Page 1 QuickStick 100 User Manual...
Page 2 This product is protected under one or more U.S. and International patents. Additional U.S. and International patents pending. Copyright © 2013–2020 MagneMotion, Inc., a Rockwell Automation Company. All Rights Reserved. The information that is included in this manual is proprietary or confidential to MagneMotion, Inc. Any disclosure, reproduction, use, or redistribution of this information by or to an unintended recipient is prohibited.
Page 3: Table Of Contents
Overview..........................27 QuickStick 100 Transport System Overview ..............28 QS 100 Transport System Components...............29 Transport System Overview ....................30 Transport System Software Overview ................31 Getting Started with the QuickStick 100 Transport System..........33 QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 4 EU RoHS and EU WEEE Compliance................36 Equipment Regulatory Guidelines................37 Safety Considerations ......................38 Personnel Safety Guidelines ..................38 Equipment Safety Guidelines ..................39 QuickStick 100 Transport System Hazard Locations..........40 Symbol Identification ......................41 Label Identification and Location..................43 Motors ..........................43 Magnet Arrays ......................44 Electronics ........................46 Mechanical Hazards......................47...
Page 5 TCP/IP Communication – Host Controller to HLC..........111 EtherNet/IP Communication – Host Controller to HLC ........112 RS-232 Serial Interface Connection ................112 RS-422 Serial Interface Connection ................112 Node Controller to Motor ..................112 Motor to Motor ....................114 QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 6 Network Connections ....................137 Electrical Connections ....................138 E-stop Circuit .......................139 Interlock Circuit ....................139 Light Stack Circuit....................140 General Purpose Digital I/O ................140 Node Electronics....................140 Software ...........................141 Software Overview ....................141 Software Configuration....................141 Node Controller Software Installation ..............142 MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 7 Facility Checks ....................143 Pre-operation Checks ...................143 System Power-up .......................144 System Testing.........................147 6 Operation Overview..........................149 Theory of Operation......................150 QuickStick 100 Transport System Advantages ............150 Motion Control ......................151 Motor Topology ......................151 Motor Operation ......................152 Motor Cogging.....................153 Motor Blocks ......................154 Block Acquisition ....................154 Block Ownership ....................155...
Page 8 Data for Transport System Design Calculations..............206 Thrust Force Data ......................207 Attractive Force Data....................209 Determining Thrust Force..................211 Determining Attractive Force ..................212 File Maintenance......................213 Backup Files ......................213 Creating Backup Files....................213 Restoring from Backup Files ..................213 MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 9 Contents Additional Documentation....................214 Release Notes......................214 Upgrade Procedure ....................214 Transport System Limits....................215 Glossary ......................217 Index ........................ 225 QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
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Page 11: Figures
Locations of Hazardous Points on the QuickStick 100 Transport System ....40 Locations of Labels on the QuickStick 100 Motors ...........43 Locations of Labels on the QuickStick 100 Standard Potted Magnet Arrays ....44 Locations of Labels on the QuickStick 100 Standard Covered Magnet Arrays ..45 Locations of Labels on the QuickStick 100 Power Supply ........46...
Page 12 6-12 Transport System Wiring Diagram with Synchronization ........170 Thrust Force vs. Magnet Array Cycles, Standard Magnet Array ......208 Thrust Force vs. Vehicle Gap, Standard Magnet Array ...........208 Attractive Force Data Curves, Standard Magnet Array ..........210 MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 13: Tables
Prohibited Action Symbol Identification ..............42 Labels Used on the QuickStick 100 Motors ...............43 Labels Used on the QuickStick 100 Standard Potted Magnet Arrays ......44 Labels Used on the QuickStick 100 Standard Covered Magnet Arrays .....45 Labels Used on the QuickStick 100 Power Supply ............46 Motor Assignments .....................58...
Page 14 Node Controller Related Troubleshooting ..............190 Communication-Related Troubleshooting ..............191 Motion Control Related Troubleshooting ..............192 Light Stack Related Troubleshooting ...............193 QuickStick 100 Transport System Repair Procedures ..........195 Thrust Force Data, Standard Magnet Array ..............207 Attractive Force Data, Standard Magnet Array ............209 MagneMotion Transport System Limits ..............215 MagneMotion Transport System Motion Limits ............215...
Page 15: Changes
System Design, and Transport System Configuration sections to focus on QS 100. • Chapter 4, Specifications and Site Requirements, updated pinouts of RS-422 Cables. Updated Digital I/O Equivalent Circuits. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 16: Rev. C
15.9 N at 4.0 A stator current. Updated Vehicles figures to show the static brush that is used for grounding vehicles. • Moved the Magnet Array Types information from Chapter 4, Specifications and Site Requirements Chapter 3, Design Guidelines. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 17: Rev. D
Chapter 1, Introduction, updated the Simplified View of Transport System Software Relationships. • Chapter 2, Safety, corrected the locations of labels on the QuickStick 100 High Flux Magnet Arrays. • Chapter 3, Design Guidelines, corrected description of Ground for NC LITE and SYNC IT modules.
Page 18: Ver. 05
Back Cover. Updated the following: • Changed the revision from alpha (Rev. D) to numeric (Ver. 05). • Changed logo to Rockwell Automation Company version. • Trademark and copyright information. • Titles for all referenced manuals. • Updated the Glossary.
Page 19 Moving Path node. • Chapter 6, Operation, removed detailed information about E-stops, Interlocks, Light Stacks, FastStop, and Digital I/O. This information is now in the Node Control- ler Hardware User Manual. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
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Page 21: About This Manual
QS 100 transport system. Audience This manual is intended for all users of QuickStick 100 transport systems and provides infor- mation on how to install, configure, and operate the QS 100 transport system.
Page 22: Magnemotion Documentation
About This Manual MagneMotion Documentation The documentation that is provided with the QuickStick 100 components includes this man- ual, which provides complete documentation for the installation, operation, and use of the QS 100 components as a transport system. Other manuals in the document set, which are...
Page 23: Notes, Safety Notices, And Symbols
Examples of the standard safety notices that are used in this manual are provided in this sec- tion. Each example includes a description of the hazard level indicated. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 24: Manual Structure
This manual contains the following chapters: • Introduction: Provides an overview of the QuickStick 100 components and their use in a transport system. The QS 100 motors are used to provide fast, precise motion, posi- tioning, and tracking of medium loads.
Page 25: Related Documentation
Glossary: A list of terms and definitions that are used in this manual and for the trans- port system and its components. • Index: A cross-reference to this manual organized by subject. Related Documentation Before configuring or running the QuickStick 100 components, consult the following docu- mentation: • QuickStick Configurator User Manual, 990000559. •...
Page 26: Contact Information
About This Manual Contact Information Main Office Customer Support MagneMotion, Inc. +1 978-757-9102 A Rockwell Automation Company ICTSupport@ra.rockwell.com 139 Barnum Road Devens, MA 01434 Phone: +1 978-757-9100 Fax: +1 978-757-9200 MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 27: Introduction
This manual supports: • QuickStick 100 transport systems. Included in this chapter are overviews of: • The QuickStick 100 components in a transport system. • The transport system components. • The transport system software. • Getting started with a QuickStick 100 transport system.
Page 28: Quickstick 100 Transport System Overview
QuickStick 100 Transport System Overview QuickStick 100 Transport System Overview The QuickStick 100 (QS 100) is an intelligent transport system that provides fast, precise motion, and positioning and tracking of medium loads in a transport system. The QS 100 transport system is a configuration of linear synchronous motors and related control electron-...
Page 29: Qs 100 Transport System Components
Guideway Track System Motor Motor Mount Figure 1-1: Detailed View of QuickStick 100 Transport System Components • Track System – The components that physically support and move vehicles, this ® includes the support structure, the guideway, one or more QuickStick 100 motors, and mounting hardware.
Page 30: Transport System Overview
Introduction Transport System Overview Transport System Overview This section identifies the components of a QuickStick 100 transport system as shown in Figure 1-2 and described after the figure. DC Power Cables Vehicles Power Supply Motors Host Controller (PLC or PC)
Page 31: Transport System Software Overview
Introduction Transport System Software Overview Transport System Software Overview Several software applications are used to configure, test, and administer a QuickStick 100 transport system as shown in Figure 1-3 and described after the figure. See Related Documen- tation on page 25 for the reference manuals for these applications.
Page 32 Magnet Array Type Files – XML files (magnet_array_type.xml) that contain basic information about the specific MagneMotion magnet array type that is used on the vehicles in the QuickStick 100 transport system. The Magnet Array Type file is uploaded to all node controllers in the transport system.
Page 33: Getting Started With The Quickstick 100 Transport System
Getting Started with the QuickStick 100 Transport System Use this manual as a guide and reference when installing or servicing the QuickStick 100 motors in a transport system. Follow the steps in this section to get the entire transport system...
Page 34 Introduction Getting Started with the QuickStick 100 Transport System Node Controller Software Installation on page 142 and the Node Controller Interface User Manual). Program the motors using the Motor ERF Image files (see Motor Software Installation on page 142, the Node Controller Interface User Manual, and the NCHost TCP Inter- face Utility User Manual).
Page 35: Safety
If any additional safety-related upgrades or newly identified hazards that are associated with the QuickStick 100 components are identified, the ICT Customer Support group notifies the owner of record.
Page 36: Regulatory Compliance
Safety Regulatory Compliance Regulatory Compliance The QuickStick 100 components are CE-compliant. To determine if a spe- cific component is CE-compliant, check for the CE marking on the compo- nent. If necessary, request the official Declaration of Conformity (DoC) from MagneMotion.
Page 37: Equipment Regulatory Guidelines
QS 100 components and after produc- tion is discontinued. • Any user-caused damage during integration of the QuickStick 100 components into their equipment is the responsibility of the user. • Responsibility for work that MagneMotion authorized technicians perform or for equipment that the owner of record transports or resells, is determined on a case-by-case basis by ICT Customer Support.
Page 38: Safety Considerations
Personnel operating or servicing the QuickStick 100 transport system must be properly trained. • Be aware of the hazardous points of the QuickStick 100 transport system as described in this chapter. • High-strength Neodymium Iron Boron magnets are used with the QS 100 motors.
Page 39: Equipment Safety Guidelines
Make sure that the QS 100 components receive proper airflow for cooling. • Do not remove safety labels or equipment identification labels. • Turn OFF power before inserting or removing the power cables. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 40: Quickstick 100 Transport System Hazard Locations
Pinch Point Switch (typical, user-defined) – Mechanical Hazard Pinch Point Vehicle (typical, user-defined) – Mechanical Hazard Pinch Point Magnetic Field Hazard Figure 2-1: Locations of Hazardous Points on the QuickStick 100 Transport System MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 41: Symbol Identification
Pinch/Crush Hazard – Indicates that there are exposed parts that move, which could cause personal injury from the squeezing or compression of fin- gers, hands, or other body parts between those parts. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 42: Mandatory Action Symbol Identification
Pacemakers or Medical Implants Prohibited – Indicates that persons with medical implants are not allowed in the specified area due to the possibility of personal injury. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 43: Label Identification And Location
Label Identification and Location Label Identification and Location Safety labels and identification labels are placed on those QuickStick 100 components that require them. These labels provide operators and service personnel with hazard identification and information about the QS 100 components at the point of use. This section describes each label, identifies its location, and for safety labels gives instructions on how to avoid the haz- ard.
Page 44: Magnet Arrays
Possible injuries: Pinch between magnet arrays, danger to medical implants and other electronics Mounting Surface Information Label Magnet Hazard Label Figure 2-3: Locations of Labels on the QuickStick 100 Standard Potted Magnet Arrays MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 45: Locations Of Labels On The Quickstick 100 Standard Covered Magnet Arrays
Possible injuries: Pinch between magnet arrays, danger to medical implants and other electronics Mounting Surface Information Label Magnet Hazard Label Figure 2-4: Locations of Labels on the QuickStick 100 Standard Covered Magnet Arrays QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 46: Electronics
Table 2-8: Labels Used on the QuickStick 100 Power Supply Product Information Label Qty: 1 Location: On the bottom of the power supply housing Information Label (on bottom) Figure 2-5: Locations of Labels on the QuickStick 100 Power Supply MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 47: Mechanical Hazards
Mechanical Hazards The QuickStick 100 transport system is a complex electromechanical system. Only personnel with the proper training should install, operate, or service the QuickStick 100 transport sys- tem. All facilities to the QS 100 transport system must be disconnected as outlined in the lock- out/tagout procedure for the facility before servicing to help prevent injury from the automatic operation of the equipment.
Page 48 Mechanical Hazards CAUTION Lift Hazard The QuickStick 100 motors can weigh as much as 13.2 kg [29.1 lb]. Failure to take the proper precautions before mov- ing them could result in personal injury. Use proper techniques for lifting and safety toe shoes when moving any QuickStick 100 components.
Page 49: Electrical Hazards
Safety Electrical Hazards Electrical Hazards The QuickStick 100 components are classified as low voltage devices, no additional safety precautions are required. The power supplies, node controllers, network switches, and power modules are connected to the AC Mains of the facility and can generate hazardous energy. The proper precautions for operating and servicing electrical equipment must be observed.
Page 50: Magnetic Hazards
Safety Magnetic Hazards Magnetic Hazards The QuickStick 100 transport system uses high strength Neodymium Iron Boron (NdFeB) magnets in the magnet arrays that are attached to the vehicles. The proper precautions for using high strength magnets must be observed. WARNING Magnetic Field Hazard Strong magnets in use.
Page 51: Handling Magnet Arrays
The magnets can shatter or break when drilled or machined. The magnet dust that machining creates is hazardous and can be harmful if inhaled or allowed to get into eyes. Drilling, grinding, and machining can produce metal powder, which is flamma- QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 52: Shipping Magnet Arrays
Shipping Magnet Arrays Magnet arrays being shipped, for return to MagneMotion or to another facility, must be shipped per U.S. Department of Transportation and The International Air Transport Associa- tion (IATA) Dangerous Goods Regulations. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 53: Recycling And Disposal Information
Information regarding disposal and recycling are provided in this section. At the end of its life, the modules of the QuickStick 100 transport system must be collected separately from any unsorted municipal waste and disposed of as described in this section.
Page 54: Power Supplies
Zinc-plated Low Carbon Steel Screws. Packaging The packaging for the QuickStick 100 motors and components contains the following materi- als. If the packaging is not being saved, it must be disposed of by following all facility, local, and national procedures for the disposal of packaging material: •...
Page 55: Design Guidelines
• Design guidelines for laying out the QuickStick100 transport system and creating interfaces to the system. • Design guidelines for using QuickStick 100 motors and magnet arrays. • Guidelines for electrical wiring. • Design guidelines for the vehicles and guideways.
Page 56: Transport System Layout
This host application provides all monitoring and control of the transport system. Transport System Overview The QuickStick 100 components consist of a set of basic building-blocks that provides an easy to assemble and implement transport system. The modular nature of the QS 100 components makes it easy to implement layout or control changes.
Page 57: Motors, Switches, And Vehicles
The switch mechanism is defined and supplied by the user. Vehicles are user-designed independent platforms with integral magnet arrays that are used on QuickStick 100 transport systems. Each vehicle is independently controlled and provides a platform for securing and carrying the payload in transit. Forward vehicle motion is from upstream to downstream, however vehicles can move backwards (downstream to upstream) if necessary.
Page 58: Paths
Figure 3-2: Sample QS 100 Transport System Layout Showing Paths Table 3-1: Motor Assignments Path Motors – – 500 mm, 1 1000 mm – 500 mm – – 500 mm, 2 1000 mm MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 59: Nodes
Paths Diverge Nodes 1 Diverge 1 Merge Path 2 Path 3 Merge NOTE: Arrows indicate direction of forward motion. Figure 3-3: Sample QS 100 Transport System Layout Showing Nodes QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 60: Node Controllers
Diverge Nodes 1 Diverge 1 Merge Node Controller (NC) Path 2 Path 3 Merge NOTE: Arrows indicate direction of forward motion. Figure 3-4: Sample QS 100 Transport System Layout Showing Node Controllers MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 61: Additional Connections
Node Controller (NC) Power Supply (PS1) Path 2 (48V DC) Path 3 Merge NOTE: Arrows indicate direction of forward motion. Figure 3-5: Sample QS 100 Transport System Layout Showing Additional Connections QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 62: Transport System Design
Transport System Layout on page 56 for layout guidelines). One advantage of the QuickStick 100 transport system is that it is possible to have vehicles move at different rates of speed in the same direction, or in opposite directions without a colli- sion.
Page 63: Motors
Off-centered and/or large payloads can affect system performance. Motors The QuickStick 100 motors can be mounted in any orientation: right side up, sideways, upside down, and vertically. QS 100 motors have a required direction, with an upstream end and a...
Page 64: Motor Blocks
Vehicle Gap, and magnet array size. • The QuickStick 100 transport system allows only one vehicle at a time on a motor block (see Table 3-2). Each block is a discrete motor primary section of multiple coils within the motor that is energized over its whole length.
Page 65: Available Thrust
At the nominal Vehicle Gap of 3 mm [0.12 in] (gap between the magnet array and the top of the QuickStick 100 motor) the QS 100 motors provide approximately 16.3 N thrust per mag- net array cycle at 4 A stator current (see Table 3-3).
Page 66: Required Thrust
• Friction or drag between the vehicle and the guideway. Motor Gap For QuickStick 100 motors installed in a transport system, there is always a space (Motor Gap) between motors, as shown in Figure 3-8. The minimum space is 2 mm (for thermal...
Page 67: Downstream Gap
Design Guidelines Transport System Design expansion) and a typical space is 22 mm, which places 1 m QuickStick 100 motors on a 1 meter pitch. Vehicle Gap Motor Block Motor Gap QuickStick Motor Upstream Downstream Downstream Gap (side view) (Motor Gap + 18 mm)
Page 68: Motors On A Curve
153). Any cogging does not affect the positioning accuracy of the motor. Cogging can be minimized by the following methods: • Placing QuickStick 100 motors at the optimal pitch on the transport system (see Downstream Gap). • Maximizing the Vehicle Gap between the motor and the magnet array.
Page 69: Motor Controllers
Transport System Design Motor Controllers The motor controller for each QuickStick 100 motor is located inside the QS 100 motor. Each QS 100 motor has one motor controller, also referred to as the master. The motor controller is responsible for controlling the thrust that is applied to each vehicle by the motor and reading the sensors in the motor to determine vehicle position.
Page 70: Signal Wiring
EMO event) without losing the motor logic functions (for example, con- figuration data, vehicle data, fault information). Having separate power buses also allows the motors to be programmed and configured without enabling the propulsion power. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 71: Ground
Design Guidelines Transport System Design Ground Proper grounding of the QuickStick 100 transport system is required to make sure of proper operation and to minimize electrical safety issues. • The bodies of the motors are grounded through the PE connection on the power con- nector.
Page 72 Design Guidelines Transport System Design Figure 3-10: System Wiring Block Diagram MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 73: Magnet Arrays
Stick 100 motor. This force is an important consideration in designing the support structure for the QuickStick 100 transport system and in determining the force that is required to move a vehicle. The magnetic attractive force is always present, even if there is no power to the motor.
Page 74: Magnet Array Width
Magnet Array Use The QuickStick 100 magnet arrays are intended for use as the QS 100 motor secondary as part of the vehicle only and must not be used for any other purpose.
Page 75: Standard Potted Magnet Array, 5 Cycles, 11 Poles
The physical length can also be calculated, if the number of cycles is known. The equation to calculate the physical length of a standard potted magnet array is: MagnetArrayLength = (Cycles x 48) + 6 mm QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 76: Standard Covered Magnet Array, 5 Cycles, 11 Poles
3-13) to make sure the cycle length remains constant. This set the correct physical gap between the magnet arrays and is true for any mix of magnet array lengths. Con- tact ICT Customer Support for mounting detail drawings. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 77 Cycles is the number of whole cycles in the array. 92.6 mm is the additional length of the half cycles at each end of the array. 1.9 mm is the additional length of the cover protecting the array. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 78: Vehicles
Vehicles must be designed to hold the mass of the payload, to hold the magnet array, and to withstand the attractive force present between the magnet array and the top of the QuickStick 100 motor. There are several design elements that must be met: •...
Page 79 Design Guidelines Transport System Design Various materials can be used to construct the vehicles in a QuickStick 100 transport system. Any material that is used must be able to carry the payload without deflecting while support- ing the magnet array in the correct relationship to the motors. In general, use a lighter weight vehicle to maximize the acceleration capability of the system for moving the payload.
Page 80: Vehicle Gap
Maximum Vehicle Gap is 9 mm. Single Array Vehicle Vehicles with single magnet arrays are typically used in QuickStick 100 transport systems where all motion is in a straight line. However, they can be used where the guideway includes MagneMotion...
Page 81: Dual Array Vehicle
Figure 3-17: Single Array Vehicle Configuration Dual Array Vehicle Vehicles with two magnet arrays are typically used in QuickStick 100 transport systems where the guideway includes curves or large distances between motors. For systems where the track runs in a straight line these arrays can be mounted directly to the vehicle. For systems where the track has curves these arrays can be mounted on independent bogies.
Page 82: Vehicle Design
Design Guidelines Transport System Design Vehicle Design When designing vehicles for use with the QuickStick 100 motors, the following vehicle design guidelines and considerations must be accounted for: • Make the vehicles longer than the magnet array to help protect the array from impacts.
Page 83: Mounting Magnet Arrays To Vehicles
Figure 3-19. Locating Pin Mounting Hardware Vehicle Locating Slot Locating Pin Locating Hole Magnet Array Figure 3-19: Magnet Array Mounting QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 84: Guideways
Vehicle Guidance Surface Vehicle Suspension Surface Motor Mount QS 100 Motor Figure 3-20: QuickStick 100 Transport System, Guideway Detail Basic guideway design guidelines and considerations: • The guideway can have any orientation in relation to the motors and vehicles as long as the magnet array on the vehicle is held in position next to the top of the motor.
Page 85: Guideway And Support Materials
• Available in various weights, thicknesses, and prices. Motor Mounts The QuickStick 100 motors provide mounting features on the bottom, which provides for a simple mounting scheme (see Mechanical Specifications on page 96). The following guide- lines are provided for designing the motor mounts.
Page 86: Motor Mounting Methods
QS 100 Motor M8 T-Nut (in channel) Clearance Holes for Motor Connections Mounting Plate M8 Mounting Hardware Figure 3-21: Motor Mounting to Flat Surface MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 87 Make sure that the top surfaces of all motors are coplanar to each other. Treating each motor to motor interface as a separate operation, tighten the motor mounts. See Mounting the Motors on page 124 for details of the mounting procedure. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 88: Guideway Examples
NOTE: Vehicles are not held in place if power is removed. QS 100 Motor Vehicle Guideway Figure 3-23: Guideway Example #1 MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 89: Guideway Example #2
This guideway can be used in any orientation as the vehicles are captive. NOTE: Vehicles are not held in place if power is removed. Vehicle QS 100 Motor Guideway Figure 3-24: Guideway Example #2 QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 90: Guideway Example #3
The vehicle sits on the rollers and between the side plates, which hold the vehicle and magnet array in the correct relationship to the motors. NOTE: Vehicles are not held in place if power is removed. QS 100 Motor Vehicle Side Plate Figure 3-25: Guideway Example #3 MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 91: Transport System Configuration
Node Controller Configuration File simpler. NOTE: Different size gaps between motors must be identified in the Node Controller Configuration File (see the QuickStick Configurator User Manual). QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 92: Curve Track Configuration
Keep the Motor Gaps consistent over the length of the curve in the guideway. NOTE: Different size gaps between motors must be identified in the Node Controller Configuration File (see the QuickStick Configurator User Manual). MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 93: Switch Configuration
NOTE: Different size gaps between motors must be identified in the Node Controller Configuration File (see the QuickStick Configurator User Manual). QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 94: Moving Path Configuration
• Requires a Host-controlled drive mechanism to position the Moving Paths. • QuickStick 100 motors can be used as the drive mechanism to provide movement of the Moving Paths. • The Moving path can consist of multiple motors.
Page 95: Specifications And Site Requirements
100 transport system components and the requirements for installation. Included in this chapter are: • Mechanical specifications for all QuickStick 100 components, including dimensions. • Electrical specifications for power and communications, including connector pinouts. • Site requirements, including environmental and service access.
Page 96: Mechanical Specifications
Specifications and Site Requirements Mechanical Specifications Mechanical Specifications All drawings within this manual are generic and do not reflect specific configurations of the QuickStick 100 components. To obtain current drawings, contact ICT Customer Support. 1000 Millimeter Motor MOTOR BLOCK REGIONS [3.78] [3.78]...
Page 97: 500 Millimeter Motor
304 Stainless Steel. • TGIC powder coat. • VHB conformable foam with acrylic adhesive. • The motor has exposed D-style connectors and must not be located where harsh condi- tions exist. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 98: Magnet Array, Standard Potted
Weight: see Table 4-1 All Dimensions in Millimeters [Inches] Figure 4-3: Standard ‘F’ Potted Magnet Array Mechanical Drawing NOTE: Contact ICT Customer Support for current detail drawings. Designed for IP65 (IEC 60529). MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 99: Standard Potted Magnet Array Lengths And Weights
(see Magnet Array Length and Attractive Force on page 73). Exposed Materials • Low Carbon Steel. • Hardened Steel. • Nd-Fe-B magnets with Ni-Cu-Epoxy coating. • Oxy-Cast 607. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 100: Magnet Array, Standard Covered
NOTE: This magnet array package is fully backwards compatible with the potted arrays and is a one-for-one replacement for the potted arrays. Contact ICT Customer Support for current detail drawings. Designed for IP50 (IEC 60529). MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 101: Standard Covered Magnet Array Lengths And Weights
(see Magnet Array Length and Attractive Force on page 73). Exposed Materials • Low Carbon Steel. • Hardened Steel. • Nd-Fe-B magnets with Ni-Cu-Ni coating. • Stainless Steel. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 102: Qs 100 Power Supply
QS 100 Power Supply on page 107 for the electrical specifications. Contact ICT Customer Support for current detail drawings. Exposed Materials The power supply provides openings for airflow and must not be located where harsh condi- tions exist. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 103: Electrical Specifications
• 500 mm – 48V DC ±10%, 1 A typical, 2.5 A max 500 Millimeter Motor on page 97 for the mechanical drawing. Table 4-3: QuickStick 100 Motor Power Requirements Component Maximum Power – QS 100 Motor, 500 mm Control power –...
Page 104: Motor Electrical Connections
Table 4-5: RS-422 Pinouts J5 – DE-9, Male (Downstream) J1 – DE-9, Female (Upstream) — — TxD- RxD- RxD+ TxD+ — — — — — — TxD+ RxD+ RxD- TxD- — — MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 105: Power Connector Pinout
— — SIMO Input 3.3 V SOMI Output 3.3 V RESET Output 3.3 V — — — — — — Input 3.3 V Input 3.3 V — 3.3 V QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 106: Motor Power Cable
Connect +48V DC Logic, +48V DC Propulsion, and 48V DC Return to the Power Bus in a junction box. Connect GND (PE) to the Ground stud in the same junction box. Make sure that all junction boxes are connected to PE. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 107: Qs 100 Power Supply
QuickStick transport system is identified. NOTICE The QS 100 Power Supply uses internal NRTL/ATL approved power sup- plies. If a user-supplied power supply is used in its place, it must be NRTL/ATL approved. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 108: Qs 100 Power Supply Electrical Connections
ON – Indicates that output voltage is < 80% of rated value Red Light AC OK ON – Indicates that input voltage is > 85 V rms Green Light Table 4-11: QS 100 Power Supply DC Power Pinout Individual Terminals +48V DC MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 109: Qs 100 Power Supply Control And Monitoring Pinout
Table 4-12: QS 100 Power Supply Control and Monitoring Pinout DB-25, Female V_TRIM_B TEMP_ALARM_B DC_OK_B TEMP_ALARM_A ON/OFF_A DC_OK_A V_TRIM_A +12V_AUX V_TRIM_C SIGNAL_RETURN DC_OK_C +SENSE AC_FAIL_B ON/OFF_B AC_FAIL_A -SENSE TEMP_ALARM_C AC_FAIL_C ON/OFF_C QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 110: Control Cable
The AC power cable plugs directly into the power supply. CAUTION There is a potential shock hazard if the power supply chassis and cover are not connected to an electrical safety ground via the safety ground in the AC input connector. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 111: Communications
There is one Host control connection and four Host status connections on the HLC. If a sec- ond Host attempts to connect to the Host control TCP/IP port, it causes the first Host to be dis- QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 112: Ethernet/Ip Communication - Host Controller To Hlc
HLC must be configured as specified in the Node Controller Interface User Manual. RS-232 Serial Interface Connection RS-232 serial communication on the NC-12 node controller is not used with QuickStick 100 transport systems. RS-422 Serial Interface Connection...
Page 113 Figure 4-10: RS-422 Cables Table 4-14: RS-422 Cable Pinouts M8 Nano-Mizer, DE-9, Female DE-9, Male DE-9, Female 4-Pin, Female End ‘A End ‘B’ RxD+ TxD+ RxD- TxD- TxD+ RxD+ TxD- RxD- QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 114: Motor To Motor
See the LSM Synchronization Option User Manual for cable and connec- tion details. There is no need to construct the sync cables as all cabling is supplied with the transport system. Contact MagneMotion for additional or replacement cables. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 115: Site Requirements
Lighting, Site No special lighting is required for proper operation of the QuickStick 100 transport system. Maintenance can require a user-supplied service lamp (for example, a flashlight). QuickStick 100 User Manual...
Page 116: Floor Space And Loading
Synchronization Option User Manual for the service space required for the SYNC IT Control- ler. Make sure that installation of the QuickStick 100 transport system is such that it provides access to items required for service after installation, such as power and communication con- nections.
Page 117: Installation
100 components that are used in a transport system. Included in this chapter are: • Unpacking and inspection of the QuickStick 100 transport system components. • QuickStick 100 component installation including: hardware installation, facilities con- nections, and software installation and configuration.
Page 118: Unpacking And Inspection
Installation Unpacking and Inspection Unpacking and Inspection The QuickStick 100 transport system components are shipped in separate packages. Open each package carefully following the steps that are provided in Unpacking and Moving on page 119; inspect and verify the contents against the shipping documents. Report any damage immediately to the shipper and to MagneMotion.
Page 119: Unpacking And Moving
• Open-end Wrench, Adjustable. • Metric Hex wrenches. Unpacking and Moving Instructions The QuickStick 100 components arrive from the factory ready for installation. The informa- tion required to install these components is provided in Transport System Installation on page 121.
Page 120 Installation Unpacking and Inspection Save all shipping packaging for possible future use. If any of the QuickStick 100 components are shipped, the original shipping packaging must be used. If the original packaging has become lost or damaged, contact MagneMotion for replacements.
Page 121: Transport System Installation
Transport System Installation Transport System Installation The QuickStick 100 transport system must be properly located within the facility so that other equipment can interface to it as required. The location must also make sure that there is ade- quate space for service access and for proper operation. Make sure that installation of the QuickStick 100 components provides access to items required for service after installation, such as connection panels.
Page 122: Installation Overview
Installation Transport System Installation Installation Overview The following sequence provides an overview of the installation of the QuickStick 100 motors and other QS 100 components on user equipment or a custom track system. NOTICE Make sure that the equipment or track system where the QuickStick 100 motors are mounted and the motor mounting surfaces are properly grounded to safety ground (earth).
Page 123 Power up the system and check all operating features, safety features, and connections (see Check-out and Power-up on page 143) and install the software (see System Power-up on page 144). QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 124: System Installation
Securing the Transport System Secure the QuickStick 100 transport system to the floor to help prevent system movement. Tie-downs for facilities that require earthquake protection are the responsibility of the user. Secure the transport system to the floor and to any other equipment as required.
Page 125 File. If all motors on a path have the same Motor Gap, it can be entered once in the Motor Defaults before defining the individual motors on the path (see the QuickStick Configurator User Manual). QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 126: Installing Electronics
The power supply can be oriented in any direction required. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 127: Connecting Motors And Electronics
Transport System Installation Connecting Motors and Electronics The QuickStick 100 transport system uses daisy chained communication with all motors in the transport system. All motors in a specific path are chained together. The upstream end of each chain is always connected to a node controller. The downstream end of a chain is only con- nected to a node controller if it terminates in a node.
Page 128: Simplified Representation Of Rs-422 Motor Connections In A Merge Switch
However, all connections to the motors at the ends of all paths that meet in a node must be made to the same node controller. See the QuickStick Con- figurator User Manual for more information about nodes and paths. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 129 Port number from the node controller for entry into the Node Controller Con- figuration File. Connect a communication cable from the communication connector at the down- stream end of the motor to the communication connector at the upstream end of the QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 130 Bundle and dress all cables (use nylon cable-ties) as required to keep all cable routing clean. Facilities Connections on page 137 for external communication connections. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 131: Digital I/O
E-stops, interlocks, light stacks, and general-purpose I/O. See the Node Controller Hardware User Manual for the digital I/O con- nection locations and wiring diagrams. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 132: Installing Motor Power Cables
Connect the power cable to the terminals on the power supply. • Make sure that the power supply is properly grounded. • Make sure that the power cables are sized for the full load of all motors down- stream from the connection. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 133 Connect the Ground stud on all NC-12 node controllers to GND (PE). Bundle and dress all power cables (use nylon cable-ties) as required to keep all cable routing clean. Facilities Connections on page 137 for external power connections. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 134: Magnet Array Installation
Handle only one vehicle or magnet array at a time. • Do not place any body parts, such as fingers, between a magnet array and any QuickStick 100 motors, ferrous material, or another magnet array. • Magnet arrays or vehicles not being used must be secured individually in isolated packaging.
Page 135 Secure each additional magnet array to the vehicle as defined by the design of the vehicle. Once all arrays are secured to the vehicle, install the vehicle on the track. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 136: Vehicle Installation
Vehicles can be added or removed as needed once the QuickStick 100 transport system is installed. NOTE: The design of the guideway and of the vehicle determines the ease of adding vehi- cles.
Page 137: Facilities Connections
Network Connections The QuickStick 100 transport system uses communication over an Ethernet network with a host controller for transport system control. The same Ethernet network is used for communi- cation between node controllers. Use a dedicated, separate subnet for the transport system net- work to eliminate any unrelated network traffic.
Page 138: Electrical Connections
Node Controller Hardware User Manual for the connection locations. Electrical Connections Electrical power is connected to the QuickStick 100 transport system for operation of the motors and other subsystems. An AC electrical connection is provided on those components that require facility power.
Page 139: E-Stop Circuit
E-stop Circuit The QuickStick 100 transport system can use digital I/O, provided through a node controller, for monitoring and control of local options such as an E-stop. The optional E-stop circuit is the responsibility of the user and requires a user-supplied E-stop button and DC power supply for the digital input.
Page 140: Light Stack Circuit
Facilities Connections Light Stack Circuit The QuickStick 100 transport system can use digital I/O, provided through a node controller, for monitoring and control of local options such as a light stack. The optional light stack cir- cuit is the responsibility of the user and requires a user-supplied 3-color light stack and +5–...
Page 141: Software
See the Node Controller Interface User Manual for details. All QuickStick 100 motors ship with just a basic software image installed. This image is used for testing during manufacturing and must not be used to run the motors as part of a transport system.
Page 142: Node Controller Software Installation
NOTE: Restart the node controller for the changes to take effect. Reset the paths where the motors were programmed (for example, use the NCHost TCP Interface Utility, see the NCHost TCP Interface Utility User Manual for details). MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 143: Check-Out And Power-Up
Check-out and Power-up System Check-out Before the QuickStick 100 transport system is started for the first time, or after servicing the transport system, it is necessary to check all operating and safety features. The following startup procedure is used to apply power to the QuickStick 100 transport sys- tem in an orderly manner to make sure that all components are in known states.
Page 144: System Power-Up
Check-out and Power-up System Power-up After the QuickStick 100 transport system has been installed, all connections must be checked. Then, an initial power-up must be performed before proceeding any further with the installation process. This section describes the procedure for the initial installation check-out.
Page 145: Startup Indicators
Do not attempt to operate the QuickStick 100 trans- port system until all setup procedures that are described in this chapter have been completed. The indicators on the components of the QuickStick 100 transport system light as shown in Table 5-2.
Page 146 Program the masters and slaves for the motors. See the Node Controller Interface User Manual for details. Review the log files for each node controller to make sure that the system has been programmed and configured properly (see the Node Controller Interface User Man- ual). MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 147: System Testing
System Testing System Testing Test the QuickStick 100 transport system to verify proper operation of all nodes, paths, and vehicles. Testing can be accomplished using the MagneMotion NCHost application to move vehicles without the host controller to verify proper operation before integrating a transport system into a production environment.
Page 148 NCHost TCP Interface Utility User Manual). Move vehicles individually or create a Demo Script for repetitive testing (see the NCHost TCP Interface Utility User Manual). Monitor transport system operation with the NCHost TCP Interface Utility. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 149: Operation
Quick- Stick 100 transport system. • Controls and indicators that are provided on the system. • Simulation of QS 100 transport system operation. • Operational startup and safe shut-down. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 150: Theory Of Operation
The QuickStick 100 motors are similar in operation to a brushless DC rotary motor, with its stator (motor primary) and rotor or armature (motor secondary) ‘unrolled’ to allow linear...
Page 151: Motion Control
This feature allows having a magnet array (vehicle) right justified in the first block of a QuickStick 100 motor with a second magnet array (vehicle) left justified in the second block of the QuickStick 100 motor.
Page 152: Motor Operation
Figure 6-3: Representation of Moving Vehicles Per Motor Block Motor Operation The QuickStick 100 motors provide asynchronous control of vehicles on the transport system as directed by the host controller. This control method minimizes the load on the host control-...
Page 153: Motor Cogging
Linear motors, such as the QuickStick 100 motors from MagneMotion that use an iron core to maximize thrust (equivalent to torque in a traditional rotary motor) also exhibit cogging forces.
Page 154: Motor Blocks
Motor Cogging on page 67 installation methods to minimize cogging. Motor Blocks A motor block is a discrete motor section within each QuickStick 100 motor as shown in Figure 6-2 Figure 6-3. Each block is a set of independently controlled copper windings that are driven by one inverter, with multiple blocks creating the motor primary (stator).
Page 155: Block Ownership
Anti-Collision The QuickStick 100 transport system allows only one vehicle per motor block. This block allocation is the basic rule on which the anti-collision feature of the QS 100 transport system controls is founded. Since two vehicles are not allowed to be in the same motor block, they cannot collide.
Page 156: Safe Stopping Distance
The precise deceleration capability depends on vehicle mass (including payload), center of gravity location, speed, and track geometry. Furthermore, the thrust capability of the motors are reduced in proximity to the gaps between motors. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 157: In Queue
Other causes of a vehicle being unable to move that are considered a jam are: • A vehicle is commanded to move with a velocity of zero. • A vehicle is commanded to move with an effective PID set equal to zero. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 158: Vehicle Length Through Curves And Switches
Once a vehicle ID is assigned, it remains with that vehicle until the vehicle is removed from the QuickStick 100 transport system, the vehicle is deleted, or a Reset is issued for the path. Vehicles are removed via a Terminus Node or deleted with a Delete Vehicle command.
Page 159: Moving Vehicles By Hand
Theory of Operation Moving Vehicles by Hand Only move vehicles on the QuickStick 100 transport system using the QS 100 motors in the system. If there is an event that requires moving the vehicles by hand, the guidelines that are provided here must be followed.
Page 160 Vehicles that have been moved too far can be recovered by deleting the moved vehicles and restarting the section of the transport system where they are located to detect them. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 161: Electrical System
Power Management Within the QS 100 Motor To supplement any external power management schemes that are applied to a QuickStick 100 transport system, several means of internally consuming regenerated power within a QS 100 motor are incorporated to help protect the motor and help minimize voltage increases.
Page 162: Power Cycle Timing
DC to +53.5V DC. The coil current remains constant at 5 A for voltages above +55V DC and drops to zero for voltages above +59V DC since all inverters are turned off. This behavior is shown in Figure 6-8. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 163: Individual Block Current Vs. Internal Propulsion Bus Voltage
Under normal use conditions, this resistor is never activated or relied upon to absorb regener- ation power. This resistor is meant to handle anomalous high voltage transients that might oth- erwise lead to a catastrophic voltage induced motor failure only. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 164: Power Related Warnings And Faults
Motor operation suspended Over-voltage Fault Triggered, Inverters disabled. Motor in normal operating condition. Motor in warning condition – continues to control vehicles. Motor in fault condition – does not control vehicles (motion is undefined). MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 165 The intent of this feature is to verify proper cabling and power distribution for new systems and to support periodic assessments of the system to make sure that no degradation has occurred. A properly designed system never exhibits this alarm following system power-up. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 166: Power Related Fault Resolution
• Reduce the cable resistance between the power supply and the motors if a voltage drop in these cables leads to under voltage on motors accelerating vehicles. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 167 +48V DC power supply local to the power supply or to the motors that are exhibiting this issue. The clamping voltage should be above +51V DC but kept as low as possible. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 168: Node Controllers
The MagneMotion node controller is used to monitor vehicles and control the motors and other components of a QuickStick 100 transport system based on the commands from the host controller. The node controller also provides status information to the host controller. There can be multiple node controllers in a transport system, each responsible for a subset of the transport system.
Page 169: Controls And Indicators
The control application on the host controller must provide any needed controls or indicators that are related to transport system operation. Additional controls and indicators can be con- figured as described in this section. The controls and indicators of the QuickStick 100 compo- nents are identified in the Electrical Specifications on page 103.
Page 170: Synchronization
For synchronization, a SYNC IT controller is required for every three motors that are being synchronized as shown in Figure 6-12. See the LSM Synchronization Option User Manual for configuration and operation details to use the Sync option with the QuickStick 100 transport system. Sync Motor Sync Motor...
Page 171: E-Stops
Hardware User Manual for additional details and equivalent circuits. WARNING Automatic Movement Hazard When the interlock is cleared, automatic movement of the vehicles on the QuickStick 100 transport system resumes, which could result in personal injury. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 172: Light Stacks
A light stack is a user-installed visual signal that is used to provide transport sys- tem status. The QuickStick 100 transport system supports standard three color light stacks (typically green, yellow, and red). The light stack can be used to monitor the status of any, or all, paths on the node controller where it is connected.
Page 173: Transport System Simulation
Transport System Simulation Transport System Simulation The QuickStick 100 transport system can be simulated to verify proper configuration of all nodes and paths and proper motion of commanded vehicles within the transport system. Sim- ulations can be useful to test and observe system behavior without physically moving vehicles on the transport system.
Page 174 In the Simulated Move Time field, enter the amount of time it takes for the switch mechanism to change directions. Repeat Step 2 through Step 3 for each Merge/Diverge node in the con- figuration. Save the updated Node Controller Configuration File. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 175: Running A Simulation
Moving Path Nodes are not simu- lated. Paths All paths must be defined. All paths must be defined. Stations All stations must be defined. All stations must be defined. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 176 Vehi- cles are added at either the location that is specified in the Node Controller Configuration File or in the next available space downstream. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 177: Stopping A Simulation
The Reboot Controller page is displayed. Select Reboot Controller. The reboot status is temporarily displayed, then the General Status page is dis- played once the node controller has rebooted. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 178 Demo Script for repetitive testing (see the NCHost TCP Interface Utility User Manual). • Use the host controller application to run the system as required. All QS 100 transport system elements move as directed. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 179: Transport System Operation
Transport System Operation Transport System Operation Power-up The QuickStick 100 transport system is started by applying power as previously specified (see Check-out and Power-up on page 143). Once the system completes startup, the QS 100 com- ponents are ready to operate. If the host controller is in control of the QS 100 transport system, the system accepts commands from the host controller through the network connection.
Page 180: Safe Shut-Down
Transport System Operation Safe Shut-down The following shut-down procedure is used to remove power from the QuickStick 100 trans- port system in an orderly manner and place the components in known safe conditions. This procedure is used to prepare the components for removal, replacement, or maintenance.
Page 181: Maintenance
QS 100 transport system. Included in this chapter are: • Preventive maintenance procedures. • Troubleshooting procedures. • Contacting ICT Customer Support. • Basic repair procedures. • Component shipping procedures. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 182: Preventive Maintenance
Preventive Maintenance Preventive Maintenance The motors, node controllers, and power supplies in the QuickStick 100 transport system are self-contained components that are designed for use in a clean, inert environment, and require no maintenance other than that described here. Any deviation from this basic environment can affect the maintenance requirements, contact ICT Customer Support for additional informa- tion.
Page 183: Cleaning
Maintenance Preventive Maintenance Cleaning General cleaning of the QuickStick 100 transport system consists of cleaning the transport system surfaces as described. Required Tools and Equipment • Disposable gloves. • Microfiber cleaning cloth. • Deionized water. • Isopropyl alcohol (optional). Procedure Stop all motion on the sections of the QS 100 transport system to be cleaned.
Page 184: Cable Connection Inspection
To combat accumulated debris, keep magnet arrays not being used in their original container. • Proper precautions must be taken when magnet arrays with stainless steel covers are used in wash down applications or in environments where water or fluids are contact- MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 185: Transfer Log Files
Log files can be transferred from the node controller or SysLog server to a CD or external USB device so they can be archived or e-mailed to ICT Customer Support, see the Node Con- troller Interface User Manual. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 186: Troubleshooting
194. Initial Troubleshooting This section covers the initial determination of the problem area within the QuickStick 100 transport system and provides direction to the second step of the troubleshooting process. If a specific problem is suspected, see that problem in Table 7-2.
Page 187: Power-Related Troubleshooting
Maintenance Troubleshooting Power-Related Troubleshooting This section covers the determination of power-related problems within the QuickStick 100 transport system. Table 7-3: Power-Related Troubleshooting Symptom Problem Description Corrective Action Lights on power supplies do not No power or incorrect power Verify that the cable from the turn on.
Page 188 +43V DC. The motor reports a Soft Start not The internal power bus for the The fault clears once the power complete fault. motor is below +41V DC. bus rises above +43V DC. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 189 +48V DC power supply. Connect more motors to a com- mon +48V DC power supply to increase the number of blocks available to absorb regenerated power. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 190: Node Controller Troubleshooting
MagneMotion for repair. Use the node controller web inter- face Set Clock function to set the time (see the Node Controller Interface User Manual). MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 191: Communication Troubleshooting
E-stop or interlock circuit is acti- Make sure that any E-stops or vated. interlocks that are configured for the paths where the motors are located are in the operate state. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 192: Motion Control Troubleshooting
Maintenance Troubleshooting Motion Control Troubleshooting This section covers the determination of motion-related problems within the QuickStick 100 transport system. Table 7-6: Motion Control Related Troubleshooting Symptom Problem Description Corrective Action Material slips while the vehicles Vehicle is not designed to carry Make sure that the vehicle design are in motion.
Page 193: Light Stack Troubleshooting
Light indicates that vehicles are Verify that the light stack is prop- stopped even though there is erly wired. motion. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 194: Contact Ict Customer Support
Maintenance Contact ICT Customer Support Contact ICT Customer Support To help you receive the most value from the Rockwell Automation Independent Cart Technol- ogy (ICT) Support Specialists, have the following information ready before contacting ICT Customer Support. Download and save the node controller and HLC logs.
Page 195: Repair
Installation on page 117. NOTE: The components of the QuickStick 100 transport system are designed for easy replacement. Motors, controllers, and other modules do not contain any user service- able parts.
Page 196: Replacing Motors
Maintenance Repair Replacing Motors The QuickStick 100 motors can typically be replaced easily depending upon the location and mounting method for the motor. Required Tools and Equipment • Torque wrench. • Computer with an Ethernet port and a web browser.
Page 197: Install The New Motor
Program the masters and slaves on the new motor with the current Motor image files (see Programming Motors on page 198). Resume motion on the section of the QS 100 transport system where the motor was replaced. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 198: Programming Motors
Maintenance Repair Programming Motors When a new QuickStick 100 motor is installed, either as part of a new system installation or as a replacement for an existing motor it must be programmed with the appropriate Motor ERF Image file (motor_image.erf).
Page 199: Separating Magnet Arrays
Handle only one vehicle or magnet array at a time. • Do not place any body parts, such as fingers, between a magnet array and any QuickStick 100 motors, ferrous material, or another magnet array. • Magnet arrays or vehicles not being used must be secured individually in isolated packaging.
Page 200: Ordering Parts
If new or replacement parts are needed, contact MagneMotion Sales: Main Office Sales MagneMotion, Inc. +1 978-757-9101 A Rockwell Automation Company ICT-InsideSales@ra.rockwell.com 139 Barnum Road Devens, MA 01434 Phone: +1 978-757-9100 Fax: +1 978-757-9200 MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 201: Shipping
Shipping Shipping If a QuickStick 100 component must be shipped, either for return to MagneMotion or to another location, it must be packaged properly to make sure that it arrives undamaged. The following procedure provides the correct method for handling and packaging QS 100 compo- nents for shipment.
Page 202: Packing Procedure
Shipping Packing Procedure When any of the QuickStick 100 components are shipped, either for return to MagneMotion for service or to another location, they must be properly packaged to make sure that they arrive undamaged. The following procedure provides the correct method of handling and packaging the QuickStick 100 components for shipment.
Page 203: Shipping Components
Magnetic Field Hazard. When shipping to MagneMotion, make sure that the RMA number is clearly visible on the outside of the container. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 204 Maintenance This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 205: Appendix
The following appendices are included to provide the user with one location for additional ® information that is related to the QuickStick 100 transport system. Included in this appendix are: • Data for QuickStick 100 transport system design calculations. • File maintenance. • Additional documentation. •...
Page 206: Data For Transport System Design Calculations
The tables and curves (charts) in this appendix provide data to help in determining the optimal QuickStick 100 thrust force, Vehicle Gap, or magnet array size for a QuickStick 100 transport system design. The theoretical attractive force, which is based on Vehicle Gap and magnet length is also provided.
Page 207: Thrust Force Data
Table A-1: Thrust Force Data, Standard Magnet Array Maximum Thrust (N) at 4 Amps Stator Current QS 100 Vehicle Gap Magnet Array (mm) Length (Cycles) Recommended nominal Vehicle Gap. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 208: Thrust Force Vs. Magnet Array Cycles, Standard Magnet Array
Figure A-1: Thrust Force vs. Magnet Array Cycles, Standard Magnet Array Array Length 19 Cycles 15 cycles 11 Cycles 7 Cycles 3 Cycles Vehicle Gap (mm) Figure A-2: Thrust Force vs. Vehicle Gap, Standard Magnet Array MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 209: Attractive Force Data
Table A-2: Attractive Force Data, Standard Magnet Array QS 100 Vehicle Gap Magnet Array (mm) Length (Cycles) 1072 1179 1286 1394 1501 1608 1715 1822 1000 1930 1059 2037 1118 2144 1177 Recommended nominal Vehicle Gap. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 210: Attractive Force Data Curves, Standard Magnet Array
3 mm 1000 5 mm 7 mm 9 mm 10 11 12 13 14 15 16 17 18 19 20 Magnet Array Cycles Figure A-3: Attractive Force Data Curves, Standard Magnet Array MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 211: Determining Thrust Force
Laboratory measurements of the thrust that is obtained with a QuickStick 100 motor at various operational parameter values were used to derive a model that describes the thrust that is pro- duced.
Page 212: Determining Attractive Force
Data for Transport System Design Calculations Determining Attractive Force In addition to the thrust force produced by the QuickStick 100 motor, there is an attractive force between the steel laminations in the stator and the magnet array. This attraction, or...
Page 213: File Maintenance
Backup files are not created automatically. It is the responsibility of the user to create backups of all files by copying them to a safe location. Restoring from Backup Files Damaged files can be restored by copying the backup files into the appropriate locations. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 214: Additional Documentation
The Upgrade Procedures that are supplied with MagneMotion software provide instructions for upgrading from one version of MagneMotion software to another. They also include the procedures for file and driver upgrades that are associated with the software. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 215: Transport System Limits
Thrust at 4.0 A stator current with a nominal Vehicle Gap of 3 mm with a standard magnet array. § Thrust at 10.9 A stator current with a nominal Vehicle Gap of 12 mm with a high flux magnet array. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 216 Appendix This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 217: Glossary
This distance includes the Motor Gap. E-stop: Emergency Stop. Emergency Off: A user-supplied device that disconnects AC power to the transport system. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 218 In a transport system with only one node controller, it runs both the node controller and high-level controller applications. HLC: High-Level Controller. HLC Control Group: The portion of a multi-HLC LSM transport system under control of a specific HLC. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 219 For QuickStick HT motors the master is in the motor controller. MagneMover LITE: A MagneMotion linear synchronous motor with integrated guideways and vehicles that enable quick, efficient conveyance of small loads. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 220 All paths must begin at a Node and the beginning of a path is always the zero posi- tion for determining positions along that path. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 221 Each motor contains sensors that detect the magnetic field from the magnet array. When the signal from the sensors is higher than a threshold, the signal bit for the associated sensor is set high, otherwise it is set low. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 222 Inverters and position-sense hardware. They are internal to the motor assembly on MagneMover LITE and QuickStick 100 motors. For QuickStick HT motors the slaves are in the motor controller. Station: A specific location on a Path, which is measured from the beginning of that path, and identified with a unique ID, used as a vehicle destination.
Page 223 Zero Point: The position on the Upstream end of a Path that denotes the first part on which Vehicle travels. QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 224 This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 225: Index
Configuration File, see Node Controller Config- E-stop, uration File interlock, Configurator, see MagneMotion Configurator light stack, Connections Merge Node, communication, operation, motor power, wiring, motor to motor, 127, Downstream network, connection, network communications, gap, QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 226 Getting Started, magnet arrays, Grounding motor, power supply, network switches, transport system, 71, 124, node controllers, vehicles, overview, Guideway power cables, assembly, software, design, Interlock identification, connection, installation, operation, installation overview, MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 227 75, humidity, humidity, identification, identification, 29, installation, installation, IP rating, 96, IP rating, 98, labels, labels, 44–45 mount design, motor secondary, mounting, 86, stainless steel covered, 76, QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 228 Personnel Safety, description, Power Cables identification, AC power, RS-422 connections, connection, NC-12 identification, description, installation, identification, motor power, RS-422 connections, Power over Ethernet Wiring Diagram, NC-E Power Requirements QS 100 Motors, description, MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 229 Tandem Vehicle, see Dual Magnet Array cable, Temperature Range connections, 128, magnet array, wiring motors, motor, wiring switches, power supply, Text Files Demo Script, Safe Stopping Distance, Track File, Safety Thrust Force, alert types, QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 230 Magnet Array Type file, motor, MICS file, Motor Type file, Node Controller Configuration File, Unpacking, Restricted Parameters file, Upstream, Vehicle anti-collision, configuration, dual array, configuration, single array, design, 78, detected, MagneMotion Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 231 Notes: QuickStick 100 User Manual Rockwell Automation Publication MMI-UM006G-EN-P - January 2020...
Page 232 Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete the How Are We Doing? form at http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf. Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Product certificates are located in the Rockwell Automation Literature Library at http://www.rockwellautomation.com/global/literature-library/overview.page...

Rockwell Automation QuickStick 100 User Manual

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1 Introduction

2 Safety

3 Design Guidelines

4 Specifications and Site Requirements

5 Installation

6 Operation

7 Maintenance

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