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Mitsubishi Electric MELSEC iQ-F Series FX5 User Manual

Positioning control - intelligent function module.
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MELSEC iQ-F
FX5 User's Manual
(Positioning Control - Intelligent function module)

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Troubleshooting

   Also See for Mitsubishi Electric MELSEC iQ-F Series FX5

   Summary of Contents for Mitsubishi Electric MELSEC iQ-F Series FX5

  • Page 1

    MELSEC iQ-F FX5 User's Manual (Positioning Control - Intelligent function module)

  • Page 3: Safety Precautions

    SAFETY PRECAUTIONS (Read these precautions before use.) Before using this product, please read this manual and the relevant manuals introduced in this manual carefully and pay full attention to safety in order to handle the product correctly. This manual classifies the safety precautions into two categories: [ WARNING] and [ CAUTION].

  • Page 4

    [INSTALLATION PRECAUTIONS] WARNING ● Make sure to cut off all phases of the power supply externally before attempting installation or wiring work. Failure to do so may cause electric shock or damage to the product. ● Use the product within the generic environment specifications described in the User's Manual (Hardware) of the CPU module used.

  • Page 5

    [WIRING PRECAUTIONS] WARNING ● Make sure to cut off all phases of the power supply externally before attempting installation or wiring work. Failure to do so may cause electric shock or damage to the product. ● Make sure to attach the terminal cover, provided as an accessory, before turning on the power or initiating operation after installation or wiring work.

  • Page 6

    ● Do not disassemble or modify the PLC. Doing so may cause fire, equipment failures, or malfunctions. For repair, contact your local Mitsubishi Electric representative. ● Turn off the power to the PLC before connecting or disconnecting any extension cable. Failure to do so may cause equipment failures or malfunctions.

  • Page 7: Introduction

    • Since the examples indicated by this manual, technical bulletin, catalog, etc. are used as a reference, please use it after confirming the function and safety of the equipment and system. Mitsubishi Electric will accept no responsibility for actual use of the product based on these illustrative examples.

  • Page 8: Table Of Contents

    CONTENTS SAFETY PRECAUTIONS ..............1 INTRODUCTION .

  • Page 9: Table Of Contents

    Restarting................70 CHAPTER 8 OPR CONTROL Overview of the OPR Control .

  • Page 10: Table Of Contents

    Block start (normal start) ..............170 Condition start .

  • Page 11: Table Of Contents

    Hardware stroke limit function ............. . 239 12.5 Functions that Change Control Details .

  • Page 12: Table Of Contents

    CHAPTER 15 MONITORING/TEST 15.1 Positioning Monitor..............327 15.2 Positioning Test.

  • Page 13: Table Of Contents

    Mitsubishi Electric servo amplifier connection example ........

  • Page 14: Relevant Manuals

    RELEVANT MANUALS Manual name <manual numbers> Description MELSEC iQ-F FX5 User's Manual (Startup) Performance specifications, procedures before operation, and <JY997D58201> troubleshooting of the CPU module. MELSEC iQ-F FX5U User's Manual (Hardware) Describes the details of hardware of the FX5U CPU module, including input/ <JY997D55301>...

  • Page 15: Terms

    TERMS Unless otherwise specified, this manual uses the following terms. For details on the FX3 devices that can be connected with the FX5, refer to the User’s Manual (Hardware) of the CPU module to be used. Terms Description ■Device Generic term for FX5U and FX5UC PLCs Generic term for FX3S, FX3G, FX3GC, FX3U, and FX3UC PLCs FX5 CPU module Generic term for FX5U CPU module and FX5UC CPU module...

  • Page 16

    Abbreviation of Secure Digital Memory Card. Device that stores data using flash memory. Peripheral device Generic term for engineering tools and GOTs Generic term for Mitsubishi Electric Graphic Operation Terminal GOT1000 and GOT2000 series ■Software package Engineering tool The product name of the software package for the MELSEC PLCs...

  • Page 17: Chapter 1 Description

    DESCRIPTION The positioning module is an intelligent function module for high speed, high precision positioning with servo motors or stepping motors via drive units. Positioning control is easy The positioning module controls the position and speed using the positioning data set using GX Works3. 600 positioning data max.

  • Page 18: Chapter 2 Specifications

    SPECIFICATIONS This chapter describes the positioning module specifications. General Specifications General specifications other than those described below are the same as for the connected CPU module. See the following manuals for the general specifications. MELSEC iQ-F FX5U User's Manual (Hardware) MELSEC iQ-F FX5UC User's Manual (Hardware) Items Specifications...

  • Page 19

    Items Specifications Positioning Positioning system PTP control: Incremental system/absolute system Speed-position switching control: Incremental system/absolute system Position-speed switching control: Incremental system Path control: Incremental system/absolute system Positioning range ■When using the absolute system • -214748364.8 to 214748364.7 μm • -21474.83648 to 21474.83647 inch •...

  • Page 20: External Device Output Interface Specifications

    External Device Output Interface Specifications I/O signals electrical specifications Input specifications Signal name Rated input Use voltage ON voltage/ OFF voltage/ Input Response voltage/ range current current resistance time current Drive unit READY signal (READY) 24 V DC/5 mA 19.2 to 17.5 V DC or more/ 7 V DC or less/ Approx.

  • Page 21

    ■Relationship of the pulse outputs using "[Pr.5] pulse output mode" and "[Pr.23] output signal logic selection" The pulse output mode (PULSE/SIGN type, CW/CCW type, Phase A/Phase B type) can be selected using "[Pr.5] pulse output mode" according to the drive module specifications. Further, the output signal logic (positive or negative logic) can be selected using "[Pr.23] output signal logic selection".

  • Page 22: Part Names

    Part Names Describes the names of the positioning module parts. 2-4.5 mounting holes [10] [11] [12] [13] Name Description Connector for external devices This is the connector for connecting the drive module, mechanical inputs, and manual pulse generator. See below for the signal array. Page 50 Connector signal array for connecting external devices AX1: Axis 1, AX2: Axis 2 Expansion cable...

  • Page 23: Led Display Specifications

    LED display specifications The LED display specifications are described below. : OFF, : ON, ●: Flashing (flashing interval: ON: 200 ms/OFF: 200 ms) Positioning module status LED display Indication Power OFF AX1 POWER Positioning module power is off AX2 RUN ERROR...

  • Page 24: Chapter 3 Procedures Before Operations

    PROCEDURES BEFORE OPERATIONS This chapter describes the procedures before operation. Module mounting Mount the positioning module to the CPU module. For details, refer to the following. MELSEC iQ-F FX5U User's Manual (Hardware) MELSEC iQ-F FX5UC User's Manual (Hardware) Wiring Wire the positioning module to the external device. Adding modules Add positioning modules to the unit configuration diagram for the project using GX Works3.

  • Page 25

    MEMO 3 PROCEDURES BEFORE OPERATIONS...

  • Page 26: Chapter 4 Functions List

    FUNCTIONS LIST Control Functions The positioning module has various functions. This section describes the positioning module functions using the following classifications. Positioning functions Positioning functions are the functions that start the positioning to the designated position using the positioning data, block start data, and conditions data.

  • Page 27: Positioning Functions

    Positioning Functions A list of the positioning functions startup methods are described below. Positioning start method Description Normal start This function can start positioning controls using the simplest methods. Major positioning controls and advanced positioning controls can be started in this mode. Quick start This function quickly starts the positioning data that is implemented immediately afterwards using advance analysis.

  • Page 28

    Main functions Description Advanced Block start (normal start) With one start, executes positioning data in a block in the set order. positioning control Condition start Judges the condition set in Condition data for the specified positioning data, and executes Block start data. When the condition is established, Block start data is executed.

  • Page 29: Sub Function, Common Function

    Sub Function, Common Function Sub function A summary of the sub functions used in positioning control by the positioning module is described below. Sub function Description Sub functions specific to OPR retry function Retries the machine OPR with the upper/lower limit switches during the machine OPR. machine OPR This allows the machine OPR to be performed even if the axis is not returned to a position before the near-point dog with operations such as the JOG operation.

  • Page 30

    Sub function Description Other functions Skip function Pauses (decelerates to stop) the positioning being executed when Skip signal is input, and performs the next positioning. M code output function This function implements subsidiary task commands (such as stopping clamps or drills and changing tools) corresponding to the M code numbers using the numbers 0 to 65535, which can be set for each positioning data.

  • Page 31: Combining Main And Sub Functions

    Combining Main and Sub Functions The positioning controls used by the positioning module implement control using a combination of main and sub functions as necessary. : Must be combined : Combinations possible : Combinations have limitations : Cannot be combined Main functions Combinations with Functions Specific to Machine OPR...

  • Page 32

    Main functions Function to Compensate Control Backlash Electronic gear Near pass Output timing compensation function function selection of near function pass control OPR control Machine OPR control       Fast OPR control    Major Position control 1-axis linear control positioning...

  • Page 33

    Main functions Function to limit control Speed limit Torque limit Software stroke Hardware stroke function function limit function limit function OPR control Machine OPR control         Fast OPR control     Major Position control 1-axis linear control...

  • Page 34

    Main functions Functions that Function related to positioning start Change Control Details Target position Restart function Pre-reading start Start time change function function adjustment function OPR control Machine OPR control         Fast OPR control Major Position control 1-axis linear control...

  • Page 35

    Main functions Other functions Skip function M code output Teaching Command in- function function position function OPR control Machine OPR control         Fast OPR control     Major Position control 1-axis linear control positioning ...

  • Page 36: Combining Various Sub Functions

    Combining Various Sub Functions A list of the various sub function combinations during one main function control is described below. : Combinations possible : Combinations have limitations : Cannot be combined Function name Combinable sub functions OPR retry OP shift function Backlash Electronic gear function...

  • Page 37

    Function name Combinable sub functions Near pass Output timing Speed limit Torque limit function selection of near function function pass control     Functions specific OPR retry function to machine OPR     OP shift function ...

  • Page 38

    Function name Combinable sub functions Software stroke Hardware stroke Speed change Override function limit function limit function function     Functions specific OPR retry function to machine OPR     OP shift function    ...

  • Page 39

    Function name Combinable sub functions Acceleration/ Torque change Target position Start time deceleration time function change function adjustment change function function     Functions specific OPR retry function to machine OPR     OP shift function ...

  • Page 40

    Function name Combinable sub functions Restart function Pre-reading start Absolute position Step function function restoration function Functions specific OPR retry function     to machine OPR     OP shift function     Function to Backlash compensation function compensate control ...

  • Page 41

    Function name Combinable sub functions Stop command Continuous Stop process Skip function processing for operation function deceleration stop interrupt function function     Functions specific OPR retry function to machine OPR     OP shift function ...

  • Page 42

    Function name Combinable sub functions M code output Teaching function Command in- Acceleration/ function position function deceleration processing function Functions specific OPR retry function     to machine OPR     OP shift function   ...

  • Page 43

    Function name Combinable sub functions Deceleration start flag During uncompleted OPR Interrupt function operation setting function    Functions specific OPR retry function to machine OPR    OP shift function    Function to Backlash compensation function compensate control ...

  • Page 44: Chapter 5 System Configuration

    SYSTEM CONFIGURATION Describes the configuration functions when using the positioning module. See the following for the PLC system configuration. MELSEC iQ-F FX5U User's Manual (Hardware) MELSEC iQ-F FX5UC User's Manual (Hardware) Positioning module Drive module Manual pulse generator (Manual pulser) Mechanical inputs (switch) •...

  • Page 45

    MEMO 5 SYSTEM CONFIGURATION...

  • Page 46: Chapter 6 Wiring

    WIRING This section explains the wiring methods, wiring parts, and wiring precautions when using the positioning module. Power Supply Wiring Power connector array (Green) (Black) (Red) Power supply wiring (1) Red (2) Black Positioning (3) Green module (1) (2) (3) 24 V DC D ground (Ground resistance: 100 ...

  • Page 47: Connector Wiring

    Connector Wiring This section explains the connectors for connecting external devices. See below for the terminal array. Page 50 Connector for Connecting External Devices Precautions Check the terminal array before wiring the positioning module correctly. Usable connectors Use the connectors specified by the user for connecting external devices used by the positioning module. The connector types and recommended crimping tools are described below.

  • Page 48

    Solder the wires, and cover the heat-shrinking tubing (1). Check the terminal array, and wire to the connector. If the connector is connected to an I/O module, it is not necessary to connect the FG wires. Insert the connector into one side of the connector cover, and pass the securing screws all the way through.

  • Page 49: Connecting The Connectors

    Array the flat cables in the order described below. A1→B1→A2⋅⋅⋅⋅⋅⋅ (The diagram below shows the view from the connector insertion aperture) B20 B19 B18 B17 B16 B15 B14 B13 B12 B11 B10 B09 B08 B07 B06 B05 B04 B03 B02 B01 A20 A19 A18 A17 A16 A15 A14 A13 A12 A11 A10 A09 A08 A07 A06 A05 A04 A03 A02 A01 Connecting the connectors Mounting order...

  • Page 50: Wiring Example When Using Shielded Cables

    Wiring example when using shielded cables A wiring example for noise countermeasures if using the A6CON1 connector is described below. Connector Connector To external device (A6CON1) Shield cable (With 2 drive modules) Drive module To external device To drive module Positioning module (1) Minimize the distance between the connector and the shielded cable.

  • Page 51: Precautions

    Precautions • Correctly solder or crimp the connectors for connecting external devices (A6CON). • Securely connect the connectors for connecting external devices (A6CON) to the module, and tighten the screws (x2). • Tighten the connector mounting screws within the tightening range described below. Screws Tightening range Connector mounting screws (M2.6 screws)

  • Page 52: Connector For Connecting External Devices

    Connector for Connecting External Devices Connector signal array for connecting external devices The connector signal array for connecting external positioning module devices is described below. Pin layout (seen from the front of the Axis 2 (AX2) Axis 1 (AX1) unit) Pin No.

  • Page 53

    Signal name Axis No. Signal details (External I/O signals logic selection is negative logic) Axis 1 Axis 2 Pulse output F (PULSE F) Outputs Pulses and pulse symbols for positioning the drive module corresponding to the transistor outputs. Pulse output F common (PULSE COM) Pulse output R (PULSE R) Pulse output R common...

  • Page 54: Internal I/o Interface Circuits

    Internal I/O interface circuits A simplified diagram of the internal interface circuits for connecting a 1-axis external device to the positioning module is shown below. Inputs : Wiring required during positioning, : Wire as necessary External wiring and internal circuits Pin No.

  • Page 55

    ■Input signals ON/OFF status The input signals ON/OFF status is determined by the external wiring and logic settings. For example, near-point dog signals (DOG) (Other input signal operations are the same as for near-point dog signals (DOG).) *1*2 Logic settings External wiring Positioning module ON/OFF status Negative logic (default value)

  • Page 56

    Outputs : Wiring required during positioning, : Wire as necessary External wiring and internal circuits Pin No. Signal name Wiring requirements  Deviation counter clear signal External wiring Pin No. Internal circuit (CLEAR) Load Deviation counter clear common (CLEAR COM) 5 to 24 V DC ...

  • Page 57: Chapter 7 Starting And Stopping

    STARTING AND STOPPING This chapter describes how to start and stop positioning control operations with the positioning module. Starting The positioning module starts the positioning control when a start trigger, specific to the control, is turned on. The following table lists the start signals by control type. This section describes starting with the "[Cd.184] Positioning start signal" and external command signals.

  • Page 58

    Start with "[Cd.184] Positioning start signal" This section describes operations started with "[Cd.184] Positioning start signal". • When the "[Cd.184] Positioning start signal" is turned ON, the start complete signal ([Md.31] Status: b14) and "[Md.141] BUSY signal" turn ON, and positioning operations start. The on state of the "[Md.141] BUSY signal" indicates that the corresponding axis is in operation.

  • Page 59

    Starting using external command signals (CHG) When the positioning control is started by inputting an external command signal (CHG), the start command can be directly input to the positioning module. This method eliminates the variation time equivalent to one scan time of the CPU module. Use the start command when an operation is required to be started as soon as possible, or when the starting variation time is to be suppressed.

  • Page 60: Normal Start

    Normal start Positioning controls can be started by the simplest procedure in this mode. Major positioning controls and advanced positioning controls can be started in this mode. The following positioning data is used. • Positioning data (No. 1 to No. 600) •...

  • Page 61: Quick Start

    ■If using external command signals (CHG) Positioning can be started by setting "0: Start with external command" in "[Pr.42] External command function selection" and inputting external command signals (CHG) after implementing the following program. Page 489 External command function valid setting program Quick start Positioning controls can be started quickly by analyzing in advance the positioning data executed immediately after the current operation to prevent the analysis time affecting the start.

  • Page 62

    Control details ■Length of time before the positioning starts While "[Cd:43] Analysis mode settings" is set to "1: Pre-analysis mode", the positioning data specified in "[Cd.3] Positioning start No." is analyzed. The following shows the start timing of positioning data analysis. •...

  • Page 63

    ■Executing the quick start repeatedly The quick start can be executed repeatedly by keeping [Cd.43] Analysis mode setting set to 1: Pre-analysis mode. When [Cd.3] Positioning start No. is set to the positioning data No. used for the positioning control 2 during the operation of the positioning control 1, the operation is performed as follows.

  • Page 64

    Restrictions • The range of the positioning data No. used for the quick start is between 1 and 600. If a number other than 1 to 600 is set for [Cd.3] Positioning start No., Pre-analysis not possible (Warning code: 09A8H) occurs and the pre-analysis of positioning data is not performed.

  • Page 65

    • During pre-analysis mode, do not turn OFF→ON "[Cd.184] Positioning start signal" when "[Pr.42] External command function selection" is set to "0: Start external positioning" and "[Cd.8] Enable external commands" is set to "1: Enable external commands". Positioning start signal input at quick external start (Warning code: 09A7H) occurs and no operation is started.

  • Page 66: Multiple Axes Simultaneous Start

    Multiple axes simultaneous start In this starting mode, the simultaneous starting axis and the started axis start outputting pulses at the same timing. Control details Perform the multiple axes simultaneous start by setting the following buffer memory areas and turning on a start trigger. •...

  • Page 67

    Setting method The following table lists the data settings to perform the multiple axes simultaneous start using Positioning start signal. (Set the axis control data for the starting axis.) Setting item Setting Setting details Buffer memory address value Axis 1 Axis 2 [Cd.3] Positioning start No.

  • Page 68: Stopping

    Stopping This section describes the stop control of the positioning. The following events may stop each positioning control by the positioning module. • When each control ends normally • When Drive unit READY signal (READY) is turned OFF • When an error occurred in the CPU module •...

  • Page 69

    Classification of the stop processing types The stop processing during the operation is classified into three types: deceleration stop, sudden stop, and immediate stop. ■Deceleration stop This processing is implemented using [Pr.10] Deceleration time 0, and [Pr.28] Deceleration time 1 to [Pr.30] Deceleration time 3.

  • Page 70

    Order of priority for the stop processing The order of priority for the positioning module stop processing is as described below. (Deceleration stop) < (Sudden stop) < (Immediate stop) If the deceleration stop command is ON (i.e., the stop signal is ON) or a deceleration stop cause occurs during the deceleration to speed 0 (including automatic deceleration), the operation changes depending on the setting in [Cd.42] Stop command processing for deceleration stop selection.

  • Page 71

    Further, in the position control (including the speed-position switching control and position-speed switching control), the positioning may stop depending on the timing of the stop cause occurrence and the set value in "[Pr.36] Sudden stop deceleration time". • Sudden stop before the specified positioning address Stop cause occurs (Sudden stop cause) Deceleration curve according to sudden stop deceleration time...

  • Page 72: Restarting

    Restarting If the positioning control is stopped by a stop command ("[Cd.180] Axis stop signal" or a stop signal from an external device), the positioning can be restarted from the stopped position to the end point of the position control by using ("[Cd.6] Restart command").

  • Page 73

    Setting method Set the following data to restart the positioning. Setting item Setting Setting detail Buffer memory address value Axis 1 Axis 2 [Cd.6] Restart command Set "1: Restart". 1503 1603 For details on the settings, refer to the following. Page 458 [Cd.6] Restart command Restart time chart Dwell time...

  • Page 74: Chapter 8 Opr Control

    OPR CONTROL This chapter describes the details and usage of the OPR control. Overview of the OPR Control Two types of OPR controls The OPR control establishes a start point (= OP) for performing the positioning control, and implements positioning toward that start point.

  • Page 75: Machine Opr

    When no OPR is required In a system that does not need any OPR operation, the OPR request flag ([Md.31] Status: b3) can be ignored to implement the positioning. In this case, set all OPR parameter areas ([Pr.43] to [Pr.57]) to their default values or values that do not cause errors.

  • Page 76: Machine Opr Method

    Machine OPR method In the machine OPR, the method by which the machine OP is established (method for judging the position of the OP and the completion of the machine OPR) is specified according to the configuration and application of the positioning system. The following table shows the seven methods provided as the OPR methods.

  • Page 77

    The following table shows the external I/O signals used for the machine OPR. : Required : Use as necessary : Not required [Pr.43] OPR method Signal required for control Torque limit Near-point dog Zero signal Upper/lower limit Deviation counter switches clear output ...

  • Page 78: Near-point Dog Method

    Near-point dog method The following shows an operation overview of the near-point dog method, one of the OPR methods. Operation chart [Pr.46] OPR speed Deceleration using near-point dog ON [Pr.47] Creep speed 4. 5. [Md.34] Movement amount after near-point dog ON Adjust so that the near-point dog OFF position Near-point dog is as close to the 0-point signal HIGH center...

  • Page 79

    Precautions during the operation • Start at OP (Error code: 1940H) will occur if another machine OPR is attempted after the completion of the machine OPR when the OPR retry function has not been set ([Pr.48] OPR retry is 0). •...

  • Page 80: Stopper Method 1

    Stopper method 1 The following shows an operation overview of the stopper method 1, one of the OPR methods. Operation chart [Pr.46] OPR speed [Pr.47] Creep speed Stop using stopper 5. 6. Forced stop range of servomotor rotations using stopper Torque limit enabled range Torque limit Near-point dog...

  • Page 81

    Restrictions Always limit the servomotor torque after the speed reaches the speed set in [Pr.47] Creep speed. Otherwise the servomotor may be damaged when the workpiece hits the stopper. (Page 230 Torque limit function) Precautions during the operation • Set [Pr.49] OPR dwell time to the time that is equal to or longer than the movement time taken from when the near-point dog turns on to when the workpiece hits the stopper.

  • Page 82

    • If the time set in [Pr.49] OPR dwell time elapses before stopping at the stopper, the workpiece will stop at that position, and the position will be set as an OP. In this case, no error will occur. [Pr.46] OPR speed [Pr.47] Creep speed Stopper Torque limit enabled range...

  • Page 83: Stopper Method 2

    Stopper method 2 The following shows an operation overview of the stopper method 2, one of the OPR methods. Operation chart [Pr.46] OPR speed [Pr.47] Creep speed Stop using stopper 2. 3. 4. 5. 6. Zero signal Torque limit enabled range Torque limit Near-point dog Machine OPR start...

  • Page 84

    Restrictions • Always limit the servomotor torque after the speed reaches the speed set in [Pr.47] Creep speed. Otherwise the servomotor may be damaged when the workpiece hits the stopper. (Page 230 Torque limit function) • Use an external input signal as a zero signal. Precautions during the operation •...

  • Page 85

    • If a zero signal is input before the workpiece stops at the stopper, the workpiece stops at that position and the position is set as an OP. In this case, no error will occur. [Pr.46] OPR speed [Pr.47] Creep speed Stopper Zero signal Torque limit enabled range...

  • Page 86: Stopper Method 3

    Stopper method 3 The following shows an operation overview of the stopper method 3, one of the OPR methods. Stopper method 3 is useful for a system in which a near-point dog cannot be installed. (Note that the workpiece starts traveling at the speed set in "[Pr.47] Creep speed", which means that it takes some time until the machine OPR is completed.) Operation chart [Pr.47] Creep speed...

  • Page 87

    Restrictions • Always limit the servomotor torque after the speed reaches the speed set in [Pr.47] Creep speed. Otherwise the servomotor may be damaged when the workpiece hits the stopper. (Page 230 Torque limit function) • Use an external input signal as a zero signal. •...

  • Page 88: Count Method 1

    Count method 1 The following shows an operation overview of Count method 1, one of the OPR methods. If a machine OPR operation is started using Count method 1 from a point where the near-point dog is ON, the machine moves in the reverse direction to the OPR direction to return to a point where the near-point dog turns OFF, and a normal machine OPR operation is implemented.

  • Page 89

    Restrictions A pulse generator with a zero signal is required. When using a pulse generator without a zero signal, produce a zero signal using an external signal. Precautions during the operation • If the distance set in "[Pr.50] Setting for the movement amount after near-point dog ON" is shorter than the deceleration distance from "[Pr.46] OPR speed"...

  • Page 90: Count Method 2

    Count method 2 The following shows an operation overview of Count method 2, one of the OPR methods. If a machine OPR operation is started using Count method 2 from a point where the near-point dog is ON, the machine moves in the direction reverse to the OPR direction to return a point where the near-point dog turns OFF, and a normal machine OPR operation is implemented.

  • Page 91

    Restrictions Since an error of approximately 1 ms occurs in taking in the ON state of the near-point dog, the stop position (OP) varies compared to other OPR methods. Precautions during the operation • If the distance set in "[Pr.50] Setting for the movement amount after near-point dog ON" is shorter than the deceleration distance from "[Pr.46] OPR speed"...

  • Page 92: Data Setting Method

    Data setting method Data setting method is used to set a point at which the workpiece is positioned by a manual feed such as JOG operation as an When the machine OPR is performed using the data setting method, Deviation counter clear signal is output to the drive unit and the current feed value and machine feed value are overwritten with the OP address.

  • Page 93: Fast Opr

    Fast OPR Operation overview of the fast OPR Fast OPR operation After the OP position is established by performing a machine OPR, the positioning control to the OP position is executed without using a near-point dog or zero signal. The following shows the operation after the fast OPR is started. The fast OPR is started.

  • Page 94

    Operation timing and the processing time The following shows the details on the operation timing and processing time in the fast OPR. [Cd.184] Positioning start signal [Md.141] BUSY signal Start complete signal ([Md.31] Status: b14) Standby Position control Standby [Md.26] Axis operation status External pulse output (PULSE) Positioning operation...

  • Page 95: Chapter 9 Major Positioning Control

    MAJOR POSITIONING CONTROL This chapter describes the details and usage of the major positioning control (the control function using positioning data). As the major positioning control, Position control (positioning to the specified position using address information), Speed control (controlling a rotating body at a fixed speed), Speed-position switching control (switching the control type from Speed control to Position control), Position-speed switching control (switching the control type from Position control to Speed control), and others are provided.

  • Page 96: Data Required For Major Positioning Control

    Major positioning control [Da.2] Control Description method Other controls NOP instruction NOP instruction A control method that is not implemented. When the NOP instruction is set, the operation of the next data starts and this instruction is not implemented. Current value Current value change Changes the value in "[Md.20] Current feed value"...

  • Page 97: Operation Pattern Of Major Positioning Control

    Major positioning control from GX Works3 "Major positioning control" can be implemented using the GX Works3 positioning test. For details on the positioning test, refer to the following. Page 328 Positioning Test 600 positioning data max. (Positioning data No.1 to 600) can be set for each axis. Operation pattern of major positioning control In "Major positioning control"...

  • Page 98

    Continuous positioning control • Make sure to auto decelerate each time the positioning for one positioning data finishes, and accelerate to implement the next positioning data operation after the designated speed of the positioning module reaches zero. If a dwell time is specified, the acceleration is performed after the specified time elapses.

  • Page 99

    • In the operation by the continuous path control (operation pattern: 11), the positioning of the next positioning No. is automatically implemented. Always set Operation pattern: 00 to the last positioning data to complete the positioning. If the operation pattern is Positioning continue (01 or 11), the operation continues until Operation pattern: 00 is found. Consequently, if positioning in the operations pattern is not finished, operations are implemented until positioning data No.

  • Page 100

    ■Conditions of deceleration stop during the continuous path control The deceleration stop is not performed in the continuous path control. However, in the following three cases, the deceleration stop is performed and the speed becomes 0 once. • When the operation pattern of the positioning data currently being implemented is Continuous path control: 11 and the movement direction of the positioning data currently being implemented differs from that of the next positioning data.

  • Page 101

    • When the interpolation axis suddenly reverses its direction, the command pulses from the positioning module are output as described below. Forward command Reverse command When a command frequency is f (pulse/s), t1 and t2 are determined using the following calculation formulas. ⋅...

  • Page 102

    • In the continuous path control, the speed is not changed when the positioning data No. is switched by the near pass function. (Page 224 Near pass function) • The positioning module holds the command speed set with the positioning data and the latest speed value set with the speed change request as [Md.27] Current speed to control with the current speed when -1 is set for the command speed.

  • Page 103

    • Speed switching condition If the movement amount is small relative to the target speed and the target speed is not reached even if the acceleration/ deceleration is performed, the machine is accelerated or decelerated to get close to the target speed. If the movement amount is exceeded when automatic deceleration needs to be performed (such as when the operation pattern is 00 or 01), the machine will immediately stop at the specified positioning address, and Insufficient movement amount (Warning code: 0998H) occurs.

  • Page 104: Specifying The Positioning Address

    • Speed switching condition If the movement amount is small relative to the target speed and the target speed is not reached even if the acceleration/ deceleration is performed, the machine is accelerated or decelerated to get close to the target speed. If the movement amount will be exceeded when the automatic deceleration needs to be performed (such as when the operation pattern is 00 or 01), the machine will immediately stop at the specified positioning address, and Insufficient movement amount (Warning code: 0998H) occurs.

  • Page 105: Checking The Current Value

    Checking the current value Values indicating the current values The positioning module uses 2 types of address as described below as the positioning values. These addresses (Current feed value and Machine feed value) are stored in the monitor data area, and used for monitoring the current value display.

  • Page 106

    Monitoring the current value Current feed value and Machine feed value are stored in the following buffer memory areas, and can be read using a DFROM (P) instruction or DMOV (P) instruction from the CPU module. Buffer memory address Axis 1 Axis 2 [Md.20] Current feed value 800, 801...

  • Page 107: Handling Degree (control Unit)

    Handling degree (control unit) If degree is set as the control unit, the following items differ from the ones for when other control units are set. Addresses of Current feed value and Machine feed value The address of "[Md.20] Current feed value" is a ring address from 0 to 359.99999°. However, the address of [Md.21] Machine feed value does not become a ring address.

  • Page 108

    Positioning control method when degree is set as the control unit ■When the absolute system is used If the software stroke limit is invalid The positioning is performed in the direction nearest to the specified address, using the current value as a reference. (This control is called shortcut control.) Example (1) If moving the current value by 315°...

  • Page 109

    • The setting value in "[Cd.40] ABS direction in degrees setting" is valid only at the start of positioning control. In the continuous positioning control or continuous path control, the operation continues with the setting configured at the start even if the setting is changed during the operation. Setting item Setting detail Buffer memory address...

  • Page 110: Interpolation Control

    Interpolation control Meaning of the interpolation control With "2-axis linear interpolation control", "2-axis fixed feed control", "2-axis speed control", and "2-axis circular interpolation control", the motors set in the 2 axis directions are used to control so that the designated path is described. This type of control is called interpolation control.

  • Page 111

    Starting the interpolation control To start the interpolation control, the positioning data No. of the reference axis (the axis for which the interpolation control was set in [Da.2] Control method) are started. (Starting of the interpolation axis is not required.) If both the reference axis and interpolation axis are started, the following errors or warning will occur and the positioning will not start.

  • Page 112

    Interpolation speed specification method For the interpolation control, set the composite speed or reference axis speed with "[Pr.20] Interpolation speed specification method" or "[Da.29] Interpolation speed specification method" of the reference axis. Composite speed Reference axis speed The movement speed for the control target is specified, and the speed for The axis speed set in the reference axis is specified, and the speed for the each axis is calculated by the positioning module.

  • Page 113

    Limits of the interpolation control Limits are provided on the interpolation control that can be implemented and speed ([Pr.20] Interpolation speed specification method) that can be set, depending on the settings in [Pr.1] Unit setting of the reference axis and interpolation axis. (For example, the circular interpolation control cannot be performed if the unit of the reference axis and that of the interpolation axis differ.) The following table shows the limits of the interpolation control and speed specification.

  • Page 114: Positioning Data Settings

    Positioning Data Settings Relation between each control and positioning data The setting requirements and details on the setting items of the positioning data differ according to the setting in [Da.2] Control method. The following table shows the setting items of positioning data prepared for various control systems. (This section presumes the positioning data will be set using GX Works3.) : Always set : Set as required...

  • Page 115

    Setting items for positioning data Speed control Speed-position switching Position-speed control switching control 1-axis speed control 2-axis speed control    [Da.6] Positioning address/movement amount [Da.7] Arc address       [Da.8] Command speed [Da.9] Dwell time ...

  • Page 116: Axis Linear Control

    1-axis linear control In the 1-axis linear control ([Da.2] Control method = ABS linear 1, INC linear 1), one motor is used to perform the position control in the set axis direction. 1-axis linear control (ABS linear 1) ■Operation chart In the 1-axis linear control of the absolute system, the positioning is performed from the current stop position (start point address) to the address set in [Da.6] Positioning address/movement amount (end point address).

  • Page 117

    1-axis linear control (INC linear 1) ■Operation chart In the 1-axis linear control of the incremental system, the positioning for the movement amount set in [Da.6] Positioning address/movement amount is implemented from the current stop position (start point address). The movement direction is determined by the sign of the movement amount.

  • Page 118: Axis Linear Interpolation Control

    2-axis linear interpolation control In the 2-axis linear interpolation control ([Da.2] Control method = ABS linear 2, INC linear 2), two motors are used to implement position control in a linear path while the interpolation is implemented for the axis directions set in each axis. For details on the interpolation control, refer to the following.

  • Page 119

    ■Positioning data to be set To use the 2-axis linear interpolation control (ABS linear 2), set the following positioning data. : Always set : Set as required : Setting not required Setting item Setting requirement of Setting requirement of reference axis interpolation axis ...

  • Page 120

    2-axis linear interpolation control (INC linear 2) ■Operation chart In the 2-axis linear interpolation control of the incremental system, specified two axes are used to implement linear interpolation positioning for the movement amount set in [Da.6] Positioning address/movement amount from the current stop position (start point address).

  • Page 121

    ■Positioning data to be set To use the 2-axis linear interpolation control (INC linear 2), set the following positioning data. : Always set : Set as required : Setting not required Setting item Setting requirement of Setting requirement of reference axis interpolation axis ...

  • Page 122: Fixed-feed Control

    Fixed-feed control In Fixed-feed control ([Da.2] control method = Fixed-feed 1, fixed-feed 2), motors for the number of specified axes are used to perform the fixed-feed control in the set axis direction. In the fixed-feed control, any reminder of the movement amount specified in the positioning data is rounded down to output the same amount of pulses if it is less than that required for control accuracy.

  • Page 123

    Positioning data to be set To use the fixed-feed control, set the following positioning data. : Always set : Set as required : Setting not required Setting item Setting requirement of Setting requirement of reference axis interpolation axis   [Da.1] Operation pattern ...

  • Page 124: Axis Circular Interpolation Control With The Sub Point Specified

    2-axis circular interpolation control with the sub point specified With 2-axis circular interpolation control ([Da.2] Control method = ABS circular interpolation, INC circular interpolation), 2 motors are used to implement positioning control using the circular path that passes through the specified sub points. For details on the interpolation control, refer to the following.

  • Page 125

    ■Positioning data to be set To use the 2-axis circular interpolation control with sub point specified (ABS circular sub), set the following positioning data. : Always set : Set as required : Setting not required Setting item Setting requirement of Setting requirement of reference axis interpolation axis...

  • Page 126

    2-axis circular interpolation control with sub point specified (INC circular sub) ■Operation chart In the incremental system and 2-axis circular interpolation control with sub point specified, the positioning is implemented from the current stop position (start point address) to the position of the movement amount set in [Da.6] Positioning address/ movement amount in an arc path passing through the sub point address (sub point address) set in [Da.7] Arc address.

  • Page 127

    ■Positioning data to be set To use the 2-axis circular interpolation control with sub point specified (INC circular sub), set the following positioning data. : Always set : Set as required : Setting not required Setting item Setting requirement of Setting requirement of reference axis interpolation axis...

  • Page 128: Axis Circular Interpolation Control With The Center Point Specified

    2-axis circular interpolation control with the center point specified In 2-axis circular interpolation control ([Da.2] Control method = ABS circular right, INC circular right, ABS circular left, and INC circular left), two motors are used to perform the position control in an arc path centered at the arc address while the interpolation is implemented for the axis directions set in each axis.

  • Page 129

    Circular interpolation error compensation In the circular interpolation control with the center point specification, the arc path calculated with the start point address and center point address and the end point address set in [Da.6] Positioning address/movement amount may deviate. (Page 398 [Pr.41] Allowable circular interpolation error width) ■Calculated error ≤...

  • Page 130

    The 2-axis circular interpolation control with the center point specified (ABS circular right, ABS circular left) ■Operation chart In the absolute system and 2-axis circular interpolation control with center point specified, positioning is implemented from the current stop position (start point address) to the address (end point address) set in [Da.6] Positioning address/movement amount in an arc path whose center is the center point address (arc address) set in [Da.7] Arc address.

  • Page 131

    ■Restrictions In the following cases, the 2-axis circular interpolation control cannot be set. • When "2: degree" is set in [Pr.1] Unit setting • When the units set in [Pr.1] Unit setting are different between the reference axis and interpolation axis (The combination of "0: mm"...

  • Page 132

    The 2-axis circular interpolation control with the center point specified (INC circular right, INC circular left) ■Operation chart In the incremental system and 2-axis circular interpolation control with center point specified, positioning is implemented from the current stop position (start point address) to the position of the movement amount set in [Da.6] Positioning address/ movement amount in an arc path whose center is the center point address (arc address) set in [Da.7] Arc address.

  • Page 133

    ■Restrictions In the following cases, the 2-axis circular interpolation control cannot be set. • When "2: degree" is set in [Pr.1] Unit setting • When the units set in [Pr.1] Unit setting are different between the reference axis and interpolation axis (The combination of "0: mm"...

  • Page 134: Speed Control

    Speed control In the speed control ([Da.2] Control method = Forward run speed 1 to 2, Reverse run speed 1 to 2), pulses are output continuously at the speed set in [Da.8] Command speed until a stop command is input in the axis 1 to 2 directions set to the positioning data.

  • Page 135

    • 2-axis speed control Interpolation axis (Axis 2) [Da.8] Command speed Reference axis (Axis 1) [Da.8] Command speed [Cd.184] Positioning start signal [Md.141] BUSY signal Does not turn ON even if Positioning complete signal stopped using stop command ([Md.31] Status: b15) [Cd.180] Axis stop signal (stop command) (Either axis 1 or 2)

  • Page 136

    Restrictions • Set "00: Positioning complete" to [Da.1] Operation pattern. If "01: Continuous positioning control" or "11: Continuous path control" is set, Continuous path control not possible (Error code: 1A1EH, 1A1FH) occurs and the control will not start. ("01: Continuous positioning control" or "11: Continuous path control" cannot be set for the speed control.) •...

  • Page 137: Speed-position Switching Control (inc Mode)

    Speed-position switching control (INC mode) In the speed-position switching control (INC mode) ([Da.2] Control method = Forward run speed-position, Reverse run speed- position), pulses are output continuously at the speed set in [Da.8] Command speed in the axis direction set to the positioning data.

  • Page 138

    ■When Near-point dog signal (DOG) is used To use Near-point dog signal (DOG) as a speed-position switching signal, set the following items. Setting item Setting Setting details Buffer memory address value Axis 1 Axis 2 [Cd.45] Speed-position switching Set "1: Use near-point dog signals". 1566 1666 device selection...

  • Page 139

    Operation chart The following shows the operation timing of the speed-position switching control (INC mode). During the speed control with the speed-position switching control (INC mode), In speed control flag ([Md.31] Status: b0) is [Da.8] Command speed Movement amount set in "[Da.6] Positioning address/travel amount"...

  • Page 140

    Operation timing and the processing time [Cd.184] Positioning start signal [Md.141] BUSY signal M code ON signal ([Md.31] Status: b12) (WITH mode) [Cd.7] M code ON signal OFF request Start complete signal ([Md.31] Status: b14) Speed control [Md.26] Axis operation status Standby Position control Standby...

  • Page 141

    Current feed value [Md.20] Current feed value during the speed-position switching control (INC mode) depends on the setting of [Pr.21] Current feed value during speed control as described below. Setting of [Pr.21] Current feed value during [Md.20] Current feed value speed control 0: Current feed value is not updated During the speed control, the current feed value at the start of the control is kept.

  • Page 142

    Movement amount change of the position control In Speed-position switching control (INC mode), the movement amount of the position control can be changed during the speed control. • During the speed control, New movement amount is stored in [Cd.23] Speed-position switching control movement amount change register using a program.

  • Page 143

    Restrictions • If "11: Continuous path control" is set in [Da.1] Operation pattern, Continuous path control not possible (Error code: 1A1FH) occurs and the control will not start. • Speed-position switching control cannot be set in [Da.2] Control method in the positioning data when "11: Continuous path control"...

  • Page 144

    Positioning data to be set To use the speed-position switching control (INC mode), set the following positioning data. : Always set : Set as required : Setting not required Setting item Setting requirement [Da.1] Operation pattern   (Set Forward run speed-position or Reverse run speed-position.) [Da.2] Control method ...

  • Page 145: Speed-position Switching Control (abs Mode)

    Speed-position switching control (ABS mode) In the speed-position switching control (ABS mode) ([Da.2] Control method = Forward run speed-position, Reverse run speed-position), pulses are output continuously at the speed set in [Da.8] Command speed in the axis direction set to the positioning data.

  • Page 146

    Speed-position switching signal setting ■When External command signal (CHG) is used To use External command signal (CHG) as a speed-position switching signal, set the following items. Setting item Setting Setting details Buffer memory address value Axis 1 Axis 2 [Pr.42] External command function Set "2: Speed-position/position-speed switching selection...

  • Page 147

    Operation chart The operation timing of the speed-position switching control (ABS mode) is described below. During speed control using the speed-position switching control (ABS mode), In speed control flag ([Md.31] Status: b0) is ON. [Da.8] Command speed Movement amount set in "[Da.6] Positioning address/travel amount"...

  • Page 148

    Operation timing and the processing time [Cd.184] Positioning start signal [Md.141] BUSY signal M code ON signal ([Md.31] Status: b12) [Cd.7] M code ON signal OFF request Start complete signal ([Md.31] Status: b14) (WITH mode) [Md.26] Axis operation status Standby Speed control Position control Standby...

  • Page 149

    Current feed value [Md.20] Current feed value during the speed-position switching control (ABS mode) depends on the setting of [Pr.21] Current feed value during speed control as described below. Setting of [Pr.21] Current feed value during [Md.20] Current feed value speed control 1: Update current feed value The current feed value is updated during both speed control and position control.

  • Page 150

    • To perform the speed-position switching control (ABS mode), the following conditions must be satisfied. (1) "[Pr.1] Unit setting" is "2: Degree" (2) The software stroke limit function is disabled (Upper limit value = Lower limit value) (3) "[Pr.21] Current feed value during speed control" is "1: Update current feed value". (4) If the settings range of "[Da.6] Positioning address/travel amount"...

  • Page 151: Position-speed Switching Control

    Position-speed switching control In Position-speed switching signal ([Da.2] Control method = Forward run speed-position, Reverse run speed-position), the positioning control for the amount set in [Da.6] Positioning address/movement amount is implemented in the axis direction set to the positioning data before Position-speed switching signal is input. If Position-speed switching signal is input before the positioning is completed, pulses are continuously output at the speed set in [Da.8] Command speed until a stop command is input.

  • Page 152

    Position-speed switching signal setting ■When External command signal (CHG) is used To use External command signal (CHG) as Position-speed switching signal, set the following items. Setting item Setting Setting details Buffer memory address value Axis 1 Axis 2 [Pr.42] External command function Set "2: Speed-position/position-speed switching selection request".

  • Page 153

    Operation chart The following shows the operation timing of the position-speed switching control. During the speed control with the position-speed switching control, In speed control flag ([Md.31] Status: b0) is ON. [Da.8] Command speed Position control Speed control [Cd.184] Positioning start signal [Md.141] BUSY signal Does not turn ON even Positioning complete signal...

  • Page 154

    Operation timing and the processing time [Cd.184] Positioning start signal [Md.141] BUSY signal M code ON signal ([Md.31] Status: b12) (WITH mode) [Cd.7] M code ON signal OFF request Start complete signal ([Md.31] Status: b14) Speed control Position control Stopped [Md.26] Axis operation status Standby in operation...

  • Page 155

    Current feed value [Md.20] Current feed value during the position-speed switching control depends on the setting of [Pr.21] Current feed value during speed control as follows. Setting of [Pr.21] Current feed value during [Md.20] Current feed value speed control 0: Current feed value is not updated The current feed value is updated during the position control.

  • Page 156

    Changing the command speed of the speed control In Position-speed switching control, the command speed of the speed control can be changed during the position control. • When the command speed change is requested during the control other than the position control of the position-speed switching control, the change request is ignored.

  • Page 157

    Restrictions • If "01: Continuous positioning control" or "11: Continuous path control" is set in [Da.1] Operation pattern, Continuous path control not possible (Error code: 1A1EH, 1A1FH) occurs and the control will not start. • Position-speed switching control cannot be set to [Da.2] Control method of the positioning data when "11: Continuous path control"...

  • Page 158: Current Value Change

    Current value change In the current value change, the value in [Md.20] Current feed value of the stopping axis is changed to an address. (The value in [Md.21] Machine feed value is not changed even if the current value is changed.) One of the following two methods can be used for changing the current value.

  • Page 159

    ■Positioning data to be set To use the current value change, set the following positioning data. : Always set : Set as required : Setting not required Setting item Setting requirement [Da.1] Operation pattern   (Set Current value change.) [Da.2] Control method [Da.3]...

  • Page 160

    ■Setting method The following shows the data setting and a program example for executing the current value change using Positioning start signal. ([Md.20] Current feed value is changed to 5000.0 μm.) (1) Settings data Set the following data. Setting item Setting Setting details Buffer memory address...

  • Page 161

    (3) Program example Add the following program to the control program, and write it to the CPU module. Classification Label Name Description Module label FX5PG_1.stnAxisMonitorData_Axis_D[0].bErrorDetection_D Axis 1 Error detection signal FX5PG_1.stSystemMonitorData2_D.bnBusy_Axis_D[0] Axis 1 BUSY signal FX5PG_1.stnAxisMonitorData_Axis_D[0].bStartComplete_D Axis 1 Start complete signal FX5PG_1.stnAxisControlData2_Axis_D[0].bPositioningStart_D Axis 1 Positioning start signal FX5PG_1.stnAxisControlData_Axis_D[0].uPositioningStartNo_D...

  • Page 162: Nop Instruction

    NOP instruction The NOP instruction is a control method that is not executed. Operation The positioning data No. to which the NOP instruction is set is not processed and the operation is shifted to the one of the next positioning data No. [Application example of the NOP instruction] If the speed switching or the operation suspension (automatic deceleration) may be implemented during the positioning operation between two points in the future, the data can be reserved using the NOP instruction...

  • Page 163: Jump Instruction

    JUMP instruction The JUMP instruction is used to jump to the positioning data No. set in the positioning data during Continuous positioning control or Continuous path control. The following two JUMP instructions can be used. JUMP instruction Description Unconditional JUMP When no execution condition is set for the JUMP instruction (when 0 is set as the condition data No.) Conditional JUMP When implementation conditions are set for the JUMP instruction (The conditions are set in the condition...

  • Page 164

    Positioning data to be set To use the JUMP instruction, set the following positioning data. : Always set : Set as required : Setting not required Setting item Setting requirement [Da.1] Operation pattern   (Set the JUMP instruction.) [Da.2] Control method ...

  • Page 165: Loop

    LOOP The loop control with repetition of the LOOP to LEND instructions is implemented. Operation The loop of LOOP to LEND is repeated for the set number of the repetition. Positioning data to be set To use the LOOP instruction, set the following positioning data. : Always set : Set as required : Setting not required...

  • Page 166: Lend

    LEND The operation is returned to the head of the repeating loop (LOOP to LEND). Operation The loop is completed when the number of repetition specified in LOOP is 0 and the processing of the next positioning data No. is executed. (Even if the operation pattern is set to "Positioning complete", the setting is ignored.) To stop the operation after the implementation for the specified number of repetitions, set a dummy positioning data (for example, the positioning in the incremental system whose movement amount is 0).

  • Page 167: Chapter 10 Advanced Positioning Control

    ADVANCED POSITIONING CONTROL This chapter describes the details and usage of the advanced positioning control (the control function using Block start data). The advanced positioning control is used to implement applied controls using Positioning data, and examples of the applied controls use the condition judgment to control the positioning data set using the major positioning control, or start positioning data for multiple axes simultaneously.

  • Page 168: Data Required For Advanced Positioning Control

    Data required for advanced positioning control Advanced positioning control is performed by setting the required items in Block start data and Condition data, and starting the block start data. Whether or not the operations can be executed is judged at the execution of the control according to the condition data specified in the block start data.

  • Page 169: Block Start Data And Condition Data Configurations

    Block start data and Condition data configurations Block start data and Condition data corresponding to Block No. 7000 to 7004 can be stored in the buffer memory. (The following table shows an example for Axis 1.) 50th point Buffer memory Setting item address 2nd point...

  • Page 170: Implementation Procedure For Advanced Positioning Control

    10.2 Implementation Procedure for Advanced Positioning Control The advanced positioning control is performed using the following procedure. Preparation "High-level positioning control" is control that STEP 1 uses the specified conditions to implement Implement "major positioning control" settings the controls set in the positioning data ("major positioning control"), so first make preparations to enable implementation of the "major positioning control".

  • Page 171: Setting The Block Start Data

    10.3 Setting the Block Start Data Relation between various controls and block start data Block start data must be set to perform Advanced positioning control. The setting requirements and details of each block start data item to be set differ according to the setting of [Da.13] Special start instruction.

  • Page 172: Block Start (normal Start)

    Block start (normal start) In Block start (normal start), the positioning data groups of a block are continuously implemented in a set sequence starting from the positioning data set in [Da.12] Start data No. by one start. The following shows setting examples and a control example in which Block start data and Positioning data are set as shown in the setting examples.

  • Page 173

    Control example The following describes the control to be executed when the operation using the 1st point block start data of the axis 1 is started. • The positioning data is implemented in the following order and the operation stopped: Axis 1 positioning data No.1→2→3→4→5→6→10→15.

  • Page 174: Condition Start

    Condition start In Condition start, the condition judgment of the condition data specified in [Da.14] Parameter is implemented for the positioning data set in [Da.12] Start data No. If the conditions have been established, the block start data set as 1: Condition start is implemented, and if the conditions have not been established, that block start data is ignored, and the block start data of the next point will be executed.

  • Page 175: Wait Start

    Wait start In Wait start, the condition judgment of the condition data specified in [Da.14] Parameter is implemented for the positioning data set in [Da.12] Start data No. If the conditions have been established, the block start data is implemented, and if the conditions have not been established, the control stops (waits) until the conditions are established.

  • Page 176: Simultaneous Start

    Simultaneous start In Simultaneous start, the positioning data set in [Da.12] Start data No. and positioning data of other axes set in the condition data are simultaneously implemented. (Pulses are output at the same timing.) (Specify Condition data with [Da.14] Parameter.) The following shows setting examples and a control example in which Block start data and Positioning data are set as shown in the setting examples.

  • Page 177: Repeated Start (for Loop)

    Repeated start (FOR loop) In Repeated start (FOR loop), the data between the block start data in which 4: FOR loop is set in [Da.13] Special start instruction and the block start data in which 6: NEXT start is set in [Da.13] Special start instruction is repeatedly implemented for the number of times set in [Da.14] Parameter.

  • Page 178: Repeated Start (for Condition)

    Repeated start (FOR condition) In Repeated start (FOR condition), the data between the block start data in which 5: FOR condition is set in [Da.13] Special start instruction and the block start data in which 6: NEXT start is set in [Da.13] Special start instruction is repeatedly implemented until the conditions set in the condition data are established.

  • Page 179: Restrictions When The Next Start Is Used

    Restrictions when the NEXT start is used NEXT start instruction shows the end of the repetition when the repeated start (FOR loop) and repeated start (FOR condition) are implemented. (Page 175 Repeated start (FOR loop), Page 176 Repeated start (FOR condition)) This section describes the restrictions when 6: NEXT start is set in Block start data.

  • Page 180: Setting The Condition Data

    10.4 Setting the Condition Data Relation between various controls and condition data Set Condition data in the following cases. • When conditions are set during the implementation of the JUMP instruction (Major positioning control) • When conditions are set during the implementation of advanced positioning control Condition data includes the five setting items from [Da.15] to [Da.19], but the setting requirements and details of each setting item depend on the control system and setting conditions used.

  • Page 181

    The setting requirements and details of the setting items of the condition data [Da.16] to [Da.19] depend on the settings in [Da.15] Condition target. The following table lists the setting items of [Da.16] to [Da.19] corresponding to [Da.15] Condition target. : Setting not required (The set value is ignored.

  • Page 182: Setting Examples Of The Condition Data

    Setting examples of the condition data The following shows setting examples of Condition data. Example 1 This example uses the on/off state of a device as a condition. • [Condition] If "[Md.141] BUSY: b0" (=Axis 1 BUSY signal) is "OFF" [Da.15] Condition target [Da.16] Condition [Da.17] Address...

  • Page 183: Start Program For The Advanced Positioning Control

    10.5 Start Program for the Advanced Positioning Control Starting the advanced positioning control To execute the advanced positioning control, a program must be created to start the control in the same method as for the major positioning control. The procedure for starting the 1st point block start data (Regarded as block No.7000) set in axis 1 is described below. Positioning module Buffer memory Drive module...

  • Page 184: Start Program Example For The Advanced Positioning Control

    Start program example for the advanced positioning control The following shows a start program example for the advanced positioning control in which the 1st point block start data of the axis 1 is started. (The block No. is regarded as 7000.) Control data requiring settings The following control data must be set to execute the advanced positioning control.

  • Page 185

    Start time chart The following figure shows a time chart in a case when the positioning data No.1, 2, 10, 11, and 12 of Axis 1 are continuously implemented as an example. ■Block start data settings Axis 1 block start data [Da.11] Shape [Da.12] Start data No.

  • Page 186

    Program example Classification Label Name Description Module label FX5PG_1.stSystemMonitorData2_D.bnBusy_Axis_D[0] Axis 1 BUSY signal FX5PG_1.stnAxisMonitorData_Axis_D[0].bStartComplete_D Axis 1 Start complete signal FX5PG_1.stnAxisControlData2_Axis_D[0].bPositioningStart_D Axis 1 Positioning start signal FX5PG_1.stnAxisControlData_Axis_D[0].uPositioningStartNo_D Axis 1 Positioning start No. FX5PG_1.stnAxisControlData_Axis_D[0].uPositioningStartingPointNo_D Axis 1 Positioning starting point No. Global label, local Define the global label or local label as follows.

  • Page 187: Chapter 11 Manual Control

    MANUAL CONTROL This chapter describes the details and usage of the manual control. Manual control includes a manual pulse generator operation to generate pulse output commands that are issued during the JOG and inching operations which are executed by turning on JOG start signal, or from the manual pulse generator. The chapter describes manual control used via a program loaded in the CPU module.

  • Page 188

    Manual pulse generator operation Manual pulse generator operation performs positioning in accordance with the number of pulses input from the manual pulse generator, which is to say that it outputs the same number of pulses that were input. This method is used to manually make fine adjustments for precise positioning and to obtain positioning addresses.

  • Page 189: Jog Operation

    11.2 JOG Operation Overview of the JOG operation Use the hardware stroke limit function when performing the JOG operation at a position close to the upper or lower limit. (Page 239 Hardware stroke limit function) If the hardware stroke limit function is not used, the workpiece may be moved beyond the movement range resulting in an accident.

  • Page 190

    Precautions during the operation • For safety reasons, set [Cd.17] JOG speed to a slow speed and then gradually increase the speed while checking operation. • If the set JOG speed is out of the setting range or 0 when the JOG operation is started, Outside JOG speed range (Error code: 1980H) occurs and the operation will not start.

  • Page 191: Operation Procedure Of The Jog Operation

    Operation procedure of the JOG operation The JOG operation is performed in the following procedure. Preparation There are two different methods to accomplish this. STEP 1 Configure parameters ( [Pr.1] to [Pr.39] ) Method 1 : Use GX Works3 to directly configure the positioning module (write).

  • Page 192: Parameters Required For The Jog Operation

    Parameters required for the JOG operation To perform the JOG operation, parameters must be set. The following table shows the required parameters for performing the JOG operation. When only the JOG operation is performed, parameters not described below are not required. (Set the value within the setting range, such as the initial value.) : Always set : Set as required (set a value within the setting range such as the initial value when the item is not used.)

  • Page 193: Creating A Start Program For The Jog Operation

    Creating a start program for the JOG operation To perform the JOG operation, create a program. When creating a program, consider Control data requiring settings, Start condition, and Start time chart. The following shows an example when the JOG operation is started for the axis 1. ([Cd.17] JOG speed is set to 100.00 mm/min.) Control data requiring settings The following control data must be set to execute the JOG operation.

  • Page 194

    Start time chart Forward JOG operation Reverse JOG operation [Cd.181] Forward JOG Start Signal [Cd.182] Reverse JOG Start Signal [Cd.190] PLC READY signal READY signal ([Md.140] Module Status: b0) [Md.141] BUSY signal Error detection signal ([Md.31] Status: b13) Program example For the program example of the JOG operation, refer to the following.

  • Page 195: Operation Example Of The Jog Operation

    Operation example of the JOG operation Example 1 When Stop signal is turned on during the JOG operation, the deceleration stop is executed and the JOG operation will stop. When JOG start signal is turned on while Stop signal is turned on, Stop signal ON at start (Error code: 1908H) occurs. The operation can be started when Stop signal is turned off and JOG start signal is off and on again.

  • Page 196

    Example 3 When JOG start signal is turned on again during the deceleration due to turning off of JOG start signal, the JOG operation is performed from the point when JOG start signal is turned on. Forward JOG operation [Cd.181] Forward JOG start signal [Md.141] BUSY signal Example 4...

  • Page 197: Inching Operation

    11.3 Inching Operation Operation overview of the inching operation Use the hardware stroke limit function when performing the inching operation at a position close to the upper or lower limit. (Page 239 Hardware stroke limit function) If the hardware stroke limit function is not used, the workpiece may be moved beyond the movement range resulting in an accident.

  • Page 198

    Operation precautions • The inching operation does not perform acceleration/deceleration processing. (Pulses for the specified inching movement amount are output at 1.77 ms. The direction of the inching operation is reversed. When the backlash compensation is performed, pulses for the backlash are output at 1.77 ms and pulses for the specified inching movement amount are output at the next 1.77 ms.) [Cd.17] JOG speed is ignored even if it is set.

  • Page 199: Operation Procedure Of The Inching Operation

    Operation procedure of the inching operation The inching operation is performed in the following procedure. There are two different methods to accomplish this. STEP 1 Preparation Configure parameters ( [Pr.1] to [Pr.31] ) Method 1 : Use GX Works3 to directly configure the positioning module (write).

  • Page 200: Parameters Required For The Inching Operation

    Parameters required for the inching operation To perform the inching operation, parameters must be set. The following table shows the required parameters for performing the inching operation. When only the inching operation is performed, parameters not described below are not required. (Set the value within the setting range, such as the initial value.) : Always set : Set as required (set a value within the setting range such as the initial value when the item is not used.)

  • Page 201: Creating A Start Program For The Inching Operation

    Creating a start program for the inching operation To perform the inching operation, create a program. When creating a program, consider Control data requiring settings, Start condition, and Start time chart. The following shows an example when the inching operation is started for the axis 1. ([Cd.16] Inching movement amount is set to 10.0 μm.) Control data requiring settings The following control data must be set to execute the inching operation.

  • Page 202

    Start time chart Forward inching operation Reverse inching operation [Cd.181] Forward JOG Start Signal [Cd.182] Reverse JOG Start Signal [Cd.190] PLC READY signal READY signal ([Md.140] Module Status: b0) [Md.141] BUSY signal Error detection signal ([Md.31] Status: b13) Positioning complete signal ([Md.31] Status: b15) Program example For the program example of the inching operation, refer to the following.

  • Page 203: Operation Example Of The Inching Operation

    Operation example of the inching operation Example 1 When JOG start signal is turned on while Stop signal is turned on, Stop signal ON at start (Error code: 1908H) occurs. The operation can be started when Stop signal is turned off and JOG start signal is off and on again. [Cd.190] PLC READY signal READY signal ([Md.140] Module Status: b0)

  • Page 204: Manual Pulse Generator Operation

    11.4 Manual Pulse Generator Operation Operation overview of the manual pulse generator operation When the manual pulse generator operation is not performed, create a program in which [Cd.21] Manual pulse generator enable flag is always 0 (disabled). Touching the manual pulse generator when [Cd.21] Manual pulse generator enable flag is 1 (enabled) may cause an accident or incorrect positioning.

  • Page 205

    Restrictions • A manual pulse generator is required to perform the manual pulse generator operation. • Do not use manual pulse generator operation when another axis is in pre-analysis mode. This is because pulses may be output at unintended timings for axes subject to manual pulse generator operation. Precautions during the operation The following details must be understood before performing the manual pulse generator operation.

  • Page 206

    Operation timing and the processing time The following shows the details on the operation timing and processing time in the manual pulse generator operation. [Cd.21] Manual pulse generator enable flag Manual pulse generator input pulse [Md.141] BUSY signal The Start complete signal does not turn on during manual pulse generator operation. The Start complete signal does not turn on during manual pulse generator operation.

  • Page 207: Operation Procedure Of The Manual Pulse Generator Operation

    Speed control by the manual pulse generator operation The speed during the positioning control by the manual pulse generator operation depends on the number of input pulses per unit time, and can be calculated using the following calculation formula. Output command frequency = Input frequency [Cd.20] Manual pulse generator 1 pulse input magnification Operation procedure of the manual pulse generator operation The manual pulse generator operation is performed in the following procedure.

  • Page 208: Parameters Required For The Manual Pulse Generator Operation

    Parameters required for the manual pulse generator operation To perform the manual pulse generator operation, parameters must be set. The following table shows the required parameters for performing the manual pulse generator operation. When only the manual pulse generator operation is performed, parameters not described below are not required.

  • Page 209: Creating A Program To Enable Or Disable The Manual Pulse Generator Operation

    Creating a program to enable or disable the manual pulse generator operation To perform the manual pulse generator operation, create a program. When creating a program, consider Control data requiring settings, Start condition, and Start time chart. The following shows an example when the manual pulse generator operation is started for the axis 1.

  • Page 210

    Start time chart Forward run Reverse run Pulse input A phase Pulse input B phase [Cd.190] PLC READY signal READY signal ([Md.140] Module Status: b0) Start complete signal ([Md.31] Status: b14) [Md.141] BUSY signal Error detection signal ([Md.31] Status: b13) [Cd.21] Manual pulse generator enable flag [Cd.20] Manual pulse generator...

  • Page 211: Chapter 12 Control Sub Function

    CONTROL SUB FUNCTION This chapter describes the details and usage of Sub function added and used in combination with the main functions. A variety of sub functions, including sub functions specific to machine OPR and generally related functions such as control compensation, are available.

  • Page 212

    Sub function Description Function related to Stop command Selects a deceleration curve when a stop cause occurs during the deceleration stop processing to speed 0. positioning stop processing for deceleration stop function Continuous operation Interrupts the continuous operation. When this request is accepted, the operation will stop at the completion interrupt function of the positioning data being executed.

  • Page 213: Sub Functions Specific To Machine Opr

    12.2 Sub Functions Specific to Machine OPR The sub functions specific to machine OPR include OPR retry function and OP shift function. Each function is executed based on the parameter setting. OPR retry function If a workpiece passes over the OP without stopping during the position control, the workpiece may not move back in the direction of the OP although the machine OPR is commanded, depending on the workpiece position.

  • Page 214

    ■OPR retry operation when the workpiece is outside the range between the upper/lower limits • When the direction from the workpiece to the OP is the same as the direction set in [Pr.44] OPR direction, the normal machine OPR is performed. The following is an example of when [Pr.44] OPR direction is set to 0: Forward direction. Machine OPR start Zero point [Pr.44] OPR direction...

  • Page 215

    ■Setting the dwell time during OPR retry The OPR retry function can perform such a function as the dwell time using [Pr.57] Dwell time during OPR retry when the reverse run operation is performed due to the detection of Upper limit signal or Lower limit signal or when the machine OPR is executed after Near-point dog signal is turned off to stop the operation.

  • Page 216

    Setting method To use the OPR retry function, configure the required settings in the parameters shown in the following table, and write them to the positioning module. When the parameters are set, the OPR retry function will be added to the machine OPR control. The settings are validated at the rising edge (when turned off and on) of [Cd.190] PLC READY signal.

  • Page 217: Op Shift Function

    OP shift function When the machine OPR is performed, the OP is normally established using a near-point dog, stopper, and Zero signal. However, by using the OP shift function, the machine can be moved for a specified movement amount from the position where Zero signal was detected.

  • Page 218

    Movement speed during the OP shift When the OP shift function is used, set the movement speed during the OP shift in [Pr.56] Speed specification during OP shift. Select the movement speed during the OP shift from [Pr.46] OPR speed or [Pr.47] Creep speed. Set the speed in [Pr.56] Speed specification during OP shift.

  • Page 219

    Setting method To use the OP shift function, configure the required settings in the parameters shown in the following table, and write them to the positioning module. When the parameters are set, the OP shift function will be added to the machine OPR control. The settings are validated at the rising edge (when turned off and on) of [Cd.190] PLC READY signal.

  • Page 220: Function To Compensate Control

    12.3 Function to Compensate Control The functions to compensate the control include Backlash compensation function, Electronic gear function, Near pass function, and Output timing selection of near pass control. Each function is executed by setting parameters or creating and writing a program. Backlash compensation function This function compensates the backlash amount in the machine system.

  • Page 221: Electronic Gear Function

    Setting method To use Backlash compensation function, set Backlash compensation amount in the parameters shown in the following table and write them to the positioning module. The settings are validated at the rising edge (when turned off and on) of [Cd.190] PLC READY signal. Setting item Setting Setting detail...

  • Page 222

    Movement amount per pulse [Pr.2] No. of pulses per rotation (Ap), [Pr.3] Movement amount per rotation (Al), and [Pr.4] Unit magnification (Am) are the items for determining how many rotations (equivalent to how many pulses) a motor should operate to move a machine for the movement amount set in the program.

  • Page 223

    ■Setting range of Ap, Al, and Am The 16-bit mode and 32-bit mode are provided for each Ap, Al, and Am, and they can be switched by setting a value in [Pr.62] Electronic gear selection. When the resolution of the servo amplifier is high, values of Ap and Al can be set without reducing the values by using an electronic gear with 32 bits.

  • Page 224

    Error compensation method When the position control is performed using the movement amount per pulse set in the positioning module parameters, an error sometimes occurs between the command movement amount (L) and actual movement amount (L'). That error is compensated in the positioning module by adjusting the values in [Pr.2] No. of pulses per rotation, [Pr.3] Movement amount per rotation, and [Pr.4] Unit magnification.

  • Page 225

    Set the post-compensation [Pr.2] No. of pulses per rotation (Ap'), [Pr.3] Movement amount per rotation (Al'), and [Pr.4] Unit magnification (Am') in the parameters, and write them to the positioning module. The settings are validated at the rising edge (when turned off and on) of [Cd.190] PLC READY signal. Setting item Setting value Setting detail...

  • Page 226: Near Pass Function

    Near pass function When the continuous path control is performed using the interpolation control, the near pass function is performed. This function suppresses the machine vibration occurring at the time of switching the positioning data when the continuous path control is performed using the interpolation control. [Near pass function] The extra movement amount occurring at the end of each positioning data being continuously executed is carried over to the next positioning data.

  • Page 227

    Control precautions • If the movement amount specified by the positioning data is small during the execution of the continuous path control, the output speed may not reach the command speed. • The movement direction is not checked during the interpolation control. Thus, the deceleration stop is not performed even if the movement direction is changed.

  • Page 228: Output Timing Selection Of Near Pass Control

    Output timing selection of near pass control This function allows the user to select the timing to output the difference (Δd) between the actual and the set positioning end addresses in the continuous path control, in which the difference (d) is output during the execution of the next positioning data.

  • Page 229

    Control precautions When the relation of command speed V1 and V2 is one of the following, the same command output as the one for At constant speed is executed even if the near pass output timing is set to At deceleration. •...

  • Page 230: Function To Limit Control

    12.4 Function to Limit Control Functions to limit the control include Speed limit function, Torque limit function, Software stroke limit function, and Hardware stroke limit function. Each function is executed by setting parameters or creating and writing a program. Speed limit function Speed limit function limits the command speed to a value within the setting range of Speed limit value when the command speed during the control exceeds Speed limit value.

  • Page 231

    Setting method To use the speed limit function, configure the required settings in the parameters shown in the following table, and write them to the positioning module. The set data is validated when the data is written into the positioning module. Setting item Setting Setting detail...

  • Page 232: Torque Limit Function

    Torque limit function If the torque generated in the servo motor exceeds Torque limit value, this function limits the generated torque to a value within the setting range of Torque limit value. This function protects the reducer and limits the power of the pressing operation against the stopper. This function controls the operation so that an excessive load or excessive force is not applied to the machine.

  • Page 233

    Relation between the torque limit function and various controls The following table shows the relation between Torque limit function and various controls. : Set as required : Setting not required (The set value is ignored. Set the value within the setting range, such as the initial value.) Control type Torque limit Torque limit value...

  • Page 234

    Control precautions • To limit the torque with the value set in [Pr.17] Torque limit setting value, check that [Cd.22] New torque value is set to 0. If a value other than 0 is set for [Cd.22] New torque value, the value is validated and used for the torque limit. (Page 230 Torque limit function) •...

  • Page 235: Software Stroke Limit Function

    Software stroke limit function In this function, the address established by the machine OPR is used to set the upper/lower limits of the movable range of the workpiece. If a movement command is issued to an address outside the set range, the command is not performed. In the positioning module, Current feed value and Machine feed value are used as the addresses indicating the current value.

  • Page 236

    ■Current value change When the current value is changed from 2000 to 1000, the current feed value changes to 1000, but the machine feed value remains 2000. • When the machine feed value is set as a limit, the machine feed value of 5000 (current feed value: 4000) becomes the upper stroke limit.

  • Page 237

    Relation between the software stroke limit function and various controls : Check valid : Check is not performed when the current feed value is not updated at the setting of Current feed value in "[Pr.14] Software stroke limit" selection during the speed control.

  • Page 238

    Precautions for the software stroke limit check • To execute Software stroke limit function properly, the machine OPR must be performed beforehand. • During the interpolation control, the stroke limit check is performed for every current value of both the reference axis and interpolation axes.

  • Page 239

    Setting method To use the software stroke limit function, set the required values in the parameters shown in the following table, and write them to the positioning module. The settings are validated at the rising edge (when turned off and on) of [Cd.190] PLC READY signal. Setting item Setting Setting detail...

  • Page 240

    Invalidating the software stroke limit To invalidate the software stroke limit, set a single value in both [Pr.12] Software stroke limit upper limit value and [Pr.13] Software stroke limit lower limit value and write them to the positioning module. (Set a value within the setting range.) (To invalidate only the manual operation, set "1: Software stroke limit invalid"...

  • Page 241: Hardware Stroke Limit Function

    Hardware stroke limit function In Hardware stroke limit function, limit switches are set at the upper/lower limits of the physical movement range, and the control is stopped (by deceleration stop) by the input of a signal from the limit switch. This function prevents the machine from being damaged by stopping the operation before the workpiece reaches the upper or lower limit of the physical movement range.

  • Page 242

    Wiring the hardware stroke limit When the hardware stroke limit function is used, wire the terminals of the FLS (Upper limit signal) and RLS (Lower limit signal) of the positioning module as illustrated in the following figure. ([Pr.22] Input signal logic selection is initialized) Positioning module 24 V DC •...

  • Page 243: Functions That Change Control Details

    12.5 Functions that Change Control Details Functions that change the control details include Speed change function, Override function, Acceleration/deceleration time change function, and Torque change function. Each function is executed by setting parameters or creating and writing a program. Both Speed change function and Override function change the speed. The following shows the differences between these functions.

  • Page 244

    Control precautions • When the speed is changed during the continuous path control, the next positioning data is controlled with [Cd.14] New speed value if no speed is specified (current speed) in the next positioning data. When a speed is specified in the next positioning data, the next positioning data is controlled at the speed of [Da.8] Command speed.

  • Page 245

    • If the speed is changed during the deceleration by a stop command or during the automatic deceleration in the positioning control, Deceleration/stop speed change (Warning code: 0990H) occurs and the speed cannot be changed. • When the value set in [Cd.14] New speed value exceeds the one in [Pr.8] Speed limit value, Speed limit value over (Warning code: 0991H) occurs and the speed is controlled with [Pr.8] Speed limit value.

  • Page 246

    ■Program example Add the following program to the control program, and write it to the CPU module. Page 493 Speed change program Setting the function using an external command signal The speed can also be changed using an external command signal. The following shows the data setting and a program example for changing the control speed of the axis 1 using an external command signal.

  • Page 247

    ■Program example Add the following program to the control program, and write it to the CPU module. Classification Label Name Description Module label FX5PG_1.stnParameter_Axis_D[0].uExternalCommandFunctionSelection_D Axis 1 External command function selection FX5PG_1.stnAxisControlData_Axis_D[0].uExternalCommandValid_D Axis 1 External command valid FX5PG_1.stnAxisControlData_Axis_D[0].udNewSpeedValue_D Axis 1 New speed value Global label, local Define the global label or local label as follows.

  • Page 248: Override Function

    Override function Override function changes the command speed by a specified percentage (0 to 300%) for all controls to be executed. The speed can be changed by setting the percentage (%) by which the speed is changed in [Cd.13] Positioning operation speed override.

  • Page 249

    Control precautions • When the speed is changed using Override function during the continuous path control, the speed change is ignored and Insufficient remaining distance (Warning code: 0995H) occurs if a distance enough to perform the speed change cannot be ensured.

  • Page 250

    Setting method The following shows the data setting and a program example for setting the override value of the axis 1 to 200%. ■Setting data Set the following data. Setting item Setting Setting detail Buffer memory address value Axis 1 Axis 2 [Cd.13] Positioning operation...

  • Page 251: Acceleration/deceleration Time Change Function

    Acceleration/deceleration time change function Acceleration/deceleration time change function is used to change the acceleration/deceleration time during the speed change to an arbitrary value when the speed change is performed using Speed change function and Override function. In a normal speed change (when the acceleration/deceleration time is not changed), the acceleration/deceleration time previously set in the parameters (values in [Pr.9], [Pr.10], and [Pr.25] to [Pr.30]) is set in [Da.3] and [Da.4] of the positioning data, and the control is performed with that acceleration/deceleration time.

  • Page 252

    Control precautions • When 0 is set in [Cd.10] New acceleration time value and [Cd.11] New deceleration time value, the acceleration/ deceleration time is not changed even if the speed change is performed. In this case, the operation is controlled at the acceleration/deceleration time previously set in the parameters.

  • Page 253

    Setting method To use the acceleration/deceleration time change function, write the following data into the positioning module using a program. The following shows the data setting and a program example for changing the acceleration/deceleration time of the axis 1 by the command sent from the CPU module.

  • Page 254: Torque Change Function

    Torque change function Torque change function changes the torque limit value during the control. The torque limit value during the control is normally the value in [Pr.17] Torque limit setting value that was previously set in the parameters. However, by setting a new torque limit value in [Cd.22] New torque value, the axis control data, and writing it to the positioning module, the torque generated in the servomotor during the control can be limited with the new torque value.

  • Page 255

    Control precautions • If a value other than 0 is set in [Cd.22] New torque value, the torque generated in the servomotor is limited with that value. To limit the torque with the value set in [Pr.17] Torque limit setting value, set 0 in [Cd.22] New torque value. •...

  • Page 256: Target Position Change Function

    Target position change function Target position change function changes a target position to a newly specified target position at a specified timing during the position control (1-axis linear control). The command speed can also be changed simultaneously with the target position change.

  • Page 257

    Control precautions • If the positioning movement direction from the stop position to a new target position is reversed, the operation stops once and the positioning to the new target position is performed. • If a command speed exceeding the speed limit value is set to change the command speed, Speed limit value over (Warning code: 0991H) occurs, and the new command speed becomes the speed limit value.

  • Page 258

    Setting the function from the CPU module The following shows the data setting and a program example for changing the target position of the axis 1 by the command sent from the CPU module. (In this example, the target position is changed to 300.0 μm and the command speed is changed to 10000.00 mm/min.) ■Setting data Set the following data.

  • Page 259: Function Related To Start

    12.6 Function Related to Start As the functions related to start, Pre-reading start function and Start time adjustment function are provided. Each function is executed by setting parameters or creating and writing a program. Pre-reading start function Pre-reading start function does not output pulses while Execution prohibition flag is on if a positioning start request is given with the Execution prohibition flag on, and starts outputting pulses within 0.88 ms after the off state of Execution prohibition flag is detected.

  • Page 260

    Program example The following shows a program example of the pre-reading start function. ■Using [Cd.184] Positioning start signal Classification Label Name Description Module label FX5PG_1.stnAxisMonitorData_Axis_D[0].bErrorDetection_D Error detection signal FX5PG_1.stSystemMonitorData2_D.bnBusy_Axis_D[0] Axis 1 BUSY signal FX5PG_1.stnAxisMonitorData_Axis_D[0].bStartComplete_D Axis 1 Start complete signal FX5PG_1.stnAxisControlData2_Axis_D[0].bPositioningStart_D Axis 1 Positioning start signal FX5PG_1.stnAxisControlData2_Axis_D[0].uExecutionProhibitionFlag_D Axis 1 Execution prohibition flag...

  • Page 261

    ■When the dedicated instruction (GP.PSTRT) is used Classification Label Name Description Module label FX5PG_1.stnAxisMonitorData_Axis_D[0].bStartComplete_D Axis 1 Start complete signal FX5PG_1.stnAxisControlData2_Axis_D[0].bPositioningStart_D Axis 1 Positioning start signal FX5PG_1.stnAxisControlData2_Axis_D[0].uExecutionProhibitionFlag_D Axis 1 Execution prohibition flag Global label, local Define the global label or local label as follows. Setting Assign (Device/Label) for labels is not necessary because the unused internal label relay and data device are automatically assigned to the labels.

  • Page 262: Start Time Adjustment Function

    Start time adjustment function Start time adjustment function is used together with Quick start function to adjust the time from when a positioning start trigger is input to when the pulse starts outputting pulses. This function allows users to make a fine adjustment in the start timing without repositioning a sensor. Control details The start time adjustment function starts the positioning after a positioning start trigger is input and the time set in [Pr.82] Start adjustment time elapses, as shown in the following figure.

  • Page 263

    Restrictions • The start time adjustment function is valid only for Quick start. • For [Pr.82] Start adjustment time, the setting at the analysis of the positioning data is valid. • Turn on a start trigger after the analysis of the positioning data is completed. If a start trigger is turned on before the analysis is completed, Pre-analysis incomplete start (Warning code: 09A2H) occurs and the positioning module starts outputting pulses immediately after the analysis is completed.

  • Page 264: Absolute Position Restoration Function

    12.7 Absolute Position Restoration Function Absolute position restoration function restores the absolute position of the specified axis using the absolute position detection system. When this function is used, the OPR after power off due to an instantaneous power failure and emergency stop is not required, and the restoration operation at site can be performed easily.

  • Page 265: Overview Of The Absolute Position Detection System

    Overview of the absolute position detection system The detector comprises an encoder for the detection of position in one rotation in addition to the A, B, and Z phase signals for the position control in normal operation and an accumulative revolution counter for the detection of the number of rotations. The absolute position detection system detects the absolute position of the machine constantly and stores it with the backup of the battery irrespective of the state of the power supply to the PLC system.

  • Page 266

    Connection example The following figure shows an example of the connection between the PLC system and the Mitsubishi Electric servo amplifier (MR-J4-A). PLC system Servo amplifier FX5U-32MT/ES MR-J4-A Positioning module ABS transmission data bit 0 22(ABSB0) 0(X20) FX5-32ET/ES ABS transmission data bit 1...

  • Page 267: Control Precautions

    Control precautions • When an absolute position detection system is constructed, absolute position restoration must be performed at least once after the power supply is turned on or reset. Also, the servo amplifier does not servo on unless the absolute position restoration is completed.

  • Page 268

    Condition 2: Positioning address The following positioning addresses can be specified for the positioning module: Unit setting Range of positioning addresses -214748364.8 to 214748364.7μm inch -21474.83648 to 21474.83647inch pulse -2147483648 to 2147483647 pulse degree 0 to 359.99999° ■Example 1 Using the formula 1, this example calculates the positioning address which can be specified in the system with the OP address 214740000.0 (μm).

  • Page 269: Function Related To Stop

    12.8 Function Related to Stop As the functions related to stop, Stop command processing for deceleration stop function, Continuous operation interrupt function, and Step function are provided. Each function is executed by setting parameters or creating and writing a program. Stop command processing for deceleration stop function Stop command processing for deceleration stop function is provided to set the deceleration curve if a stop cause occurs during the deceleration stop processing (including automatic deceleration).

  • Page 270

    Control precautions • In the manual control (JOG operation, inching operation, and manual pulse generator operation), the stop command processing for deceleration stop function is invalid. • The stop command processing for deceleration stop function is valid when 0: Normal deceleration stop is set in [Pr.37] Stop group 1 sudden stop selection to [Pr.39] Stop group 3 sudden stop selection as the stopping method for the stop cause occurrence.

  • Page 271: Continuous Operation Interrupt Function

    Continuous operation interrupt function Continuous operation interrupt function can interrupt the positioning operations in the continuous positioning control and continuous path control. When the continuous operation is interrupted, the control will stop when the operation of the positioning data being executed is completed. To interrupt the continuous operation, set 1: Continuous operation interrupt request for [Cd.18] Continuous operation interrupt request.

  • Page 272

    • If the operation cannot be decelerated to a stop because the remaining distance is insufficient when Continuous operation interrupt request is executed with the continuous path control, the interruption of the continuous operation will be postponed. The interruption is executed until the positioning data No. that secures a sufficient remaining distance, the positioning data No.

  • Page 273: Step Function

    Step function Step function is used to check each operation of the positioning control. This function is used in debugging work for the major positioning controls. The positioning operation in which the step function is used is called a step operation. In step operations, the timing for stopping the control can be set.

  • Page 274

    Step start request The control stopped by a step operation can be continued by using Step start request. (Step start request is set in the control data [Cd.36] Step start request.) Once accepted, the setting of [Cd.36] Step start request is automatically cleared. The following table shows the results of starts using the step start request during the step operation.

  • Page 275

    Control details ■Deceleration unit step The following figure shows a step operation during Deceleration unit step. [Cd.35] Step enabled flag [Cd.184] Positioning start signal [Md.141] BUSY signal Positioning complete signal ([Md.31] Status: b15) Dwell time Positioning No.10 No.11 Positioning data No. [Da.1] Operation pattern Positioning is performed in steps of automatic deceleration instead of positioning numbers.

  • Page 276

    Setting the step function To use the step function, set the following data into the positioning module using a program. For the setting timing, refer toPage 272 Using the step operation refer to the following. The set data is validated when the data is written into the positioning module.

  • Page 277: Other Functions

    12.9 Other Functions As other functions, Skip function, M code output function, Teaching function, Command in-position function, Acceleration/ deceleration processing function, Deceleration start flag function, During uncompleted OPR operation setting function, and Interrupt function. Each function is executed by setting parameters or creating and writing a program. Skip function Skip function is used to perform the deceleration stop on the positioning data No.

  • Page 278

    Control precautions • When Skip signal is turned on during positioning of the positioning data for which Positioning complete is set in [Da.1] Operation pattern, the operation is completed after the deceleration stop. • When the control is skipped (when Skip signal is turned on during the control), the Positioning complete signal ([Md.31] Status: b15) will not turn on.

  • Page 279

    Setting the function using an external command signal The skip function can also be executed using an external command signal. The section shows a setting example and program example for skipping the control being executed in the axis 1 using an external command signal.

  • Page 280: M Code Output Function

    M code output function M code output function is used to command a subsidiary work (such as clamping, drilling, and tool replacement) related to the positioning data being executed. When M code ON signal ([Md.31] Status: b12) turns on during positioning, a number called an M code is stored in [Md.25] Valid M code.

  • Page 281

    M code ON signal OFF request When M code ON signal ([Md.31] Status: b12) turns on, the signal must be turned off by a program. To turn off M code ON signal, set 1 (M code ON signal is turned OFF) in [Cd.7] M code ON signal OFF request. Setting item Setting Setting detail...

  • Page 282

    Control precautions • During the interpolation control, M code ON signal of the reference axis is turned on. • M code ON signal will not turn on if 0 is set in [Da.10] M code. The M code will not be output, and the previously output value will be held in [Md.25] Valid M code.) •...

  • Page 283

    ■Buffer memory to be used Setting item Setting Setting detail Buffer memory address value Axis 1 Axis 2 [Pr.18] M code ON signal output → Set the output timing of M code ON signal. timing • 0: WITH mode • 1: AFTER mode [Da.27] M code ON signal output →...

  • Page 284: Teaching Function

    Teaching function Teaching function is used to set the address where the target is positioned using the manual control operation (JOG operation, inching operation, or manual pulse generator operation) in the positioning addresses ([Da.6] Positioning address/ movement amount, [Da.7] Arc address). Control details ■Teaching timing Teaching is executed using a program while [Md.141] BUSY signal is off.

  • Page 285

    Data used in teaching The following control data is used in teaching. Setting item Setting Setting detail Buffer memory address value Axis 1 Axis 2 [Cd.1] Module data backup Write the data in the buffer memory to a storage 1900 request destination specified by the extension parameter storage setting.

  • Page 286

    Teaching procedure The following figure shows the procedure for the teaching operation. ■Example 1 The following figure illustrates the process of teaching for [Da.6] Positioning address/movement amount (example with the axis 1). Start Return to the axis 1 machine zero point position. Use manual operation to This is performed via JOG operation, inching operation, move to the target position.

  • Page 287

    ■Example 2 The following figure illustrates the process of teaching for [Da.7] Arc address and then continuing onto [Da.6] Positioning address/movement amount (example for the 2-axis circular interpolation control with a sub point specified on the axis 1 and Start Use buffer memory addresses [1648] and [1649] Run the teaching process for the...

  • Page 288

    ■Operation chart (axis 2) Forward direction Circular interpolation motion *1 Sub point address *2 End address (arc address) (positioning address) OP address Arc center point (current stop position) Reverse direction Forward direction (axis 1) Zero point Reverse direction *1 The sub point address is stored in Arc address. *2 The end point address is stored in Positioning address via teaching.

  • Page 289: Command In-position Function

    (2) Program example Perform the teaching operation with the following program. Page 495 Teaching program • Before setting positioning data, check the teaching function and teaching procedure. • The positioning addresses to be written are absolute address (ABS) values. • When the positioning operation is normally completed with the written positioning data, registering the positioning data in the flash ROM of the positioning module is recommended.

  • Page 290

    • Command in-position flag will be turned off in the following cases. (0 will be stored in [Md.31] Status: b2.) At the position control start At the speed control start At the start of the speed-position switching control or position-speed switching control At the OPR control start At the JOG operation start At the inching operation start...

  • Page 291: Acceleration/deceleration Processing Function

    Acceleration/deceleration processing function Acceleration/deceleration processing function adjusts the acceleration/deceleration of each control to the acceleration/ deceleration curve suited for the target device. Setting the acceleration/deceleration time changes the slope of the acceleration/deceleration curve. One of the following two methods can be selected for the acceleration/deceleration curve: •...

  • Page 292

    ■S-curve acceleration/deceleration processing method In this method, the motor burden at the start and stop is reduced. The acceleration/deceleration is reduced gradually, based on the acceleration time, deceleration time, speed limit value, and the value set in [Pr.35] S-curve ratio (1 to 100%) set by users. Speed Time When an event that generates a speed change request occurs during the S-curve acceleration/deceleration processing (when...

  • Page 293: Deceleration Start Flag Function

    Deceleration start flag function Deceleration start flag function turns on a flag when the speed is switched from the constant speed or acceleration to the deceleration during the position control whose operation pattern is Positioning complete. The flag can be used as a signal to start the operation to be performed by another device at every completion of the position control or to perform preparatory operation for the next position control.

  • Page 294

    Control precautions • The deceleration start flag function is valid for the control methods of 1-axis linear control, 2-axis linear interpolation control, speed-position switching control, and position-speed switching control. For the linear interpolation control, this function is valid only for the reference axis. (Page 29 Combining Main and Sub Functions) •...

  • Page 295: During Uncompleted Opr Operation Setting Function

    Checking Deceleration start flag The status of Deceleration start flag is stored in the following buffer memory address. Monitor item Monitor Monitor details Buffer memory address value Axis 1 Axis 2 [Md.48] Deceleration start flag → • 0: Status other than below •...

  • Page 296: Interrupt Function

    Interrupt function The interrupt function sends an interrupt request to the CPU module when an interrupt factor is detected. By using this function, an interrupt program can be started by detecting the occurrence of an interrupt factor such as the completion of the positioning.

  • Page 297

    Interrupt factor setting To use the interrupt function, set the interrupt parameter. For the interrupt parameter, the setting value when [Cd.190] PLC READY signal is turned off and on is valid. After the power is switched on or the CPU module is reset, turn off and on [Cd.190] PLC READY signal.

  • Page 298

    If an interrupt factor occurs, the value in [Md.65] Interrupt factor detection flag changes as follows. Monitor item Monitor Monitor details Buffer memory address value [Md.65] Interrupt factor detection 0, 1 Stores the detecting status of an interrupt factor. 55000+n flag •...

  • Page 299

    Operation example The following shows an example of the interrupt factor setting and the operation in which the interrupt program of the interrupt pointer I50 is executed if the interrupt factor is detected. Setting item Setting Setting detail Buffer memory address value [Pr.900] Interrupt factor setting...

  • Page 300

    Interrupt program example The following figure shows a program example for the interrupt processing with Axis 1 command in-position shown in the operation example. (Page 297 Operation example) ■Interrupt setting program This program configures the following interrupt setting for the interrupt setting 1. •...

  • Page 301

    ■Interrupt program This program executes the processing for when an interrupt factor is detected, and resets the cause of the interrupt setting 1. Classification Label Name Description Module label FX5PG_1.stInterruptSettingData_D.unInterruptCauseResetRequest_No_D[0] Interrupt setting No.1 [Cd.51] Interrupt factor reset request Global label, local Define the global label or local label as follows.

  • Page 302: Chapter 13 Common Functions

    COMMON FUNCTIONS This chapter describes the details and usage of the positioning module common functions executed according to the user's requirements. Common functions include the functions required for using the positioning module such as the module data initialization function and module data backup function. Check the setting and execution procedures for each common function, and execute an appropriate function as required.

  • Page 303: Module Data Initialization Function

    13.2 Module Data Initialization Function This function sets module parameters and module extension parameters (positioning data and block start data) in the buffer memory of the positioning module and setting values in the module extension parameter file to their factory default settings. Module data initialization means This function is executed with a program.

  • Page 304

    Control restrictions • When the extension parameter storage setting has been set to "CPU", the module data initialization can be performed only while the CPU module status is STOP. Use "[Cd.2] Module data initialization request" for the module data initialization. •...

  • Page 305: Module Data Backup Function

    13.3 Module Data Backup Function When buffer memory data is rewritten with programs or others, the setting values in the module extension parameter file and the execution data being used in control (buffer memory data) may differ. In cases like this, the execution data will be lost if the CPU module is powered off.

  • Page 306

    Control restrictions • When the extension parameter storage setting has been set to "CPU", the module data backup can be performed only while the CPU module status is STOP. Use "[Cd.1] Module data backup request" for the module data backup. •...

  • Page 307: External I/o Signal Logic Switching Function

    13.4 External I/O Signal Logic Switching Function This function switches the signal logics according to the external device connected to the positioning module. For the system in which Drive unit READY signal handled as a normally closed contact, upper limit switch, and lower limit switch are not used, controlling can be performed by this function without wiring if the parameter logic setting is changed to Positive logic.

  • Page 308: History Monitor Function

    13.5 History Monitor Function This function monitors the start history, error history, and warning history stored in the buffer memory of positioning module during the operation monitoring. Start history The start history of past 16 records of operations such as the positioning operation, JOG operation, and manual pulse generator operation can be monitored.

  • Page 309: Amplifier-less Operation Function

    13.6 Amplifier-less Operation Function With this function, user programs can be debugged at a start-up or positioning operations can be simulated by inputting a false external input signal from the buffer memory. External wiring with a drive unit or a limit switch is not required. Control details To use this function, switch the operation mode from the normal operation mode to the amplifier-less operation mode.

  • Page 310

    Restrictions • In the amplifier-less operation mode, the following monitor data operations differ from those in the normal operation mode. Monitor item Monitor details Buffer memory address Axis 1 Axis 2 [Md.30] External I/O signal The ON or OFF state of External I/O signal is stored. Lower limit signal The ON or OFF state set in [Cd.44] External input signal...

  • Page 311

    Setting method The following table lists the data used with the amplifier-less operation function. ■System control data Setting item Setting Setting detail Initial Buffer memory value value at address the factory Axis 1 Axis 2 [Cd.137] Amplifier-less → Switches the operation mode. 0000H 1926 operation mode...

  • Page 312

    Operation mode switching procedure ■Switching from the normal operation mode to the amplifier-less operation mode Stop all operating axes, and check that BUSY signals of all axes are off. Turn off "[Cd.190] PLC READY signal". Check that READY signal ([Md.140] Module status: b0) is off. Set "ABCDH"...

  • Page 313: Chapter 14 Parameter Setting

    PARAMETER SETTING This chapter describes the parameter setting of the positioning module. By setting parameters, the parameter setting by program is not needed. The parameter setting has two types including the module parameter and module extension parameter. 14.1 Parameter Setting Procedure Add the positioning module in GX Works3.

  • Page 314: Module Parameters

    14.2 Module Parameters Set the module parameter. The module parameter has the basic setting, application setting, interrupt setting, and refresh setting. Select the module parameter from the tree on the following window. [Navigation]  [Parameter]  [Module Information]  [Target module]  [Module Parameter] Basic setting Set the parameter required to use the positioning module.

  • Page 315

    Item Setting range Reference Rotation direction setting • 0: Current value increment with forward run pulse Page 377 [Pr.6] Rotation direction setting output (default value) • 1: Current value increment with reverse run pulse output Bias speed at start Refer to the right item. (default value: 0) Page 378 [Pr.7] Bias speed at start ■Basic parameter 2 Speed limit value...

  • Page 316

    Item Setting range Reference ■Detailed parameter 2 Acceleration time 1 1 to 8388608 ms (default value: 1000) Page 391 [Pr.25] Acceleration time 1 to [Pr.27] Acceleration time 3 Acceleration time 2 Acceleration time 3 Deceleration time 1 Page 391 [Pr.28] Deceleration time 1 to [Pr.30] Deceleration time 3 Deceleration time 2 Deceleration time 3...

  • Page 317

    Item Setting range Reference ■OPR detailed parameter OPR dwell time 0 to 65535 ms (default value: 0) Page 404 [Pr.49] OPR dwell time Setting for the movement amount after Refer to the right item. (default value: 0) Page 405 [Pr.50] Setting for the movement amount near-point dog ON after near-point dog ON OPR acceleration time selection...

  • Page 318: Application Setting

    Application setting Set CPU error output mode setting of the positioning module. 14 PARAMETER SETTING 14.2 Module Parameters...

  • Page 319: Interrupt Setting

    Interrupt setting Set the interrupt function of the positioning module. Item Setting range Reference Interrupt factor setting • 0: Do not detect (Default value) Page 473 [Pr.900] Interrupt factor setting • 1: Status_M code ON • 2: Status_Error detection • 3: BUSY •...

  • Page 320: Refresh Settings

    Refresh settings Configure the setting to transfer the values in the buffer memory of the positioning module to devices in the CPU module. By configuring these refresh settings, reading the data by program is not needed. Select the transfer destination from the following at "Target". •...

  • Page 321

    Item Reference Target speed Page 447 [Md.33] Target speed OPR request flag ON cause Page 448 [Md.63] OPR request flag ON factor Positioning control end cause Page 448 [Md.64] Positioning control complete factor Movement amount after near-point dog ON Page 448 [Md.34] Movement amount after near-point dog ON Torque limit stored value Page 449 [Md.35] Torque limit stored value Special start data instruction code setting value...

  • Page 322: Module Extension Parameter

    14.3 Module Extension Parameter Set the module extension parameter. The module extension parameter has positioning data and block start data number 0 to 4 for each axis. Select the module extension parameter from the tree on the following window. [Navigation]  [Parameter]  [Module Information]  [Target module]  [Module Extended Parameter] Positioning data Set the positioning data for each axis.

  • Page 323

    Item Setting range Reference Control method • 01H: ABS1 1-axis linear control (ABS) Page 412 [Da.2] Control method • 02H: INC1 1-axis linear control (INC) • 03H: FEED1 1-axis fixed-feed control • 04H: VF1 1-axis speed control (forward run) • 05H: VR1 1-axis speed control (reverse run) •...

  • Page 324

    M code comment edit Set comments for M codes. The set comments are saved in a project. ■Setting method Double-click "M code comment edit" in "Axis  Positioning data". Input an M code number for which a comment is set in "M Code"...

  • Page 325

    Automatic Command Speed Calculation The automatic command speed calculation calculates the command speed from various conditions. ■Setting method Double-click on "Automatic Command Speed Calculation" for the "Axis  Positioning Data". Set "Positioning Data No." to the positioning data number for which you want to calculate the command speed.

  • Page 326

    Automatic Sub Arc Calculation The automatic sub arc calculation calculates the sub arc setting value (positioning data) so that the operation (waveform) between two sets of positioning data is smooth. The start point address is determined from the positioning data or the direct address specification.

  • Page 327: Block Start Data

    Block start data Set the block start data number 0 to 4 for each axis. Item Setting range Reference Shape • 0: Termination Page 422 [Da.11] Shape • 1: Continue Start data No. 1 to 600 Page 423 [Da.12] Start data No. Special start instruction •...

  • Page 328

    ■Setting item Item Setting range Reference Condition Operator Refer to the right item. Page 426 [Da.16] Condition operator Condition Identifier Refer to the right item. Page 425 [Da.15] Condition target Condition data Buffer address Refer to the right item. Page 426 [Da.17] Address Parameter Refer to the right item.

  • Page 329: Chapter 15 Monitoring/test

    MONITORING/TEST 15.1 Positioning Monitor With the positioning monitor function, the positioning module operating status can be checked for each axis. The following monitors are available in this function. Monitor type Description Operation monitor The status of positioning control being performed such as the current feed value and axis feedrate can be checked.

  • Page 330: Positioning Test

    "Module Information List" is always displayed on the right of the "Positioning Monitor" window. In "Module Information List", the on state is indicated in color (green) for each axis. When an error occurs, the axis in which the error occurs is indicated in orange in "Error Detection". When a warning occurs, the axis in which the warning occurs is indicated in orange in "Status Axis warning detection".

  • Page 331

    ■Starting window The following figure and table show the configuration of the "Positioning Test" window. (1) Monitor part (2) Test part Button name Description Starting Starts positioning control. Skip Performs the skip function to skip the control of the positioning data being performed. Stop Target Axis Stops the positioning control of the axis set as the target axis.

  • Page 332

    Positioning control test Specify a positioning data No. or point No. of block start data to perform the test operation. Select a target axis to be tested from the pull-down menu of "Target Axis". Select "Positioning control" from the pull-down menu of "Select Function". Select a control method from "Start Type".

  • Page 333

    ■Performing the positioning control test with the step operation In the positioning control test, positioning control can be performed with the step operation. Before clicking the [Starting] button, select "Start step". Select a step mode from the pull-down menu of "Step Mode". Click the [Starting] button to start the test operation.

  • Page 334

    JOG/manual pulse generator/OPR test The following tests can be performed with the JOG operation or manual pulse generator operation when the positioning control is debugged. • Checking the forward run/reverse run direction • Checking the on/off state of external input signals such as an upper/lower limit switch, Zero signal, and Near-point dog signal •...

  • Page 335

    ■Manual pulse generator operation Select a target axis to be tested from the pull-down menu of "Target Axis". Select "JOG/Manual Pulse Generator/OPR" from the pull-down menu of "Select Function". Set "Manual Pulse 1 Pulse Generator Input Magnification". Select "Manual pulse generator enable flag". The test for manual pulse generator operation starts using the manual pulse generator connected to the positioning module.

  • Page 336

    ■OPR control Select a target axis to be tested from the pull-down menu of "Target Axis". Select "JOG/Manual Pulse Generator/OPR" from the pull-down menu of "Select Function". Select "Machine OPR" or "Fast OPR" from the pull-down menu of "OPR Method". Click the [OPR] button.

  • Page 337

    Speed change test For the axes started with the positioning start test, OPR test, and JOG operation test, perform the speed change function, acceleration/deceleration time change function, or override function to check the proper speed or acceleration/deceleration time. ■Speed change Select a target axis to be tested from the pull-down menu of "Target Axis".

  • Page 338

    Set "Speed Override". Click the [Speed Override Change] button. The set value of "Speed Override" is reflected to the positioning control being performed. ■Acceleration/deceleration time change Select a target axis to be tested from the pull-down menu of "Target Axis". Select "New Speed"...

  • Page 339

    Other control tests Change the current feed value of the positioning module to a specified address. Select a target axis to be tested from the pull-down menu of "Target Axis". Select "Other control" from the pull-down menu of "Select Function". Set "New Current Value".

  • Page 340: Chapter 16 Specifications Of I/o Signals With Cpu Module

    SPECIFICATIONS OF I/O SIGNALS WITH CPU MODULE 16.1 List of I/O Signals with CPU Module The positioning module uses buffer memory for transfers of data with the CPU module. The following shows the list of I/O signals for positioning module. Input signal Buffer memory address Signal name...

  • Page 341: Details Of Input Signals

    16.2 Details of Input Signals The following tables shows the ON/OFF timing and conditions of the input signals. Buffer Signal name Description memory address 31500.b0 READY ON: READY • When [Cd.190] PLC READY signal is turned off and on, the parameter setting OFF: Not READY/ range is checked.

  • Page 342: Details Of Output Signals

    16.3 Details of Output Signals The following tables shows the ON/OFF timing and conditions of the output signals. Buffer Signal name Description memory address 1950 PLC READY • Other than 1: PLC (a) This signal notifies the positioning module that the CPU module is normal. READY OFF •...

  • Page 343: Chapter 17 Data Used For Positioning Control

    DATA USED FOR POSITIONING CONTROL This chapter describes the parameters and data used for performing the positioning control with the positioning module. In the positioning system using the positioning module, the various parameters and data are used for the control. The parameters and data include parameters set according to the device configuration, such as the system configuration, and parameters and data set according to each control.

  • Page 344

    Monitor Data The data indicates the control status. The data is stored in the buffer memory. Monitor the data as necessary. The setting data is classified as follows. Item Description System monitor Monitors the positioning module specifications and the operation history. Axis monitor data Monitors the data related to the operating axis, such as the current position and speed.

  • Page 345: Setting Items For Positioning Parameters

    Setting items for positioning parameters The following table lists the setting items for Positioning parameter. For Positioning parameter, set the same setting for all controls using the positioning module for each axis. OPR control : Always set : Set as required : Setting restricted : Setting not required (Because this item is an irrelevant item, the set value is ignored.

  • Page 346

    Positioning parameter OPR control [Pr.37] Stop group 1 sudden stop selection   [Pr.38] Stop group 2 sudden stop selection [Pr.39] Stop group 3 sudden stop selection   [Pr.40] Positioning complete signal output time  [Pr.41] Allowable circular interpolation error width ...

  • Page 347

    Positioning parameter Position control Axis speed control 1-axis linear control Fixed-feed control 2-axis circular 2-axis linear interpolation interpolation control control     [Pr.30] Deceleration time 3 [Pr.31] JOG speed limit value        ...

  • Page 348

    Positioning parameter Speed-position or position- Other controls speed switching control Current value change JUMP instruction, NOP instruction LOOP to LEND    [Pr.150] Speed-position function selection ■Detailed parameter 2    [Pr.25] Acceleration time 1    [Pr.26] Acceleration time 2 [Pr.27] Acceleration time 3 ...

  • Page 349

    Positioning parameter Manual pulse generator JOG operation operation Inching operation [Pr.16] Command in-position width     [Pr.17] Torque limit setting value   [Pr.18] M code ON signal output timing   [Pr.19] Speed switching mode   [Pr.20] Interpolation speed specification method [Pr.21] Current feed value during speed control ...

  • Page 350: Setting Items For Opr Parameters

    Setting items for OPR parameters OPR parameters must be set to perform OPR control. The following table lists the setting items for OPR parameter. For OPR parameter, set the same setting for each axis. : Always set : Use parameters set for the machine OPR control : Setting not required (Because this item is an irrelevant item, the set value is ignored.

  • Page 351: Setting Items For Positioning Data

    Checking OPR parameters OPR parameters are checked at the following timings. • When [Cd.190] PLC READY signal output from the CPU module to the positioning module changes from off to on • When the [Start] button is clicked for the "Positioning Test" in GX Works3 Setting items for positioning data Positioning data must be set to perform Major positioning control.

  • Page 352

    Setting items for positioning data Speed control Speed-position switching Position-speed switching control control 1-axis speed control 2-axis speed control    [Da.4] Deceleration time No. : 2-axis interpolation control   [Da.5] Axis to be interpolated : 1-axis control ...

  • Page 353: Block Start Data Setting Items

    Block start data setting items Values indicating the current values Block start data must be set to perform Advanced positioning control. The following table lists the setting items for Block start data. Up to 50 points of Block start data can be set for each axis. : Set as required : Setting not required (Because this item is an irrelevant item, the set value is ignored.

  • Page 354: List Of Buffer Memory Addresses

    17.2 List of Buffer Memory Addresses This section lists the buffer memory addresses of the positioning module. For details on the buffer memory addresses, refer to the following. Page 341 DATA USED FOR POSITIONING CONTROL Do not write data to system areas and monitor data ([Md.]) in the buffer memory. Writing data to these areas may cause malfunction.

  • Page 355

    ■Basic parameter 2 Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  [Pr.8] Speed limit value 200000 (AH) (A0H) (BH) (A1H)  [Pr.9] Acceleration time 0 1000 (CH) (A2H) (DH) (A3H)  [Pr.10] Deceleration time 0 1000 (EH) (A4H)

  • Page 356

    ■Detailed parameter 2 Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  [Pr.25] Acceleration time 1 1000 (24H) (BAH) (25H) (BBH)  [Pr.26] Acceleration time 2 1000 (26H) (BCH) (27H) (BDH)  [Pr.27] Acceleration time 3 1000 (28H) (BEH)

  • Page 357

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2   System area (3FH) (D5H) (45H) (DBH) (78H) (10EH)  [Pr.82] Start adjustment time (86H) (11CH) (87H) (11DH) ■OPR basic parameter Buffer memory address Name Default Auto refresh Decimal (Hexadecimal)

  • Page 358

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  [Pr.57] Dwell time during OPR retry (59H) (EFH) [Pr.58] Setting of operation during uncompleted OPR  (5AH) (F0H)   System area (5BH) (F1H) (63H) (F9H) Monitor Data ■Axis monitor data...

  • Page 359

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  [Md.33] Target speed (334H) (398H) (335H) (399H)  [Md.63] OPR request flag ON factor (336H) (39AH) [Md.64] Positioning control complete factor  (337H) (39BH)  [Md.34] Movement amount after near-point dog ON (338H) (39CH)

  • Page 360

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2   System area (350H) (3B4H) (358H) (3BCH)  [Md.60] Analysis mode (359H) (3BDH) [Md.61] Analysis complete flag  (35AH) (3BEH)   System area (35BH) (3BFH) (382H) (3E6H)

  • Page 361

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  1232(4D0H) Start history 4 [Md.3] Start information 0000H 1233(4D1H) [Md.4] Start No. 0000H   1234(4D2H) [Md.5] Start (date/hour) 0000H 1235(4D3H) [Md.6] Start (minute/second) 0000H ...

  • Page 362

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  1272(4F8H) Start history 12 [Md.3] Start information 0000H  1273(4F9H) [Md.4] Start No. 0000H 1274(4FAH) [Md.5] Start (date/hour) 0000H   1275(4FBH) [Md.6] Start (minute/second) 0000H 1276(4FCH) [Md.7] Error judgment...

  • Page 363

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  1313(521H) Error history 5 [Md.9] Axis in which the error occurred 1314(522H) [Md.10] Error No.   1315(523H) [Md.11] Error occurrence (date/hour) 0000H 1316(524H) [Md.12] Error occurrence (minute/second) 0000H ...

  • Page 364

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  1353(549H) Error history 15 [Md.9] Axis in which the error occurred  1354(54AH) [Md.10] Error No. 1355(54BH) [Md.11] Error occurrence (date/hour) 0000H   1356(54CH) [Md.12] Error occurrence (minute/second) 0000H 1471(5BFH)

  • Page 365

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  1394(572H) Warning history 9 [Md.14] Axis in which the warning occurred 1395(573H) [Md.15] Warning No.   1396(574H) [Md.16] Warning occurrence (date/hour) 0000H 1397(575H) [Md.17] Warning occurrence (minute/second) 0000H ...

  • Page 366

    Control Data ■Axis control data Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  1500 1600 [Cd.3] Positioning start No. (5DCH) (640H)  1501 1601 [Cd.4] Positioning starting point No. (5DDH) (641H)  1502 1602 [Cd.5] Axis error reset (5DEH)

  • Page 367

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  1526 1626 [Cd.23] Speed-position switching control movement amount change (5F6H) (65AH) register 1527 1627 (5F7H) (65BH)  1528 1628 [Cd.24] Speed-position switching enable flag (5F8H) (65CH) 1529 1629...

  • Page 368

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2   1568 1668 System area (620H) (684H) 1589 1689 (635H) (699H)  1590 1690 [Cd.43] Analysis mode setting (636H) (69AH) 1591 1691 System area  ...

  • Page 369

    Positioning data ■Positioning data Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  2000 8000 Positioning data Positioning identifier (7D0H) (1F40H) No.1 • [Da.1] Operation pattern • [Da.2] Control method • [Da.3] Acceleration time No. •...

  • Page 370

    Block start data ■Start block 0 (Block No. 7000) Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  26000 27000 Block start data [Da.11] Shape (6590H) (6978H) 1st point [Da.12] Start data No.  26050 27050 [Da.13] Special start instruction...

  • Page 371

    ■Start block 1 (Block No. 7001) Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  26200 27200 Block start data (6658H) (6A40H) 26299 27299 (66BBH) (6AA3H)  26300 27300 Condition data (66BCH) (6AA4H) 26399 27399 (671FH) (6B07H)

  • Page 372

    ■PLC CPU memo area Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Axis 1 Axis 2  30000(7530H) to 30099(7593H) Target data for condition judgment of the condition data Interrupt setting ■Interrupt setting data Buffer memory address Name Default Auto refresh Decimal (Hexadecimal)

  • Page 373

    Buffer memory address Name Default Auto refresh Decimal (Hexadecimal) value Common for axes 1 and 2  55008(D6E0H) Interrupt setting [Md.65] Interrupt factor detection flag No.9 55072(D720H) [Cd.50] Interrupt factor mask   55136(D760H) [Cd.51] Interrupt factor reset request 55200(D7A0H) [Pr.900] Interrupt factor setting ...

  • Page 374: Basic Setting

    17.3 Basic Setting Basic parameter 1 This section describes the details on the basic parameter 1. [Pr.1] Unit setting Set the command unit used for the positioning control. Select a unit from the following depending on the control target: mm, inch, degree, or pulse.

  • Page 375

    [Pr.2] No. of pulses per rotation (16 bits) (Ap) Set the number of pulses required for a rotation of the motor shaft with 16 bits. When [Pr.62] Electronic gear selection is set to 0: 16 bits, this area is valid. If a Mitsubishi servo amplifier is used, set the value given as Resolution per rotation of the servomotor in the speed-position detector specifications.

  • Page 376

    [Pr.3] Movement amount per rotation (16 bits) (Al) Set the distance of machine movement (movement amount) per rotation of the motor shaft with 16 bits. When [Pr.62] Electronic gear selection is set to 0: 16 bits, this area is valid. When the movement amount per rotation of the motor shaft exceeds the setting range of this area in the system used, adjust the setting value with the following method.

  • Page 377

    [Pr.5] Pulse output mode Set the pulse output mode to match the servo amplifier used. Pulse output mode Setting value PULSE/SIGN mode CW/CCW mode A phase/B phase mode (multiple of 4) A phase/B phase mode (multiple of 1) The only valid value of [Pr.5] Pulse output mode is the value at the moment when [Cd.190] PLC READY signal is turned off and on for the first time after the power is switched on or the CPU module is reset.

  • Page 378

    ■A phase/B phase mode Forward run and reverse run are controlled with the phase difference of the A phase (Aφ) and B phase (Bφ). When the B phase is 90°behind the A phase, the motor will forward run. When the B phase is 90°ahead of the A phase, the motor will reverse run.

  • Page 379

    [Pr.6] Rotation direction setting Set the relation of the positioning direction (increment direction or decrement direction of [Md.20] Current feed value) and the pulse output. For the relation of "Forward run pulse output, Reverse run pulse output" and "CW/A phase/PULSE signal, CCW/ B phase/SIGN signal", refer to the following.

  • Page 380

    [Pr.7] Bias speed at start Set Minimum speed at start for Bias speed at start. Set Bias speed at start to allow the motor to start smoothly especially when a stepping motor is used. (A stepping motor does not start smoothly if a low rotation speed is instructed at the start.) ■Bias speed at start is "0"...

  • Page 381

    [Pr.62] Electronic gear selection Select an electronic gear (16 bits or 32 bits) to use. Electronic gear selection Setting value 16 bit 32 bit The addresses used by the buffer memory areas shown below depend on the setting of this area. Setting value of [Pr.62] Address of [Pr.2] No.

  • Page 382

    [Pr.3] Movement amount per rotation (32 bits) (Al) Set the distance of machine movement (movement amount) per rotation of the motor shaft with 32 bits. When [Pr.62] Electronic gear selection is set to 1: 32 bits, this area is valid. When the movement amount per rotation of the motor shaft exceeds the setting range of [Pr.3] Movement amount per rotation (16 bits) in the system used, use this area.

  • Page 383: Basic Parameter 2

    Basic parameter 2 This section describes the details on the basic parameter 2. [Pr.8] Speed limit value Set the maximum speed during positioning control and OPR control. If the specified speed exceeds the speed limit value, positioning is limited at the speed limit value. Positioning control speed must be limited properly depending on the device and control subject.

  • Page 384

    [Pr.9] Acceleration time 0, [Pr.10] Deceleration time 0 For [Pr.9] Acceleration time 0, set the time for the speed to increase from 0 to [Pr.8] Speed limit value (to [Pr.31] JOG speed limit value during a JOG operation control) in units of ms. For [Pr.10] Deceleration time 0, set the time for the speed to decrease from [Pr.8] Speed limit value (from [Pr.31] JOG speed limit value during a JOG operation control) to 0 in units of ms.

  • Page 385: Detailed Parameter 1

    Detailed parameter 1 [Pr.11] Backlash compensation amount The error that occurs due to backlash when the machine is moved via gears can be compensated. (When the backlash compensation amount is set, pulses equivalent to the compensation amount is output each time the direction changes during the positioning.) [Pr.44] OPR direction Workpiece...

  • Page 386

    [Pr.12] Software stroke limit upper limit value Set the upper limit for the machine's movement range during positioning control. ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2 [Pr.12] Software stroke limit upper limit value ■Setting range The setting range depends on the setting of [Pr.1] Unit setting.

  • Page 387

    [Pr.14] Software stroke limit selection Set whether to apply the software stroke limit to Current feed value or Machine feed value. The software stroke limit is validated according to the set value. Software stroke limit selection Setting value Apply the software stroke limit to the current feed value Apply the software stroke limit to the machine feed value ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 388

    ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2 [Pr.16] Command in-position width ■Setting range The setting range depends on the setting of [Pr.1] Unit setting. Setting of [Pr.1] Unit setting Setting value via GX Works3 Setting value with programs 0: mm...

  • Page 389

    [Pr.18] M code ON signal output timing Set the timing of outputting the M code ON signal. Select either the WITH mode or the AFTER mode as timing of outputting the M code ON signal. WITH mode (setting value: 0) AFTER mode (setting value: 1) An M code is output and the M code ON signal ([Md.31] Status: b12) is turned An M code is output and the M code ON signal ([Md.31] Status: b12) is turned...

  • Page 390

    ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2 [Pr.19] Speed switching mode ■Default value The default value is 0: Standard speed switching mode for all the axes. [Pr.20] Interpolation speed specification method When performing linear interpolation/circular interpolation, set whether to specify the composite speed or the speed for the reference axis.

  • Page 391

    ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2 [Pr.21] Current feed value during speed control ■Default value The default value is 0: Current feed value is not updated for all the axes. [Pr.22] Input signal logic selection Set the logic of each input signal according to the external device.

  • Page 392

    ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2 [Pr.23] Output signal logic selection ■Default value Each input signal of all the axes is set to 0: Negative logic. [Pr.24] Manual pulse generator input selection Set the input pulse mode from the manual pulse generator.

  • Page 393: Detailed Parameter 2

    Detailed parameter 2 [Pr.25] Acceleration time 1 to [Pr.27] Acceleration time 3 Set the time for the speed to increase from 0 to [Pr.8] Speed limit value (to [Pr.31] JOG speed limit value during a JOG operation control) during positioning. The specifications of this area are the same as those of [Pr.9] Acceleration time 0. For details, refer to the following.

  • Page 394

    [Pr.31] JOG speed limit value Set the maximum speed for the JOG operation. Set the value in JOG speed limit value to a value equal to or less than the value set in [Pr.8] Speed limit value. If the value exceeds the value set in Speed limit value, JOG speed limit value error (Error code: 1AB8H) occurs.

  • Page 395

    [Pr.33] JOG operation deceleration time selection Set which of Deceleration time 0 to 3 to use for the deceleration time during JOG operation. JOG operation deceleration Setting value Description time selection Deceleration time 0 Use the value set in [Pr.10] Deceleration time 0. Deceleration time 1 Use the value set in [Pr.28] Deceleration time 1.

  • Page 396

    [Pr.35] S-curve ratio Set the S-curve ratio (1 to 100%) for performing the S-curve acceleration/deceleration processing. The S-curve ratio indicates where to draw the acceleration/deceleration curve using the sine curve as shown below. (Example) Positioning speed S-curve ratio of 100% Positioning speed Sin curve b/a = 0.7...

  • Page 397

    [Pr.36] Sudden stop deceleration time Set the time for the speed to decrease from [Pr.8] Speed limit value (from [Pr.31] JOG speed limit value during a JOG operation control) to 0 at a sudden stop in units of ms. Set this parameter to stop (sudden stop) operations in a shorter time than the deceleration time for positioning when a stop cause occurs.

  • Page 398

    [Pr.37] to [Pr.39] Stop group 1 to 3 sudden stop selection Set the method to stop operations when the stop causes in the following stop groups occur. • Stop group 1: Stop with the hardware stroke limit • Stop group 2: CPU module error occurrence, [Cd.190] PLC READY signal off, fault in the test mode •...

  • Page 399

    [Pr.40] Positioning complete signal output time Set the output time of Positioning complete signal ([Md.31] Status: b15) output from the positioning module in units of ms. A positioning completes when the set dwell time is elapsed after the positioning module terminates outputting pulses. For the interpolation control, Positioning completed signal of interpolation axis is output only for the time set to the reference axis.

  • Page 400

    [Pr.41] Allowable circular interpolation error width For Allowable circular interpolation error width, set the allowable error range of the calculated arc path and end point address. If the error of the calculated arc path and end point address is within the setting range, circular interpolation is performed to the set end point address while the error is compensated with spiral interpolation.

  • Page 401

    [Pr.42] External command function selection Select a function with which external command signals are associated. External command function Setting Description selection value Start with external command Starts a positioning operation by inputting an external command signal. External speed change request Changes the speed in the current positioning operation by inputting an external command signal.

  • Page 402: Opr Basic Parameter

    OPR basic parameter [Pr.43] OPR method Set OPR method for performing the machine OPR. OPR method Setting Description Reference value Near-point dog method After the speed of the OPR is decelerated when the near-point dog is on, the OPR stops Page 76 when the zero signal is detected and the machine OPR completes.

  • Page 403

    [Pr.44] OPR direction Set the direction of the movement when the machine OPR starts. OPR direction Setting Description value Forward direction (address Moves the workpiece in the address increment direction. (Arrow (2)) increment) Reverse direction (address Moves the workpiece in the address decrement direction. (Arrow (1)) decrement) Because the OP is normally set near the lower limit or the upper limit, [Pr.44] OPR direction is set as follows.

  • Page 404

    [Pr.45] OP address Set the address used as the reference point for positioning control (ABS system). (When the machine OPR is completed, the stop position address is changed to the address set in [Pr.45] OP address. At the same time, the value set in [Pr.45] OP address is stored in [Md.20] Current feed value and [Md.21] Machine feed value.) ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 405

    [Pr.47] Creep speed Once the near-point dog turns on, the control decelerates from OPR speed and stops. Set the speed of right before the stop, which is a creep speed. Set the creep speed within the following range. • ([Pr.46] OPR speed) ≥ ([Pr.47] Creep speed) ≥ ([Pr.7] Bias speed at start) The creep speed is related to the detection error in the OPR method using the zero signal, and to the size of the shock when a collision occurs in the OPR method using the stopper method.

  • Page 406: Opr Detailed Parameter

    [Pr.48] OPR retry Set whether to perform OPR retry. OPR retry Setting value Do not perform OPR retry by limit switch Perform OPR retry by limit switch For the operation of OPR retry, refer to the following. Page 211 OPR retry function ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 407

    [Pr.50] Setting for the movement amount after near-point dog ON When the OPR method is count method 1 or 2, set the movement amount from the position where the near-point dog signal turns on to the OP. (Set the value for the movement amount after near-point dog ON to a value equal to or greater than the sum of the "distance covered by the deceleration from the OPR speed to the creep speed"...

  • Page 408

    [Pr.51] OPR acceleration time selection Set which of Acceleration time 0 to 3 to use for the acceleration time during OPR. OPR acceleration time Setting Description selection value Acceleration time 0 Uses the value set in [Pr.9] Acceleration time 0. Acceleration time 1 Uses the value set in [Pr.25] Acceleration time 1.

  • Page 409

    [Pr.53] OP shift amount Set the amount to shift (move) the OP from the stop position with machine OPR. The OP shift function is used to compensate the OP position stopped with machine OPR. If the OP position is physically limited due to the installation position of the near-point dog, use this function to compensate the OP to an optimum position.

  • Page 410

    [Pr.54] OPR torque limit value Set the value to limit the servomotor torque after the creep speed is reached during machine OPR in units of %. If the torque is not limited, the servomotor may be in failure. When the value set in [Pr.54] OPR torque limit value exceeds the value set in [Pr.17] Torque limit setting value, OPR torque limit value error (Error code: 1B0EH) occurs.

  • Page 411

    [Pr.57] Dwell time during OPR retry When OPR retry is performed, set the stop time after the deceleration of (2) and (4) in the following figure in units of ms. Pauses after the time Pauses after the time set with [Pr.57] set with [Pr.57] Position Start position...

  • Page 412: Positioning Data

    17.4 Positioning Data The following figure shows the configuration of the positioning data stored in the buffer memory of the positioning module. • Up to 600 positioning data registrations per axis can be configured 7990 7980 (stored) via buffer memory addresses as illustrated in the left Positioning data No.

  • Page 413

    [Da.1] Operation pattern The operation pattern is used to specify whether to end the positioning of a certain data number with just that data or to perform the positioning of the next data number in succession. Operation pattern Setting Description value Positioning Complete Set this value to execute the positioning to the specified address to complete the positioning.

  • Page 414

    [Da.2] Control method Set Control method for performing the positioning control. The following table lists the available control methods. Control method Setting value ABS1: 1-axis linear control (ABS) INC1: 1-axis linear control (INC) FEED1: 1-axis fixed-feed control VF1: 1-axis speed control (forward run) VR1: 1-axis speed control (reverse run) VPF: Speed-position switching control (forward run) VPR: Speed-position switching control (reverse run)

  • Page 415

    [Da.3] Acceleration time No. Set which of Acceleration time 0 to 3 to use for the acceleration time during positioning. Acceleration time No. Setting Description value Acceleration time 0 Uses the value set in [Pr.9] Acceleration time 0. Acceleration time 1 Uses the value set in [Pr.25] Acceleration time 1.

  • Page 416

    [Da.6] Positioning address/movement amount Set the address used as the target value for positioning control. The setting range differs according to the value set in [Da.2] Control method. ■Absolute (ABS) system and current value change Set the value (positioning address) with an absolute address (address from the OP) for the ABS system and current value change.

  • Page 417

    ■Setting range The setting range depends on the setting of [Pr.1] Unit setting and [Da.2] Control method. • When [Pr.1] Unit setting is "0: mm" Setting of [Da.2] Control method Setting value via GX Works3 Setting value with programs ABS linear 1: 01H Set the address.

  • Page 418

    • When [Pr.1] Unit setting is "1: inch" Setting of [Da.2] Control method Setting value via GX Works3 Setting value with programs ABS linear 1: 01H Set the address. Set the address. ABS linear 2: 0AH -21474.83648 to 21474.83647 (inch) -2147483648 to 2147483647 (×10 inch) New current value: 81H...

  • Page 419

    • When [Pr.1] Unit setting is "2: degree" No control method requires the setting of the arc address with degree. • When [Pr.1] Unit setting is "3: pulse" Setting of [Da.2] Control method Setting value via GX Works3 Setting value with programs ABS circular sub: 0DH Set the address.

  • Page 420

    [Da.9] Dwell time Set Dwell time or Positioning data No. according to the value set in [Da.2] Control method. • When a method other than JUMP instruction is set in [Da.2] Control method, set the value in Dwell time in units of ms. •...

  • Page 421

    [Da.10] M code Set M code, Condition data No., or Number of LOOP to LEND repetitions depending on how [Da.2] Control method is set. • If a method other than JUMP instruction and LOOP is selected as the setting value in [Da.2] Control method, set M code. If M code does not need to be output, set 0 (default value).

  • Page 422

    [Da.28] ABS direction in degrees Set the ABS movement direction for each positioning data when the unit is degree. ABS direction in degrees Setting value Use the setting value in [Cd.40] ABS direction in degrees ABS clockwise ABS counterclockwise Shortcut (Direction setting invalid) For the setting, refer to the following and check the assignment of this area.

  • Page 423

    17.5 Block Start Data The following figure shows the configuration of the block start data stored in the buffer memory of the positioning module. 50th point Buffer memory Parameter address Up to 50 points of block start data can be configured (stored) via buffer memory addresses as illustrated in 2nd point the left figure.

  • Page 424

    To perform an advanced positioning control using Block start data, set a number between 7000 and 7004 for [Cd.3] Positioning start No. and use [Cd.4] Positioning starting point No. to specify a point number between 1 and 50, a position counted from the beginning of the block.

  • Page 425

    [Da.12] Start data No. Set Positioning data No. specified with Block start data. For the setting, refer to the following and check the assignment of this area. Page 422 [Da.11] Shape ■Buffer memory address For the buffer memory address of this area, refer to the following. Page 542 Block start data ■Setting range The setting range is 1 to 600 (01H to 258H).

  • Page 426

    [Da.14] Parameter Set a value according to the value set in [Da.13] Special start instruction. Special start instruction Description Block start Not used. (Setting this item is not required.) Condition start Set the condition data No. (number of Condition data which is set to perform condition judgment). (For more on condition data, refer to Page 425 Condition Data) Wait start Simultaneous start...

  • Page 427: Condition Data

    17.6 Condition Data The following figure shows the configuration of the condition data stored in the buffer memory of the positioning module. No.10 Buffer memory Setting item address No.2 Up to 10 condition data registration per block number can be configured (stored) via buffer memory addresses No.1 Buffer memory Setting item...

  • Page 428

    [Da.16] Condition operator Set the condition operator according to the value set in [Da.15] Condition target. Setting of [Da.15] Condition Condition Operator Setting Description target value 01H: Axis monitor data SIG=ON When the state (ON or OFF) of I/O signals is set as a condition, select ON or 02H: Control Data OFF as the trigger.

  • Page 429

    [Da.18] Parameter 1 Set the parameters according to the value set in [Da.16] Condition operator. Setting of [Da.16] Condition Setting Description operator value Set the value of P1 to be equal to or smaller than the value of P2 (P1 ≤ P2). 01H: **=P1 Numerical value...

  • Page 430

    [Da.19] Parameter 2 Set the parameters according to the value set in [Da.16] Condition operator. Setting of [Da.16] Condition Setting Description operator value  01H: **=P1 Not used. (Setting this item is not required.) 02H: **≠P1 03H: **≤P1 04H: **≥P1 05H: P1≤**≤P2 Numerical Set the value of P2 to be equal to or greater than the value of P1 (P1 ≤...

  • Page 431: Monitor Data

    17.7 Monitor Data System monitor data [Md.1] In test mode flag This area stores information indicating whether or not the GX Works3 test mode is in use. In test mode flag Stored value Not in test mode In test mode ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 432

    [Md.3] Start information This area stores the start information (restart flag, start origin, and starting axis). • Restart flag: Indicates whether the operation has been temporarily stopped and restarted • Start source: Indicates the source of the start signal. • Starting axis: Indicates the started axis The following figure shows the information to be stored.

  • Page 433

    ■Configuration of start history Information on starts is stored in the start history of pointer 0 to 15. The following figure shows the configuration of the start history. [Md.8] 1292 Start history pointer This area stores the next pointer number after the pointer number assigned to the most recent start history record.

  • Page 434

    [Md.4] Start No. This area stores the start number. Start No. Stored value Positioning operation • 1 to 600(1H to 258H) • 7000(1B58H) • 7001(1B59H) • 7002(1B5AH) • 7003(1B5BH) • 7004(1B5CH) JOG operation 9010(2332H) Manual pulse generator operation 9011(2333H) Machine OPR 9001(2329H) Fast OPR 9002(232AH)

  • Page 435

    [Md.6] Start (minute/second) The start time (minute/second) is stored with the BCD code. Monitor the value in hexadecimal format. Buffer memory configuration Stored contents Stored value Minute (tens place) 0 to 5 b15 b14 b13 b12 b11 b10 b9 Minute (ones place) 0 to 9 Second (tens place) 0 to 5...

  • Page 436

    [Md.9] Axis in which the error occurred This area stores the axis number in which the error is detected. Axis in which the error occurred Stored value Axis 1 Axis 2 ■Buffer memory address For the buffer memory address of this area, refer to the following. Page 356 Monitor Data ■Configuration of error history Information on errors is stored in the error history of pointer 0 to 15.

  • Page 437

    [Md.51] Error occurrence (year/month) This area stores the time (year/month) when an error occurs with the BCD code. Monitor the value in hexadecimal format. Buffer memory configuration Stored contents Stored value Year (tens place) 0 to 9 b15 b14 b13 b12 b11 b10 b9 Year (ones place) 0 to 9 Month (tens place)

  • Page 438

    [Md.14] Axis in which the warning occurred This area stores the axis number in which the warning is detected. Axis in which the warning occurred Stored value Axis 1 Axis 2 ■Buffer memory address For the buffer memory address of this area, refer to the following. Page 356 Monitor Data ■Warning history configuration Information on warnings is stored in the warning history of pointer 0 to 15.

  • Page 439

    [Md.52] Warning occurrence (year/month) This area stores the time (year/month) when a warning occurs with the BCD code. Monitor the value in hexadecimal format. Buffer memory configuration Stored contents Stored value Year (tens place) 0 to 9 b15 b14 b13 b12 b11 b10 b9 Year (ones place) 0 to 9 Month (tens place)

  • Page 440

    [Md.19] No. of write accesses to flash ROM This area stores the number of module data backups and module data initializations performed with a program after the power-on. The count is cleared to 0 when Flash ROM write number error (Error code: 1080H) and the error is reset. ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 441

    [Md.55] Date of write accesses to flash ROM (minute/second) This area stores the latest date (minute/second) when the data is written to flash ROM with the BCD code. Monitor the value in hexadecimal format. Buffer memory configuration Stored contents Stored value Minute (tens place) 0 to 5 b15 b14 b13 b12 b11 b10 b9...

  • Page 442

    [Md.140] Module status This area stores the on/off state of various flags. Monitor the value in hexadecimal format. Buffer memory configuration Stored contents Stored value READY 0, 1 b15 b14 b13 b12 b11 b10 b9 Module access flag 0, 1 b2 to b15 Use prohibited Fixed to 0...

  • Page 443: Axis Monitor Data

    Axis monitor data [Md.20] Current feed value This area stores the currently commanded address or the address of the current position. The stored value is different from the actual motor position during operation. Multiplying the stored value by the following converted value enables the monitoring of the converted value in each unit.

  • Page 444

    [Md.22] Feedrate This area stores the command output speed of the operating workpiece. The stored value may be different from the actual motor speed during operation. Multiplying the stored value by the following converted value enables the monitoring of the converted value in each unit.

  • Page 445

    [Md.26] Axis operation status This area stores the axis operation status. The following table shows the stored values. Axis operation status Stored value Step standby Error Standby Stopped Interpolation JOG operation Manual pulse generator operation Analyzing Special start standby Position control Speed control Speed control in speed-position switching control Position control in speed-position switching control...

  • Page 446

    [Md.28] Axis feedrate This area stores the speed which is actually output as a command in each axis at that time. The stored value may be different from the actual motor speed. Multiplying the stored value by the following converted value enables the monitoring of the converted value in each unit.

  • Page 447

    [Md.30] External I/O signal This area stores the on/off state of external I/O signals. External I/O signal Stored value Values are stored in the bits corresponding to each external I/O signal. The following table shows the assignment of each external I/O signal. Buffer memory Assignment of I/O signals Lower limit signal...

  • Page 448

    Flag Description OPR request flag This signal turns on when the power is switched on, Drive unit READY signal is turned off, [Cd.190] PLC READY signal in turned on, or a machine OPR starts. This signal turns off when the machine OPR completes. OPR complete flag This signal turns on when a machine OPR completes normally.

  • Page 449

    [Md.32] Target value This area stores the target value ([Da.6] Positioning address/movement amount) for a positioning operation. The stored value depends on the positioning operation as shown below. Positioning operation Stored value When the position control and current value change are started The value of [Da.6] Positioning address/movement amount is stored.

  • Page 450

    [Md.63] OPR request flag ON factor This area stores the cause which turns on OPR request flag ([Md.31] Status: b3). OPR request flag ON cause Stored value No cause Power-on PLC READY is turned off and on Drive unit READY OFF Test mode Machine OPR start ■Buffer memory address...

  • Page 451

    [Md.35] Torque limit stored value This area stores the value set in [Pr.17] Torque limit setting value or [Cd.22] New torque value. • During positioning start, JOG operation start, manual pulse generator operation (when [Cd.21] Manual pulse generator enable flag is turned on), the value set in [Pr.17] Torque limit setting value is stored. •...

  • Page 452

    [Md.39] In speed limit flag This area stores whether the operation is performed with the speed limited. In speed limit flag Stored value Not in speed limit (off) In speed limit (on) • If the speed exceeds the value set in [Pr.8] Speed limit value due to a speed change or override, the speed limit functions, and this area turns on.

  • Page 453

    [Md.43] Start data pointer being executed This area stores a point number (1 to 50) of the start data currently being executed. When a positioning operation completes, it stores 0. ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2...

  • Page 454

    [Md.47] Positioning data being executed The details of the positioning data currently being executed (data with the positioning data No. set by [Md.44] Positioning data No. being executed) are stored in the following buffer memory addresses. Buffer memory address of this area Stored item Axis 1 Axis 2...

  • Page 455: Control Data

    [Md.48] Deceleration start flag • When the speed status is changed from the constant speed or acceleration to deceleration during the position control whose operation pattern is Positioning complete, this area stores 1. • At the next operation start or manual pulse generator operation enable, it stores 0. ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 456

    [Cd.2] Module data initialization request Set this area to initialize module parameters and module extension parameters (positioning data and block start data) in the buffer memory and setting values in the module extension parameter file to their factory default settings. Module data initialization request Setting value Not requested...

  • Page 457

    [Cd.43] Output timing selection of near pass control Select the timing to output the difference (Δd) between the actual and the set positioning end addresses in continuous path control, in which the difference is output during the execution of the next positioning data. Output timing selection of near pass control Setting value At constant speed...

  • Page 458

    [Cd.137] Amplifier-less operation mode switching request Switch the operation mode. Amplifier-less operation mode switching request Setting value Switching from the normal operation mode to the amplifier-less operation ABCDH mode Switching from the amplifier-less operation mode to the normal operation 0000H mode ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 459: Axis Control Data

    Axis control data [Cd.3] Positioning start No. Set the positioning start No. Positioning start No. Setting value Positioning data No. 1 to 600 Block start specification 7000 to 7004 Machine OPR 9001 Fast OPR 9002 Current value change 9003 Multiple axes simultaneous start 9004 *1 Only 1 to 600 can be set for the pre-reading start function.

  • Page 460

    [Cd.6] Restart command Set this area to restart positioning from the stop status. • When positioning is stopped for any reason (when the axis operation status is Stopped), setting 1: Restart for this area performs the positioning again from the stop position to the end point of the stopped positioning data. •...

  • Page 461

    [Cd.9] New current value Set a new feed value to change the current feed value using the start No. 9003. ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2 [Cd.9] New current value 1506 1606...

  • Page 462

    [Cd.12] Acceleration/deceleration time change during speed change, enable/disable selection Set whether to enable modifications to the acceleration/deceleration time during a speed change. Acceleration/deceleration time change during speed change, Setting value enable/disable selection Acceleration/deceleration time change enabled Acceleration/deceleration time change disabled Other than 1 ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 463

    [Cd.15] Speed change request Set this area to request a speed change. • After setting [Cd.14] New speed value, set 1: Change the speed to request a speed change (validate the value set in [Cd.14] New speed value). • After the speed change is accepted, 0 is automatically stored. Storing 0 indicates the completion of the speed change acceptance.

  • Page 464

    [Cd.18] Continuous operation interrupt request Set this area to interrupt continuous operation. • The continuous operation is interrupted by setting 1: Interrupt continuous control or continuous path control for this area. • After the continuous operation interruption is accepted, 0 is automatically stored. Storing 0 indicates the completion of the continuous operation interruption.

  • Page 465

    [Cd.21] Manual pulse generator enable flag Set whether to enable manual pulse generator operations. Manual pulse generator enable flag Setting value Disable manual pulse generator operation Enable manual pulse generator operation ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2...

  • Page 466

    [Cd.24] Speed-position switching enable flag Set whether to enable the external control signal (External command signal (CHG): Speed-position/position-speed switching request is selected). Speed-position switching enable flag Setting value Speed control is not switched to position control even when External command signal (CHG) is turned on Speed control is switched to position control when External command signal (CHG) is turned on ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 467

    [Cd.27] Target position change value (new address) Set a new positioning address to change the target position during positioning. ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2 [Cd.27] Target position change value (new address) 1534 1634...

  • Page 468

    [Cd.30] Simultaneous starting axis start data No. (Axis 1 start data No.) Set the simultaneous starting axis start data No. ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2 [Cd.30] Simultaneous starting axis start data No.

  • Page 469

    [Cd.35] Step valid flag Set whether to validate step operations. Step valid flag Setting value Do not carry out step operation Carry out step operation ■Buffer memory address The following table shows the buffer memory address of this area. Buffer memory name Axis 1 Axis 2 [Cd.35] Step valid flag...

  • Page 470

    [Cd.38] Teaching data selection Set the data to which the teaching result is written. When the teaching has been completed, this data is cleared to 0. Teaching data selection Setting value Take the current feed value as a positioning address Take the current feed value as arc data ■Buffer memory address The following table shows the buffer memory address of this area.

  • Page 471

    [Cd.45] Speed⇔position switching device selection Select the device used for the speed to position switching. Speed-position switching device selection Setting value Speed-position switching control Position-speed switching control External command signal is used for switching speed control to External command signal is used for switching position control to position control speed control Near-point dog signal is used for switching speed control to position...

  • Page 472

    [Cd.180] Axis stop signal • When Axis stop signal is turned on, the OPR control, positioning control, JOG operation, inching operation, and manual pulse generator operation will stop. • By turning on the axis stop signal during the positioning operation, the operation will be stopped. •...

  • Page 473

    [Cd.183] Execution prohibition flag • If the Execution prohibition flag is on when the Positioning start signal turns on, positioning control does not start until this flag turns off. (no pulse output) • The Execution prohibition flag is acquired when positioning starts. Execution prohibition flag Setting value During execution prohibition...

  • Page 474

    17.9 Interrupt Setting [Md.65] Interrupt factor detection flag This area stores the detecting status of an interrupt factor. Interrupt factor detection flag Stored value Interrupt factor not detected Interrupt factor detected ■Buffer memory address For the buffer memory address of this area, refer to the following. Page 370 Interrupt setting [Cd.50] Interrupt factor mask Set the interrupt factor mask.

  • Page 475

    [Pr.900] Interrupt factor setting Specify the target (module) for the interrupt detection. The following table lists the available targets. Interrupt factor setting Detection timing Setting value Do not detect OFF → ON M code ON Error detection BUSY Start complete Positioning complete ON →...

  • Page 476: Basic Parameter 3

    17.10 Basic Parameter 3 This section describes the basic parameter 3 of the positioning module. The storage location of module extension parameters can be changed with the basic parameter 3. The basic parameter 3 can be changed only with "Module Parameter" in GX Works3.

  • Page 477: Parameter Reflection

    17.11 Parameter Reflection The parameters of the positioning module are classified into the module parameter and module extension parameter. The parameters are stored in the CPU module or the positioning module as a module parameter file and module extension parameter file. CPU module Positioning module Buffer memory...

  • Page 478

    Each parameter is reflected to the buffer memory of the positioning module at the following reflection timings. Parameter Operation Parameter setting value reflected to the buffer memory storage timing Module parameter Module extension parameter (Extension parameter storage setting) CPU module Positioning module Power-on Power-on...

  • Page 479

    Parameter reflection In the positioning module, the parameter is reflected to the buffer memory at power-on or when the CPU module status is changed from STOP to RUN. The following table shows the parameters reflected to the buffer memory. CPU module status: STOP → RUN Parameter type Extended parameter Power-on...

  • Page 480

    Parameter backup The module extension parameter in the buffer memory of the positioning module can be reflected to the module extension parameter file with the following methods. Backup method Parameter to be backed up Module parameter Module extension parameter  ...

  • Page 481: Chapter 18 Programming

    PROGRAMMING This chapter describes the program required for performing the positioning control with the positioning module. When creating a program required for the control, consider Start condition, Start time chart, Device setting, and the configuration of the whole control. (According to the control to be performed, set data such as parameters, positioning data, block start data, and condition data for the positioning module, and create a setting program of control data and a start program of each control.) 18.1 Precautions on Programming...

  • Page 482: Creating Programs

    18.2 Creating Programs This section describes Operation programs for the positioning control actually used. Overall configuration of programs The following table shows the overall configuration of positioning control operation programs. Program name Remarks Parameter setting program • The programs are unnecessary when parameters, positioning data, and block start data are set using GX Works3.

  • Page 483: Example Positioning Program Using Labels

    18.3 Example Positioning Program Using Labels List of Labels Used The following table lists the assignment of the labels to be used for the program examples in this section. Module label Label Name Description ■Positioning module input signal FX5PG_1.stSystemMonitorData2_D.bReady_D READY ([Md.140] Module Status: b0) FX5PG_1.stSystemMonitorData2_D.bModuleAccessFlag_D Module access flag ([Md.140] Module status: b1) FX5PG_1.stnAxisMonitorData_Axis_D[0].bMcodeOn_D...

  • Page 484

    Label Name Description FX5PG_1.stnAxisControlData_Axis_D[0].uStepValidFlag_D Axis 1 [Cd.35] Step valid flag FX5PG_1.stnAxisControlData_Axis_D[0].uSkipCommand_D Axis 1 [Cd.37] Skip command FX5PG_1.stnAxisControlData_Axis_D[0].uInterruptionRequest_ContinuousOperation_D Axis 1 [Cd.18] Continuous operation interrupt request FX5PG_1.stnAxisMonitorData_Axis_D[0].uStatus_D.3 Axis 1 [Md.31] Status: OPR request flag FX5PG_1.stnAxisMonitorData_Axis_D[0].uStatus_D.9 Axis 1 [Md.31] Status: Axis warning detection FX5PG_1.stnAxisMonitorData_Axis_D[0].uAnalysisMode_D Axis 1 [Md.60] Analysis mode Global label...

  • Page 485

    • Global labels for which Assign (Device/Label) is not set (When Assign (Device/Label) is not set, the unused internal relay and data device are automatically assigned.) 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 486: Program Example

    Program example This section shows program examples for positioning of Axis 1. Parameter setting program When parameters are set using "Module Parameter" in GX Works3, this program is unnecessary. ■Setting of basic parameter 1 (axis 1) (270) For using the electronic gear function in 16 bits 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 487

    ■Setting of OPR basic parameter (axis 1) ■Parameter setting program for the speed-position switching control (ABS mode) This program is unnecessary when the speed-position switching control (ABS mode) is not executed. 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 488

    Positioning data setting program When positioning data is set using "Module Extended Parameter" in GX Works3, this program is unnecessary. 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 489

    18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 490

    Block start data setting program When positioning data is set using "Module Extended Parameter" in GX Works3, this program is unnecessary. 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 491

    OPR request OFF program When "Setting of operation during uncompleted OPR" is set to "1: Execute positioning control" in "Module Parameter" of GX Works3, this program is unnecessary. External command function valid setting program [Cd.190] PLC READY signal ON program Positioning start No.

  • Page 492

    ■Positioning with the positioning data No.1 ■Speed-position switching control (positioning data No.2) For the ABS mode, writing the target movement amount after change is unnecessary. ■Position-speed switching control (positioning data No.3) ■Advanced positioning control ■Turning off a fast OPR command and fast OPR command storage This program is unnecessary when the fast OPR is not used.

  • Page 493

    Positioning start program Quick start program M code OFF program 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 494

    JOG operation setting program Inching operation setting program JOG operation/inching operation execution program 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 495

    Manual pulse generator operation program Speed change program Override program 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 496

    Acceleration/deceleration time change program Torque change program Step operation program Skip program 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 497

    Teaching program Continuous operation interrupt program Target position change program 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 498

    Absolute position restoration program 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 499

    Restart program Module initialization program 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 500

    Module backup program 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 501

    Error reset program Stop program 18 PROGRAMMING 18.3 Example Positioning Program Using Labels...

  • Page 502: Chapter 19 Troubleshooting

    TROUBLESHOOTING This chapter describes errors that may occur when the positioning module is used, and those troubleshooting. 19.1 Troubleshooting Procedure If a problem occurs, perform troubleshooting by following the procedure below. Check that each module is mounted correctly. MELSEC iQ-F FX5U User's Manual (Hardware) MELSEC iQ-F FX5UC User's Manual (Hardware) Check the LEDs on the CPU module.

  • Page 503: Check Of Module Status

    The RUN LED has turned off Check item Action The power is not supplied. Check that the voltage supplied to the CPU module is within the rated range. The capacity of the power supply module is not sufficient. Calculate the total current consumption of mounted CPU module, I/O modules, and intelligent function modules and check that the power capacity is sufficient.

  • Page 504: Troubleshooting By Symptom

    19.2 Troubleshooting by Symptom A motor does not rotate The check items and actions are listed below. Check item Action PLC READY signal is off. Review and edit the program so that [Cd.190] PLC READY signal turns on. The drive unit is not powered on. Power on the drive unit.

  • Page 505

    ■A motor does not rotate at the set speed Check item Action The value in [Md.28] Axis feedrate is same with or different from the set [When the value in [Md.28] Axis feedrate is same with the set speed] speed. •...

  • Page 506: Error And Warning Details

    19.3 Error and Warning Details Error type Errors detected by the MELSEC iQ-F series modules are classified into three levels: major error, moderate error, and minor error. The positioning module detects moderate errors and minor errors. Moderate errors and minor errors include parameter setting range errors and errors at the operation start or during operation. Parameter setting range errors Parameters are checked on the rising edge of [Cd.190] PLC READY signal (turning on of the signal) and if the setting of a parameter is not correct, an error occurs.

  • Page 507: Error Code Classification

    Error code classification Error level Error code Error type Moderate error 3000H to 3BFFH H/W error Minor error 17C0H to 17DFH Module extension parameter file error 1800H to 185FH Error at interrupt function setting range check 1860H to 18BFH Dedicated instruction error 1900H to 193FH Error common to positioning control 1940H to 197FH...

  • Page 508: Warning Type

    Warning type Warnings include the ones that occur in each operation (positioning operation, manual pulse generator operation, and JOG operation) and the ones that occur in the settings common to positioning control. Warning classification Warning code Warning type 0900H to 093FH Warning common to positioning control 0980H to 098FH Warning in manual operation (JOG operation and manual pulse generator operation)

  • Page 509: Clearing Errors Or Warnings

    Clearing errors or warnings Eliminate the cause of an error or warning by referring to the actions described in the following, and clear the error or warning using the error reset. Page 508 List of Warning Codes Page 512 List of Error Codes Clearing errors/warnings by each axis By setting 1 to the following buffer memory address of [Cd.5] Axis error reset, the error or warning is cleared after the completion of the processing below.

  • Page 510: List Of Warning Codes

    19.4 List of Warning Codes Warning Warning name Cause and description Action code ■Warning common to positioning control 0900H Start during The start request has been performed while the axis is in Do not perform the start request while the axis is in BUSY operation BUSY state.

  • Page 511

    Warning Warning name Cause and description Action code 0981H JOG speed limit JOG speed at the start is over the speed set in [Pr.31] Correct the value within the setting range. For details, value JOG speed limit value. refer toPage 392 [Pr.31] JOG speed limit value. [Operation of when the warning has occurred] JOG operation is controlled at the speed set in [Pr.31] JOG speed limit value.

  • Page 512

    Warning Warning name Cause and description Action code 0996H Step not possible 1: Step continue is set in [Cd.36] Step start request when Do not set 1: Step continue in [Cd.36] Step start request 0: Do not carry out step operation is set in [Cd.35] Step when 0: Do not carry out step operation is set in [Cd.35] valid flag or "-2: Step standby"...

  • Page 513

    Warning Warning name Cause and description Action code 09A6H Step start disabled 1: Step continue has been set in [Cd.36] Step start Do not set 1: Step continue in [Cd.36] Step start request request in pre-analysis mode. in pre-analysis mode. [Operation of when the warning has occurred] The step does not start.

  • Page 514: List Of Error Codes

    19.5 List of Error Codes Error code Error name Cause and description Action ■Error common to the CPU 1080H Flash ROM write Writing to the flash ROM has been executed more than • Correct the program so that writing to the flash ROM is number error 25 times in a row with the program.

  • Page 515

    Error code Error name Cause and description Action 1864H Dedicated The GP.TEACH instruction has been executed when a Set the value within the setting range in the teaching instruction error value other than 1 to 600 is set in the teaching positioning positioning data No.

  • Page 516

    Error code Error name Cause and description Action 1904H Hardware stroke The start request has been performed while Upper limit • Check the wiring of Upper limit signal (FLS). limit (+) signal (FLS) is off. • Check that the specifications of the limit switch match [Operation of when the error has occurred] the setting of [Pr.22] Input signal logic selection.

  • Page 517

    Error code Error name Cause and description Action 1942H Zero signal At the machine OPR using the stopper method 2, Zero • Slow down the OPR speed. For details, refer detection timing signal has turned off while the speed is decelerating from toPage 402 [Pr.46] OPR speed.

  • Page 518

    Error code Error name Cause and description Action 1990H Error before • The partner axis for the simultaneous start is in BUSY • Start the operation after BUSY state of the simultaneous start state. simultaneous starting axis is cleared. • The partner axis for the simultaneous start does not •...

  • Page 519

    Error code Error name Cause and description Action ■Error in positioning operation 1998H Interpolation while The interpolation operation has been started while the • Correct the value in [Da.2] Control method. For details, partner axis BUSY partner axis is operating. refer toPage 412 [Da.2] Control method.

  • Page 520

    Error code Error name Cause and description Action 199EH Simultaneous start An error (except the error of 199EH) has occurred in any • Find the axis where the error (except the error of not possible of the simultaneous starting axes. 199EH) has occurred with the error history and [Operation of when the error has occurred] eliminate the error cause.

  • Page 521

    Error code Error name Cause and description Action ■Block start data setting error 19F0H Illegal condition The positioning of block start using condition data has Correct the condition data No. For details, refer data No. been performed by the special start instruction (condition toPage 424 [Da.14] Parameter.

  • Page 522

    Error code Error name Cause and description Action ■Positioning data setting error 1A10H Illegal data No. The positioning data No. for the JUMP destination is Correct the positioning data. For details, refer currently being executed. toPage 418 [Da.9] Dwell time. [Operation of when the error has occurred] ■At the start of operation The operation is not performed.

  • Page 523

    Error code Error name Cause and description Action 1A19H Software stroke limit The sub point is over the value in [Pr.12] Software stroke • Correct the sub point address (arc address). For limit upper limit value when the circular interpolation details, refer toPage 416 [Da.7] Arc address.

  • Page 524

    Error code Error name Cause and description Action 1A20H Continuous path The speed control, speed-position switching control, Do not set the speed control, speed-position switching control not possible position-speed switching control, or fixed-feed control control, position-speed switching control, or fixed-feed has been set in [Da.2] Control method of the positioning control in [Da.2] Control method of the positioning data data next to the one where "11: Continuous path control"...

  • Page 525

    Error code Error name Cause and description Action 1A25H Control method The number of controlled axes or the value in [Da.5] Axis • Correct the value in [Da.2] Control method. For details, setting error to be interpolated was different from the previous data refer toPage 412 [Da.2] Control method.

  • Page 526

    Error code Error name Cause and description Action 1A2CH End point setting The end point address is outside the range of - Correct the end point address with [Da.6] Positioning error 2147483648 to 2147483647 when the circular address/movement amount. For details, refer toPage interpolation control has been performed with the sub 414 [Da.6] Positioning address/movement amount.

  • Page 527

    Error code Error name Cause and description Action 1A33H Control method The number of LOOP repetition is 0 when LOOP is set in Set a value of 1 to 65535 as the number of LOOP LOOP setting error [Da.2] Control method. repetition.

  • Page 528

    Error code Error name Cause and description Action 1A65H Rotation direction A value outside the setting range is set in [Pr.6] Rotation Configure the value so that it is within the setting range setting error direction setting of basic parameter 1. and then turn on [Cd.190] PLC READY signal.

  • Page 529

    Error code Error name Cause and description Action 1AA2H Software stroke limit When the unit other than degree is set, [Pr.12] Software When the unit is other than degree, set values so that upper limit stroke limit upper limit value is smaller than [Pr.13] [Pr.12] Software stroke limit upper limit value becomes Software stroke limit lower limit value.

  • Page 530

    Error code Error name Cause and description Action 1AADH Manual pulse A value outside the setting range is set in [Pr.24] Manual Configure the value so that it is within the setting range generator input pulse generator input selection of detailed parameter 1. and then turn on [Cd.190] PLC READY signal.

  • Page 531

    Error code Error name Cause and description Action 1AB4H Deceleration time 1 A value outside the setting range is set in [Pr.28] Correct the value within the setting range and turn on setting error Deceleration time 1 of detailed parameter 2. [Cd.190] PLC READY signal if the signal is off.

  • Page 532

    Error code Error name Cause and description Action 1ABCH JOG acceleration A value outside the setting range is set in [Pr.32] JOG Correct the value within the setting range and turn on time selection operation acceleration time selection of detailed [Cd.190] PLC READY signal if the signal is off.

  • Page 533

    Error code Error name Cause and description Action 1AC3H Stop group 3 A value outside the setting range is set in [Pr.39] Stop Correct the value within the setting range and turn on sudden stop group 3 sudden stop selection of detailed parameter 2. [Cd.190] PLC READY signal if the signal is off.

  • Page 534

    Error code Error name Cause and description Action 1B05H OPR speed error A value set in [Pr.46] OPR speed of OPR basic Correct the value so that [Pr.46] OPR speed is equal to or parameter is below [Pr.7] Bias speed at start. over [Pr.7] Bias speed at start, and turn on [Cd.190] PLC [Operation of when the error has occurred] READY signal.

  • Page 535

    Error code Error name Cause and description Action 1B11H Setting of operation A value outside the setting range is set in [Pr.58] Setting Configure the value so that it is within the setting range during uncompleted of operation during uncompleted OPR of OPR detailed and then turn on [Cd.190] PLC READY signal.

  • Page 536: Appendices

    APPENDICES Appendix 1 Dimensions Diagram Shows the external dimensions of the positioning module. FX5-20PG-P (Unit: mm) APPX Appendix 1 Dimensions Diagram...

  • Page 537: Appendix 2 Standards

    Compliance to EMC directive and LVD directive of the entire mechanical module should be checked by the user/ manufacturer. For more details please contact to the local Mitsubishi Electric sales site. Requirement for compliance with EMC directive...

  • Page 538: Caution For Compliance With Ec Directive

    Make 2 turns around the ferrite core and attach within approximately 200 mm from the terminal block and connectors of the power cable. (Ferrite core used in Mitsubishi Electric's test: E04SR401938 manufactured by SEIWA ELECTRIC MFG. CO., LTD.) Caution for when the control signal line is used For the control signal line, use a shielded cable and ground to both sides of the cable.

  • Page 539: Appendix 3 Module Label

    Appendix 3 Module Label The functions of the positioning module can be set by using module labels. Module label of I/O signals The label names of I/O signals are defined with the following configuration. • "Module name"_"Module number".bPLCReady_D • "Module name"_"Module number".stSystemMonitorData2_D.b"Label name"_D •...

  • Page 540

    Module label of buffer memory areas The names of the module labels of the buffer memory areas are defined with the following configuration. • "Module name"_"Module number"."Data type"_D"."Data format""Label name"_D • "Module name"_"Module number"."Data type"_D"."Data format""Label name"_D.[Bit No.] • "Module name"_"Module number"."Data type"_D"."Data format""Label name"_"Axis_D[ax]" •...

  • Page 541: Appendix 4 Dedicated Instruction

    Appendix 4 Dedicated Instruction The following table lists dedicated instructions. Application Dedicated instruction Function overview Absolute position restoration G.ABRST1 Restores the absolute position of a specified axis of the positioning module. G.ABRST2 Positioning start GP.PSTRT1 Starts the positioning control of a specified axis of the positioning module. GP.PSTRT2 Teaching GP.TEACH1...

  • Page 542: Appendix 5 How To Find Buffer Memory Addresses

    Appendix 5 How to Find Buffer Memory Addresses This section describes how to find the buffer memory addresses of positioning data, block start data, and condition data. Positioning data Positioning data No. 1 to No. 600 are assigned to each axis. Positioning data has the following structure. 7990 •...

  • Page 543

    When setting positioning data using a program, determine buffer memory addresses using the following calculation formula and set the addresses. • 2000+6000×(Ax-1)+10×(N-1)+S For each variable, substitute a number following the description below. Item Description The axis number of the buffer memory address to be determined. Substitute a number from 1 to 2. The positioning data No.

  • Page 544

    Block start data Block start data consists of five start blocks from Start block 0 to 4, and the block start data of 1 to 50 points is assigned to each block. The start blocks are assigned to each axis. Block start data has the following structure. 50th point Buffer memory Setting item...

  • Page 545

    When setting block start data using a program, determine buffer memory addresses using the following calculation formula and set the addresses. ■Calculation formula for [Da.11] Shape and [Da.12] Start data No. Use the following calculation formula. • 26000+(1000×(Ax-1))+(200×M)+(P-1) For each variable, substitute a number following the description below. Item Description The axis number of the buffer memory address to be determined.

  • Page 546

    Condition data Condition data consists of five start blocks from Start block 0 to 4, and the condition data No.1 to 10 are assigned to each block. The start blocks are assigned to each axis. Condition data has the following structure. No.10 Buffer memory Setting item...

  • Page 547: Appendix 6 External Connection Diagram

    Appendix 6 External Connection Diagram Mitsubishi Electric servo amplifier connection example Positioning module and MR-J4-A connection example Configure a sequence to turn OFF MC using alarms and emergency stop. MR-J4-A Servomotor CNP1 CNP3 Power supply 3-phase 200 V AC CNP2...

  • Page 548: Appendix 7 Configuration Device List

    Transistor output Drive unit  Servo amplifier, etc.  Manual pulse generator (manual pulse Recommended: MR-HDP01 (Mitsubishi Electric) emitter)  Connector cable The cable for connecting the positioning module and the drive unit, manual pulse generator, and mechanical input signals.

  • Page 549: Appendix 8 Precautions For Using A Stepping Motor

    Appendix 8 Precautions for Using a Stepping Motor Describes the precautions for using a stepping motor. For S-curve acceleration/deceleration Implementing the S-curve acceleration/deceleration may cause step out in the axis connected to the stepping motor. Before using the S-curve acceleration/deceleration, check that step out does not occur. For circular interpolation control The axis connected to the stepping motor cannot use circular interpolation control.

  • Page 550: Index

    INDEX 0 to 9 [Cd.23] Speed-position switching control movement ....463 amount change register ..114 1-axis linear control (ABS linear 1) .

  • Page 551

    ....340 Execution prohibition flag ....340 Forward run JOG start .

  • Page 552

    ..... .211 [Md.34] Movement amount after near-point dog ON OPR retry function ........448 .

  • Page 553

    ..408 [Pr.56] Speed specification during OP shift ..409 [Pr.57] Dwell time during OPR retry ... . .254 Target position change function .

  • Page 554: Revisions

    First Edition This manual confers no industrial property rights or any 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 555: Warranty

    WARRANTY Please confirm the following product warranty details before using this product. Gratis Warranty Term and Gratis Warranty 2. Onerous repair term after discontinuation of production Range If any faults or defects (hereinafter "Failure") found to Mitsubishi shall accept onerous product repairs for be the responsibility of Mitsubishi occurs during use of seven (7) years after production of the product is the product within the gratis warranty term, the...

  • Page 556: Trademarks

    TRADEMARKS   Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries. Ethernet is a trademark of Xerox Corporation. Anywire and ANYWIREASLINK is a registered trademark of the Anywire Corporation. ...

  • Page 558

    Manual number: SH(NA)-081805ENG-A Model: FX5-U-POS-I-E Model code: 09R572 When exported from Japan, this manual does not require application to the Ministry of Economy, Trade and Industry for service transaction permission. HEAD OFFICE: TOKYO BUILDING, 2-7-3 MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN Specifications are subject to change without notice.

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