tm410 the basics of asim

The Basics of ASiMTM410

2 TM410 The Bas cs of AS M

Introduction

Requirements

Training modules: TM210 – The Basics of Automation Studio

TM400 – The Basics of Drive Technology

Software: Automation Studio 3 or higher

Hardware: B&R drive system (controller, network, ACOPOS, B&R motor)

i i

Introduction

Table of contents

1. INTRODUCTION 4

1.1 Training guide objectives 5

2. DRIVE DESIGN 6

2.1 Drive hardware 72.2 Software concept 10

3. THE FIRST PROJECT 13

4. DRIVE CONFIGURATION SECTIONS 15

4.1 Configuration modules 164.2 Motion system settings 22

5. INITIAL STARTUP AND DIAGNOSTICS ENVIRONMENT 23

5.1 Command interface 275.2 Parameter management 305.3 Display of axis information 325.4 Trace function 355.5 Checklist for initial startup 41

6. SIMULATION OPTIONS 44

6.1 Axis simulation 446.2 Motor simulation 44

7. SUMMARY 45

The Basics of ASiM TM410 3

Introduction

1. INTRODUCTION

The B&R drive concept is fully integrated in Automation Studio. The result is a simple and uniform tool for developing projects as well as implementing control and positioning tasks.

This training module explains step-by-step how to create a drive configuration in an Automation Studio project.

It then provides detailed descriptions of components that can be used to manage and edit your configuration, including their respective tools and interfaces.

Fig. 1: Motion control

Integrated diagnostic tools provide an efficient environment for testing and implementation.

4 TM410 The Basics of ASiM

Introduction

1.1 Training guide objectives

You will learn how to set up a drive configuration in Automation Studio with the help of example tasks.

You will learn how to…

… Insert a drive axis

… Configure and set parameters for servo drives

… Use motion diagnostic tools

… Simulate a servo drive

Fig. 2: Overview


Drive design

2. DRIVE DESIGN

The following section deals with the system architecture of the B&R drive solution. Our goal is to establish a basic understanding of the procedures and relationships in this system.

Fig. 3: Drive concept structure

Project creation

Project development is performed using B&R Automation Studio. The following tools are available:

Hardware configuration: The components must be correctly applied to the different configurations. These settings are made using Automation Studio.

Software generation: For controlling the drive and implementing the positioning sequences using an application program. For the B&R drive solution, the software is generated using the PLCopen motion control library.

Diagnostic and testing tools: Automation Studio and the System Diagnostics Manager provide the user with a variety of diagnostic and testing possibilities. Processes (e.g. positioning) can be accurately adjusted and values can be recorded for analysis.

Simulation of motors and servo drives is supported byAutomation Studio.

The components required for a drive configuration are shown in the figure above. In order to understand how this works, we will first take a closer look at the individual components and then the shared interfaces.


Drive design

2.1 Drive hardware

Different areas of application require different types of drive technology. These different types are fully integrated in the B&R system.Communication between the controller and the drives takes place either viaX2X or POWERLINK.

Fig. 4: Hardware configuration

ACOPOS family

ACOPOS

Integrated in the ACOPOS module: Line filter, braking resistor and and electronic restart inhibit

ACOPOSmulti

Rack-based structure with different cooling methods and power regeneration via regeneration choke.

ACOPOSmulti SafeMC

Also offers expanded safety functions in addition to the system properties of the ACOPOSmulti series (e.g. Safely Limited Speed)

ACOPOSmicro

Ideal application in the lowest power ranges for servo and stepper motor applications.

ACOPOSinverter

Broad performance range for cost-effective applications without positioning tasks.


Drive design

X20 / X67

SM – Stepper motors

Up to two stepper motors can be operated using a single module from the X20 or X67 series.

MM – Motor bridge modules

Up to four DC motors can be operated using a single module from the X20 or X67 series.

Note:

Detailed information regarding functionality and wiring can be found in the respective user's manuals.

Drives use two types of internal parameters:

Parameters for the hardware configuration

The servo drive must be configured according to the connected hardware:

Characteristics of the motor and holding brake (if present)

Plug-in cards (encoder and network cards)

Parameters for positioning sequences

The servo drive processes parameters that are used to control and check positioning sequences:

Movement parameters, commands and status values

Monitor functions

We will take a closer look at the processes in the servo drive in the section"Software concept".


Drive design

Control and communication

The drive is operated with the help of parameters.

Data is exchanged between the controller and the drive on the bus system and is controlled by the NC Manager.

This acts as the link between the user application and the NC operating system on the servo drive.

Fig. 5S: Drive control and communication

There are two types of data to be exchanged:

Parameter data and commands are sent from the controller to the servo drive.

Status data is sent from the servo drive to controller.

The system provides global structure for operating and setting the parameters for the respective drive.

Commands are sent to the NC Manager using simple functions. The NC Manager then communicates with the NC operating system to execute the respective actions.


Drive design

2.2 Software concept

The software concept is extremely simple because it works the same way for all types of drive technology.

The application specifies set values, which are then forwarded to the configured hardware via selected function types.

NC objects are created for motion control, CNC and robotics.

Fig. 6: Software concept

These objects are accessed via a global operating structure.

The following objects are available:

Real axis

Virtual axis

CNC system

Robotics

These objects are managed via the NC Manager.It transfers the control commands and their defined parameters from the object to the corresponding drive.

It also ensures that the corresponding status values are returned to the structure of the respective object.

The flexibility of the software concept makes it possible to use the same application for different drive types.


Drive design

Real axis

This NC object is used to operate a real drive with a motor and a position encoder.

Virtual axis

In addition to the real axes, ACOPOS also offers the option of operating a virtual drive. This drive works solely as a type of "set value generator" (i.e. generates values for position and speed) and is operated identically to a real axis. It can be used for various applications such as linking a real axis to the position of a virtual axis.


Drive design

CNC system

A CNC system is an application in which multiple axes are linked with each other and perform defined movements. The CNC system handles the management and coordination of the individual CNC axes.

Robotics

A robotics system is an application in which multiple axes are linked with each other and perform defined movements. Unlike a CNC system however a robotics system is based on kinematics.

The operating structure for NC objects differs according to the type of application in which they are used. For example, a virtual axis requires fewer operating parameters than a real axis because it does not have encoder or control parameters.

Automation Studio Help: Motion / Reference manual / ACP10 / NC objects


The first project

3. THE FIRST PROJECT

In this section, we will use the Automation Studio Help system to create a motion project, transfer the project to a CompactFlash card and test the axis using NC Test.

Task: Create your first project using the Help system

You can open the right chapter of the Automation Studio Help system directly from the start page.

Procedure:

Choose the "Create a motion application" section from the start page

Select the sub-section "First motion application"

Work through each of the steps


The first project

Results

The Online Help system can be used to help create a first project, and to insert, configure and test the axis.

The next sections will provide a more detailed explanation of the components created with the wizard.

Fig. 7: Procedure for creating the motion application

Note:

The "Getting Started" examples can also be accessed directly via theAutomation Studio Help system.

Automation Studio Help: Automation Software / Getting Started


Drive configuration sections

4. DRIVE CONFIGURATION SECTIONS

A variety of settings and parameters are required for a drive configuration.

These are managed via hardware-independent access. This prevents any limitations from occurring due to the drive technology being used.

For example, this means that replacing a servo drive with a stepper motor will not cause any problems.

The drive configuration consists of the following components:

Configuration modules

Motion system settings

Fig. 8: Drive configuration components



4.1 Configuration modules

The modules created when adding the drive will be described in the following sections.

NC mapping table

The NC mapping table assigns the following configuration modules to an axis:

NC Init module

ACOPOS parameter table

NC error text module

Axis reference (e.g. gAxis01)

Fig. 9: Linking the drive with an axis variable

When configuring a drive, the wizard creates a global variable.

The name of this variable is referred to as the axis name and is specified by the user. It is used for linking between the application and the physical drive.

Each drive can be assigned an NC Init module and an ACOPOS parameter table via the NC mapping table.



The global NC mapping table can be opened by double-clicking on the NCmapping file in the Configuration View (the ".ncm" file extension).

Fig. 10: Opening the NC mapping table

Automation Studio Help: Motion / Configuration / Motion Control / Configuration modules / NC mapping table



NC Init module

The NC Init module contains basic axis parameters that are used by the NC Manager to initialize the axis reference when starting up the controller.

The NC Init module is accessed via the Logical View. Double-clicking on the corresponding file with the extension ".ax" opens a window where the initialization parameters can be changed.

Fig. 11: NC Init module

Automation Studio Help: Motion / Configuration / Motion Control / Configuration modules / NC Init module



ACOPOS parameter table

Unlike the NC Init module, specific axis parameters are defined in theACOPOS parameter table.

This can be started by double-clicking on the ACOPOS parameter table in the Logical View (".apt" file extension).

Fig. 12: ACOPOS parameter table

Automation Studio Help: Motion / Configuration / Motion Control / Configuration modules / ACOPOS parameter table



Task: Searching parameter IDs (ParIDs)

Use Automation Studio Help to search ParIDs for the following parameters:

Temperature of the temperature sensor (current motor temperature)

Motor torque (current torque)

DC bus voltage

Cooler temperature - Temperature sensor on the power element

Procedure:

Start the Automation Studio Help system

Select the Motion folder from the Help system

Select the hot spot "Parameter IDs Drive Functions"

Search required parameters



NC Error Text module

The NC Error Text module contains the text groups for the drive, which makes it possible to generate clear text error messages. When using the Motion Wizard, the name and language must first be specified.

This can be started by double-clicking on the NC Error Text module in theLogical View (".ett" file extension).

Automation Studio Help: Motion / Configuration / Motion Control / Configuration modules / NC Error Text module

NC Manager configuration / NC configuration

The NC Manager is configured using the NC Manager configuration. These settings are separate from the actual hardware.

For more information on this, please see the section "Motion system settings".



4.2 Motion system settings

This can be opened by double-clicking on the NC Manager configuration in the Configuration View (".ncc" file extension).

Fig. 13: NC Manager configuration

The system settings are used to configure the NC Manager. For example, the user can define the buffer size for the network command trace or the restart behavior of the drive.

Fig. 14: Motion system settings

Note:

Communication between the NC Manager and the operating system on the servo drive is lost when the control voltage is shut off. Change the setting "Execute automatically after ACOPOS reset" to "Yes" if communication should be re-established automatically.

Automation Studio Help: Motion / Configuration / Motion Control / Configuration modules / NC Manager configuration


Initial Startup and diagnostics environment

5. INITIAL STARTUP AND DIAGNOSTICS ENVIRONMENT

Two environments are available for quickly and easily starting up the drive configuration and running diagnostics on it. These environments are controlled separately from the resulting application.

This involves the following sections

SDM – System Diagnostics Manager

NC Test

Possibilities:

Send commands

Access the drive's parameters

Display status parameters

Record real-time data on thenetwork

Additionally, a "Checklist for initial startup" is also provided.

SDM – System Diagnostics Manager

The SDM can be used to quickly and easily evaluate drive status data, such as current speed or limit switch positions.This can be accessed using a standard web browser.

Other functions are also provided such as starting a trace recording and then uploading the resulting data or the network command trace.

Note:

Automation Studio Version 3.0.90 or higher is required in order to use the specific SDM functions for motion.

Automation Studio Help: Diagnostics and service / System DiagnosticsManager



NC Test

Unlike the SDM, Automation Studio is required for the NC Test environment. A number of functions and parameters are included that are used for startup and diagnostics.

These include:

Command interface

Parameter management

Display of axis information

Trace functions

Fig. 15: Motion diagnostics

Note:

A connection between Automation Studio, the controller and the drive is required in order to use the NC Test.



Opening NC Test

The mapping table is opened by double-clicking on the ACOPOS instance in the hardware tree.The NC Test can be opened by right-clicking on the corresponding axis object in the mapping table and selecting Test.

Fig. 16: Opening NC Test

The following dialog box appears when the Test window is opened:

Fig. 17: NC Test mode

The user can decide whether the NC Test should access the axis parallel or exclusively. In exclusive mode, the application commands are not forwarded to the axis. Instead, operation takes place exclusively via the NC Test.



NC Test window appearance

The NC Test consists of the following four sections:

Command interface (1)

Parameter window (2)

NC watch (3)

NC trace (4)

Fig. 18: NC Test window structure

If the NC Test window is closed during an active movement, then the user must choose whether the movement should be stopped or not.

Automation Studio Help: Motion / Diagnostics / NC Test



5.1 Command interface

The command interface is used for controlling an axis.

Fig. 19: Command interface

Automation Studio Help: Motion / Diagnostics / NC Test / Command interface

The command interface is divided into the following sections:

Preparation

Basis movement

Limits

Service interface

Motor simulation

Setup



Preparation

Before an axis can be put into motion, the drive's closed loop controller must be activated using the command "Switch On". The axis is referenced using the "Homing" command. A basis movement can then be executed.

The "Initialize" command can be used if parameters need to be initialized.

Note:

The digital inputs (limit switch, E-stop) and the closed loop controller can only be initialized when the closed loop controller is turned on. The section "Parameter management" describes where the parameters are located and how to change them.

Basis movement

After being prepared, the drive is then ready to perform basis movements. These are the movement procedures that can be implemented in an application using PLCopen function blocks. They are performed by selecting the corresponding movement.

Note:

A detailed description of the movement procedures can be found in the respective PLCopen function blocks. The "Positive" and "Negative" movements correspond to a MC_MoveVelocity in the positive or negative direction of movement.

Automation Studio Help: Programming / Libraries / Motion libraries / ACP10_MC / Function blocks / Basis movements

Service interface

The service interface can be used to read ("Read drive parameters") or write ("Write drive parameters") individual parameters from the drive. Some examples include: Motor temperature, torque limitation, etc.



Limits

The command "Initialize" can be used for any limits that have been changed and must be initialized. This requires that the closed loop controller is switched off.

Note:

The section "Parameter management" provides more information regarding where parameters can be managed and changed.

Motor simulation

Simulation for a motor can be enabled using "Switch on" in the event that a motor must be simulated because it is not physically available, or should not be moved (for tests).The simulation can be disabled using "Switch off" if this function is no longer needed.

Setup

The Setup area is used for tuning a motor.

Task: Read ParIDs

Determine the following drive parameters:

Motor ambient temperature

Actual position

Procedure:

Search ParIDs in the Automation Studio Help system

Read-out values using the Watch window

Results

The values of the specified ParIDs were determined right on the drive.



5.2 Parameter management

The drive parameters are managed in the parameter window.

Fig. 20: Parameter window

The parameter structure contains parameters for the INIT parameter module.



Values that are changed manually are compared with the saved parameters and identified with a black checkmark.

Fig. 21: Changed parameters

If initial parameters have been changed, then they can be transferred to theINIT parameter module (individually for each group of parameters) using the menu command Test / Save Parameter Group.

A dialog box appears when exiting the NC Test if there is no explicit memory command. This is where the user can choose whether or not the changed INIT values will be saved in the INIT parameter module.

Fig. 22: Exiting the NC Test

Automation Studio Help:Diagnostics \ NC Test \ Parameter window



5.3 Display of axis information

The NC Watch shows the user the current status of an NC object.

The NC Watch window can be divided into three sections:

Object states (1)

Object data (2)

Error text (3)

Fig. 24: Error texts

Fig. 23: NC Watch window

Note:

This tool can also be opened outside of the NC Test (same procedure as opening the NC Test, Selection: Watch).

Automation Studio Help: Diagnostics \ NC Test \ NC Watch



5.3.1 Object states

Icons in the bar at the top display the most important drive states.

Any connection errors that occur between the NC object and the controller appears as follows:

Fig. 25: Watch: Problem with the communication

After the connection has been established successfully and the drive has been prepared, the object states appear as follows:

Fig. 26: Watch: Status icons

The traffic light icon (far right) is used for switching to and from the NC Watch window. This is needed to display the error text for any errors that are pending.

There is no error on the axis

There is an error on the axis

If there is an error, a detailed error description appears below the icons.

Fig. 27: Error text



The button in the Watch command area can be used to acknowledge pending errors.

Multiple errors caused simultaneously by an action will be acknowledged in order.

Automation Studio Help: Diagnostics \ NC Test \ NC Watch

5.3.2 Object data

The first time the NC Watch is opened, this section displays elements from the operating structure that are used frequently. The user can modify the list to include other parameters.

This is done by right-clicking: Add

Fig. 28: Adding a command

Fig. 29: Selecting the command

The desired elements are selected from the NC object operating structure subgroups in the corresponding dialog box.

The selected entries are then added to the NC Watch.

In general: The list of the parameters displayed in the parameter window is saved (without the parameter values) when the NC Watch window isclosed. This list is restored the next time the NC Watch is opened.



5.4 Trace function

The target system provides two different trace functions.

One is the NC Trace, which makes it possible to record real-time data right on the drive. The other is the network command trace, which can be used to log commands at the network level.

5.4.1 NC Trace

Real-time data is recorded directly on the drive. The recorded data is loaded to Automation Studio from the ACOPOS device via the PLC and displayed graphically.

Among other things, the trace provides the following features:

Set the control parameters

Check the motor load

Check the load on the ACOPOS

Check the positioning sequence

Multi-axis trace (synchronous recording of multiple axes)

The following image shows how the results are displayed in NC Trace:

Fig. 30: Example for a parameter trace



A number of different tools can be used for detailed analysis of the data.

Note:

Like NC Watch, the Trace function can be operated independent of theNC test by opening it directly for the NC object.

Saving trace data

The collected Trace data can be saved in a file and used again later byright-clicking in the NC Trace window and selecting "Save Chart Data".

Fig. 31: Saving trace data

Automation Studio Help: Motion \ Diagnostics \ NC Trace



5.4.2 Network command trace

The network command trace can be used to record communication between the PLC and the drive. This means that the data sent/received by the NC Manager will be stored in the recorded entries.

Fig. 32: Network command trace

Among other things, this function can help check the order in which commands will be sent by the tasks to the PLC. The procedure is traceable and any errors that might occur can be found quickly and easily.

The network command trace is an expansion of the NC Trace and is therefore also opened in the trace environment.

The network command trace is opened by right-clicking on the NC Trace interface and selecting Show Network Command Trace. This method can also be used to switch back to the cyclic Trace.

Fig. 33: Opening the network command trace



The network command trace is constantly active. Depending on the defined size for the recording buffer (dialog box: NC Properties), a certain number of entries can be viewed. To display the results in the Trace window, right- clicking and select Load Data from Target.

Fig. 34: Loading the records

The network command trace shows a list of entries. These entries provide information about the parameters that have been sent to the ACOPOS by the NC Manager. Information about the drive's corresponding response is also provided.

Fig. 35: Example of a network command trace

More detailed information can be found in the Automation Studio Help documentation.

Automation Studio Help: Motion \ Diagnostics \ Network Command Trace



Task: Record lag errors using the trace function

Set up a recording for an additive movement using NC Trace.

Determine the average speed based on the current speed.

Check the following settings in the parameter window:

s = 10000

v = 10000

Procedure:

Prepare drive (initialize and turn on controller)

Configure the trace

Actual speed / set speed

Lag error

Start recording

Execute additive movement

After finishing the recording, set the measurement cursors for the current speed to the beginning and end

Adjust the chart properties for the current speed curve to display the average speed.

Determine the lag error

Acknowledge any axis errors

Set the average speed as maximum speed

Results

The trace indicates that the lag error increases up to the configured value and pushes the drive into an error state.

The average value for an axis can be displayed in the area between the measurement cursors by making a simple change to the chart properties.



Task: Recording the deceleration ramp

Use a trigger to start recording the deceleration ramp. The following parameters must be recorded:

Actual speed / set speed

Lag error

The trigger should have the following conditions:

Set speed is within the range v_max and v_max – 10%

Command for a Stop has been sent

Procedure:

Set trigger conditions

Perform a movement in the positive direction

Stop movement

Evaluate the resulting recording

Results

Deceleration of the drive can be seen in the recordings.



5.5 Checklist for initial startup

This section provides step-by-step instructions for starting up a hardware configuration with drives.

The following points needs to be taken into account:

Safety

It is particularly important to test the safety features. This includesthe emergency stop and the limit switches installed on the machine.

Units / Parameters

The defined units must be checked as well as the settings that have been made, for example:

Triggering a motor rotation

Lag error

Software limits

Acceleration values / speed values

Stop functions - direction of motor rotation

Etc.



Jolt time

The use of a jolt time is recommended to prevent placing unnecessary load on the mechanical components. This is set up using the parameter t_jolt.

Tuning

Tuning is necessary in order to adjust the controller settings to the exact mechanical requirements.

Homing methods

To ensure that positioning is accurate, a homing procedure must first be executed on the drive. There a few different ways to do this.

Automation Studio Help: Programming / Libraries / Motion libraries / ACP10_MC / Function blocks / Drive preparation / MC_Home



Digital inputs

Check whether the servo drive's digital inputs have been wired according to the defined parameters.

Task: Startup parameters

Change the following parameters and check their functionality.

Parameters:

Jolt time (t_jolt)

Lag error

Direction of motor rotation (count_dir)

Procedure:

Find and change the parameters in the parameter window

Save and transfer the changed values

Initialize the servo drive

Start movement and trace

Evaluate trace data

Results

The motor rotates in the opposite direction. The jolt time as well as the lag error were changed.


Simulation options

6. SIMULATION OPTIONS

Automation Studio supports two types of software simulation.

6.1 Axis simulation

If the "PC-based software simulation" is used as a controller, then axes can be added and configured for this configuration.

This is done by right-clicking on Slot MO1 in the Physical View and selecting "Insert". A dialog box appears indicating where the MotionIF is selected.

To insert an axis, open the MotionIF and select the SimACOPOS by right- clicking and choosing "Insert". The same wizard as before guides the user through the dialog boxes, creating configuration modules just like for a real drive.

Fig. 36: Simulating an axis

There is no limitation to the use of diagnostics tools in the simulation. Full functionality is available to the user.

6.2 Motor simulation

Motors that are included in a hardware structure but are not connected, or should not be moved, can be simulated.

Motor simulation is enabled in the NC Test window using the command interface under "Motor Simulation". The command "switch on" is used to start and "switch off" to stop the simulation.


Summary

7. SUMMARY

Drives are managed and configured centrally in Automation Studio.

The NC Manager uses the controller to communicate with the NC operating system on the servo drive over an entire network.

The NC Manager is the contact point for controlling the drives.It handles the transfer of parameters and commands to the drive as well as the status information updates for the user.

Fig. 37: Automation Studio with integrated drive concept

Diagnostic tools provide an efficient environment for testing and implementation.

This considerably reduces the engineering expenditure for software as well as the cost and duration of initial start-up and maintenance.


tm410 the basics of asim

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