SureServo2 Fully Engaged Flying Shear from AutomationDirect

in this video for ecam we're going to look at the fully engaged flying Shear application there is a partial engaged flying Shear application as well that this video is not cover in this image you can see the material here is the Master axis on a conveyor or something similar and the Pulses from the Master axis are are the ones fed into the slave axis the slave axis is what synchronizes with the Master axis and the slave axis also holds the ecam table so in this application we have a saw and when the ecam table starts it will follow synchronously with the movement of the material on the Master axis and then either do a horizontal cut or whatever other application you have stamping um anything can be done with that and with the fully engaged Ed the full ecam table is the forward motion and the retract Motion in the same table and it just continues to stay engaged the ecam clutch does not disengage at all in a partially engaged flying Shear application which this video does not cover the ecam table is just the cutting synchronous portion of the uh the movement and then the ecam table is disengaged and then you can call a PR path or some other movement in order to bring it back or do another application in order to fit the ecam table into the exact length that you need for these Cuts you need to know the number of pulses that are output from the Master axis for the length of cut that you need and then those pulses are fed into the ecam axis and the ecam table will have to finish its forward move within that cycle of pulses for example if you have a 100,000 pulses between cuts of the Master axis then your full ecam table needs to fit within those 100,000 pulses that would be the synchronous following and the reset or retract portion of the ecam table this full ecam cycle would also be considered a 360° cycle of the cam in order to not waste material you can use P5 087 which is the initial lead pulse before the clutch engages so you can have a certain amount of time delayed before you get the material to a proper point where you can do full ecam cycles and cutting in this image here you can see this synchronous speed zone is where the cut actually happens this is the acceleration point to where it gets up to speed to match the speed of the conveyor and then the Dell zone is where it'll stop here in the fully engaged flying share application the reset Zone back to the beginning is part of the cam table in a partially engaged again this reset Zone would not happen after the Dell happens you would have to call a PR path to do whatever uh scripting you need to get back to a point where you want to start the cutting again the first thing we need to do is to create this curve in the ecam editor in sh Servo 2 Pro in this test setup I have the lower axis here is the Master axis and simulates what a conveyor would be doing with material up here is the slave axis and this is where the ecam table will be loaded into and would simulate The Cutting of the flying Shear we are currently in PR mode and have performed a power cycle PR mode is the one you need to be in for ecam open up the ecam editor and the speed fitting is the one that we're going to start with speed fitting can only go in One Direction so we'll have to do two speed fitting cam tables and then splice them together this image shows the two sets of curves that we need to create the first portion of it is 300 position points in this example and then we add the second curve in the reverse Direction at a faster speed of 100 points so the full ecam curve would be 400 points as shown in this image we click next in this example we we don't really care where the position of the data array starts and this is the uh the array element of where the ecam table position data is stored so P 5081 we can leave at 100 P 5082 is how many segment numbers are we going to need for the full cam cycle in the image we just saw we want a total of 400 position points and this first curve will be 75% of that so we will use 300 position points for this curve these subsequent values here will thoroughly depend on your application and what you need to do for the cutting for this one we don't need uh a weight zone so we'll have 0% of this curve for that the acceleration Zone we'll do fairly quickly at 5% the synchronous speed zone is the length or the timing or speed of the actual cut to match the master conveyor we're going to have that at 85% of the uh of the acceleration curve the D cell we will then have at 5% again and the idle stop Zone we can have at five as you saw these kind of adjusted automatically to create 100% over here for the full curve and all of these things on the right side these are actual uh data array elements so there's 300 elements in the data array that we're going to create and these 300 elements hold 300 different positions for the curve the distance in P you use we will calculate later the S curve value is your standard motion profile S curve of how sharp you want the changes to happen this S curve uh needs to be shorter than the stop zone so if we have 20 here and then try to create the table we can see that the S curve is greater than the stop zone so the the positions aren't going to be exactly what you were expecting we can knock that back down down to 10 and then we click create table this table that was created has 0 to 360° you can see the stop Zone here is the 15 elements and the acceleration or the uh the beginning of it is also at 15 uh elements this straight line is the constant speed of the uh of the cut which is 255 elements As you move along this curve you can see the values change here of course this table also created this uh this table here you can see the position of the ecam in puu and at what degrees that is happening at all the way up to 360° this stop Zone you can see over here the position is at 100,000 puu plus this very tiny fraction and that is determined by what we had here for the distance and speed to match between the two axes we need to have this distance correct and the pulse number uh P 5.84 correct as well so we have three options here the first one is manually set p 5084 and the distance if you know those numbers you can just put them in here and here the second option is based on the distance and simulated pulse number autocalculate P 5084 so this is the simulated uh number that it's referring to down here and based or the third one is based on P 5084 and the simulated pulse number autocalculate the distance so this is the distance that would be autoc calculated that is the option we're going to choose I just change these values here and I'll show you how I got to those in a minute the units here can be whatever you want they're just there for reference you can change it to inch or Lightyear nautical mile whatever and it's just a reference for U to have so we can hear we can see now the nautical miles per second is down there we'll change that back to millimeters the slave Pulse Field is how many puu will equal 1 mm so on the slave axis 568 411 pulses would move the slave axis 1 mm the master pulse is how many pulses leave the Master axis the other the other drive to equate 1 mm of the slave axis as well here are the calculations for those numbers that I have the upper conveyor is the slave axis which is also the ecam axis and if we look at the pulley diameter which is 56 mm we need to get a linear measurement out of the out of that and how far the belt goes so the circumference formula is pi * diameter so 56 mm * pi is 175. n29 MM per Revolution the 100,000 puu per rev comes from the servo e-gear parameters which are p1044 and p1045 and that is 100,000 puu here so when we divide that out we now know that we have 5685 411 puu per millimeter so that means when 5684 one1 pulses come into the slave axis it will move 1 mm the lower pulley system is the Master axis and the encoder diameter is 76.4 mm now this setup doesn't actually have an encoder but this would be the encoder wheel that is a roll-on encoder that's pushed against the material or the conveyor but in this setup this pulley is directly coupled to the shaft so the diameter of the pulley is the same as using the encoder diameter so the same Formula First circumference gives us 240. one8 mm per Revolution and the E gear in the Master axis I have set up for 10,000 puu which is again P 1044 and P 1045 that will give us 41.667 p U per millimeter so that is how many pulses will come out of the Master axis the terminals OA o and Oz those will be fed directly into cn5 of the slave axis and those two values are right here now that we have the simulated pulse number from the prior step we need to find p50 84 that will go here and that number is what the slave axis expects from the Master axis for for the number of pulses to complete one ecam cycle in this image here you can see that the lower belt is the Master axis and The Cutting length that we are going to want is 138.5 MM and that is the distance between the flags on this belt so we need to figure out how many pulses it'll take to achieve 13895 mm so we know how many puu are in a millimeter and we know how many millimeters we have to go so that's 41.667 Time 1 38.9 five and the result is 5,789 and some change pulses to equate one length of the cut but that length of the cut the whole ecam cycle needs to fit in that distance movement and that distance movement is the synchronous cutting and the retract portion of the keep ecam cycle this portion of the ecam cycle we're creating is only 75% of the full ecam table so we multiply that by 75% and we get 4 34191 and that is the value that goes into p50 84 since we can only put whole numbers in here we will put 43 4 2 into that parameter once we have these values figured out we will now calculate the distance that the slave will move we click create table and now we see this value has updated this is the number of P is that the slave axis will travel for this ecam table we can also see up here the maximum position P has also updated this table here was also updated and this is the table we want to export this is the important parameters these are the array elements rightclick export points now you can choose which points you might want to export but we want all 300 so we select all points browse for a location I've now called this flying shear Cut Zone this is this part of the ecam table click okay export okay we now have that saved as a text file and next we will create the retract zone of this full table creating the retract Zone ecam table is similar we don't care where they are in the uh data array at the moment we just want to create the points and we know we want 100 ecam segments we already know the distance the shear went out and now we're we're going to go with the same distance back we do not care about a synchronous Zone but we do care about getting back as fast as we can so we'll have an acceleration zone of 45% zero for the constant it's the synchronous speed another 45% in the Del Cel Zone and so now we have that going back here we can manually set p 5084 and the distance since we know what this number is this number now needs to change this number was 75% of the Full ecam Table we will wind up with so now we need 25% of the Full ecam Table to create the full 360° or 100% of the table and 5789 * 25% is 1447 that is how many pulses that we expect from the Master axis to cause this that portion of the D cam table to reset or retract all the way back we now click create table and we can see this new curve we can see the fast acceleration and deceleration here but it is going in the same direction we need it to go from the 533 38 position back to zero in order to change this curve the way we want it we're going to right click in the table batch change the values so this is where we exported the points before we're going to batch change these and we do want all of the points so 0 to 100 and we're going to multiply everything by1 and we're going to do another step after this we won't close the window click okay and now we're going to add cuz they're all negative right now all these values you see they're negative values so we're going to add this furthest distance that we have out here to all of them so 5 3 3 3 8 click okay or we can deselect this click okay and now we go back to zero at the end and this part of the cam table starts uh where we finished the last cam table so we redraw and now we can see it starts from the end of the cycle and goes back to the beginning now we want to export this table export points we don't care what these numbers are we want all of the points going to browse and I called it the retract Zone click okay now that we have the two portions of the curve that we want we have to combine them we're going to go back we do not use speed fitting for this portion we will go to manual click next here's where these uh the start position matters if you have multiple uh things in the data array for other reasons we'll leave it at 100 the segment number now is 400 CU it'll combine both of those together click create table we don't care what the positions are right now all we care about is that there's 400 elements in this ecam table we're going to import the points from the first cam table we did and that is the Cut Zone again these numbers here don't matter we just want to import all of the points and here they are we click draw we can see here's the first part this over here is just left over in memory from the last table that was drawn now we want to import the second file so we have the retract Zone selected here is where you'll have to change this so the first set of points ends at 300 so we want 301 to 400 those are the points we want to overwrite okay redraw and now we can see here is the cut Zone stops and then retracts back to the beginning at a much faster speed so now that we have the full table you can export those points ensuring that you click all points if you want to save the text file for reference or we can click here save and what's that what that's going to do is do a ecd file that is all of the ecam settings that are in this table and the actual data array that's what will be saved in the ecd file we can now download the table to RAM and then for the table to survive a power cycle we need to burn to RAM and again here we can see the burn process happening to the e prom click okay click next for the next screen here we can do the table engage offset what 5085 does is if you want to enter this ecam at a different element right now where we have 400 elements 100 is where it starts through 500 is the array so if we start at zero that would be starting at element 100 and if we want to start for some reason the application wanted us to start at 50 into it it would start at element 150 so it be 50 plus the beginning uh of the table Master axis position you can preset the uh the axis position here if you'd like to this is how many pulses you want to wait from the Master axis before you engage your ecam table this digital output will turn on for the first window that you set and this digital output will turn on for the second window you set and these are the two windows this is for the first window and this would be for the second window these values put in here are the degrees of the cam table they're not the element numbers ecam curve scaling we don't need to do anything here with this we don't need to enter anything into the ecam cycle number the pulse number of the Master axis this was loaded from the last time we did the ecam table calculation so this is the retract portion we want to set this back to the full ecam curve value which was 57 8 9 change this back to zero and download now this will just download to the drive it does not update the parameter editors so you'll want to read back in the values so you have those in the parameter editor going to click next this window be up to your application so right now I have the auxiliary encoder which is the cn5 input of the Drive that's where the master access pulses are coming from I want to engage off a digital input and that digital input I have wired to 6 di6 and here is ecam engage control we do not want to disengage because this is a fully engaged flying Shear so it just continues to go back and forth download and read those back in if you need to I want to add another device here so I can connect the two servos at the same time so now I have the Master axis here you can see this is device 2 I'm going to read back in the values I have the Master axis set up for Speed mode going to open the digital controls for that one first thing I will Engage The Master axis so that is moving I'll also enable the slave axis and when I click enable ecam once it sees the first flag it'll start the ecam so you can see the upper flag is now synchronously moving with the lower belt but the Cutters are not lined up the uh the top cutter is not lined up with the cut line on the Master axis so we'll stop this in order to get the axis to line up with the cutter you need to home it properly and that's that's always going to be an application dependent thing through trial and error this is the number that I came up with the lead pulse so 5550 is what I'm going to wait for the lead pulse to go through my homing routine I open the pr mode settings go to the Homing mode what I used was the look for Z pulse in the forward Direction and Define as home and then I'm going to jump to pr1 pr1 is a position move to this position and then it'll jump to the next PR move which is a statement this if we look at this value in HEX I am writing 111 into P 5.88 if we look at the parameter editor here we can see one is going to be enabling the ecam and theny is going to be the auxiliary encoder that we're writing to and then if we look at this one we're going to go to Z which is the DI cam enabled so we have the slave axis enabled we're going to open up the pr window we're going to run the Homing routine here now when I activate the Master axis in speed mode by enabling here once the first flag goes by on the Master axis it'll wait the lead pulse amount and then it'll line up with the second flag so the cutter should be synchronized once that happens first flag second and now it is synchronized with the cutting distance the ecam follows the pulses only not the speed so if I change the speed it now changes the ecam speed the table and that's it