD77_1.bSynchronizationFlag_D Axis 1 Synchronization flag RD77_1.bPLC_Ready_D Axis 1 PLC READY RD77_1.bAllAxisServoOn_D Axis 1 All axis servo ON RD77_1.bnBusy_D[0] Axis 1 BUSY RD77_1.stnAxMntr_D[0].wAxisOperationStatus_D Axis 1 Axis operation status RD77_1.bnBusy_D[3] Axis 4 BUSY Global label, Local label Defines the global label or the local label as follows.
  • Page 139 MEMO APPENDICES APPENDIX Appendix 2 Sample Program of Synchronous Control...
  • Page 140: Index

    INDEX Current value after composite main shaft gear ....... . 100,101 .
  • Page 141 ..46,47 Synchronous encoder axis warning No....29 Servo input axis current value Servo input axis phase compensation advance time ........26,27 .
  • Page 142: Revisions

    Japanese manual number: IB-0300248-B This manual confers no industrial property rights of any other kind, nor does it confer any patent licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual.
  • Page 143: Warranty

    WARRANTY Please confirm the following product warranty details before using this product. 1. Gratis Warranty Term and Gratis Warranty Range If any faults or defects (hereinafter "Failure") found to be the responsibility of Mitsubishi occurs during use of the product within the gratis warranty term, the product shall be repaired at no cost via the sales representative or Mitsubishi Service Company.
  • Page 144: Trademarks

    TRADEMARKS Microsoft, Windows, Windows Vista, Windows NT, Windows XP, Windows Server, Visio, Excel, PowerPoint, Visual Basic, Visual C++, and Access are either registered trademarks or trademarks of Microsoft Corporation in the United States, Japan, and other countries. Intel, Pentium, and Celeron are either registered trademarks or trademarks of Intel Corporation in the United States and other countries.
  • Page 146 IB(NA)-0300249-B(1502)MEE MODEL: RD77-U-ADV-E MODEL CODE: 1XB016 HEAD OFFICE : TOKYO BUILDING, 2-7-3 MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN NAGOYA WORKS : 1-14 , YADA-MINAMI 5-CHOME , HIGASHI-KU, NAGOYA , JAPAN When exported from Japan, this manual does not require application to the Ministry of Economy, Trade and Industry for service transaction permission.

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