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Example Code Manual

Example Code Manual for Linear Flying Shear on MP2000iec

Sigma-5 demo using Camming

Applicable Product: MP2000iec, MotionWorks IEC

Yaskawa Electric America

2121 Norman Drive South

Waukegan, IL 60085

1-800-927-5292

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095

Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming

July 13, 2009 Page 2 of 21

Application Overview

This document explains how to demonstrate the linear flying shear application with camming on the MP2000iec –

Sigma-5 demo box. The algorithm and core program elements are explained in detail.

Application Highlights:

Industry: Automation industry using electronic camming for registration based applications

Major Features: Electronic camming, cam shifts on the fly based on high speed registration

Products Used:

Component

Servopack

Motor

Controller

Software MotionWorks IEC, CamTool

Product and Model Number

Sigma-5 MECHATROLINK II Rotary type

SGMAV, SGMJV

MP2000iec

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095

Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming

July 13, 2009 Page 3 of 21

Application Explanation

The sample code explained in this manual simulates the linear flying shear application as shown in Figure 1

below. The conveyor is the master. The ball screw unit is the slave that cams to the master axis based on a

registration mark. The cutting axis shown in the figure has not been incorporated into the sample code.

Figure 1: Linear Flying shear unit

The relation between the master and slave is given by the following profile (figure 2).

Figure 2: Stages of slave cam profile

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095

Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming

July 13, 2009 Page 4 of 21

Figure 3: Critical positions on the cam master slave profile

Figure 3 details the critical points on the master and slave profiles. The algorithm followed to execute the linear

flying shear is shown in Figure 4. The algorithm starts with the shear axis (slave) at the home position and the

master axis running at a constant velocity. The slave axis waits for a registration mark from a part or on the

master axis. This triggers a shift in the master position such that the start of the cam cycle comes by when the

registration mark reaches the slave home position after covering the sensor to start distance (SSD). Once the

slave cams in and is synchronized, the window for capturing next registration latches opens up (when the slave

passes 30 mm of travel in the forward direction). If a registration is captured when the window for capture is

open, the position is stored and the calculation for phase and master distance is performed. The shift cannot

start immediately because when the shearing process is in progress, the slave and master need to be in tight

sync. Only after the shear is done, can the shift for the next part start. This is determined using a dead man area

on the slave’s position profile (user defined).

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095

Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming

July 13, 2009 Page 5 of 21

Figure 4: Linear flying shear algorithm

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095

Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming

July 13, 2009 Page 6 of 21

The phase is calculated by noting the difference in two consecutive latches on a 360 degree cycle. The master

distance is calculated as (SSD – (SSP – Master shifted position)) where SSD is distance the part has to travel to

get to the shear home position. SSP is the shift start position which is the position on the master from where the

shift can start. This is shown in Figure 5.

Figure 5: Implementation of cam shift

Figure 6 is an illustration of continuous part registration at unequal intervals. Shift one is executed for the first

latch (registration) seen in figure 6. Since the second registration was very early in a cycle, the shift to get the

slave back to home position is very large. This large shift over a small distance causes the slave to return back to

home in a very fast move on the return stroke as can be seen from shift 2. Since the third registration happens

almost at the end of the window, the phase shift is small and it has more distance over which to implement the

shift. It can be seen from Figure 6 that the third shift does not cause a major change in the cam profile.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095

Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming

July 13, 2009 Page 7 of 21

Figure 6: Multiple continuous registrations at unequal intervals

Figure 7 is an illustration of a first part detection or part detection after a cam out. It can be seen that at part

detection, the master position is 32 degrees. Sensor to home distance is 180 degrees. This means that the cam

cycle will have to start when the actual master position is 32 + 180 = 212 degrees. This first part shift can be

seen in Figure 7. If a part is not detected in the window area, a cam out is commanded and after the cam out is

done, a phase shift to negate all cumulative phase shifts is carried out so that the total shift becomes zero and

the master position and shifted master position match up as can be seen at the end of the profiles in figure 7.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095

Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming

July 13, 2009 Page 8 of 21

Figure 7: First part detection or part detection after a cam out

Demo Instructions:

The master axis (Left axis) is configured to be in rotary mode with a 360 degree cycle. (1 rev or motor = 360 user

units). The slave axis is configured as a linear axis with 1 rev of the motor = 100 mm of linear travel.

1) Make sure the servo axes on the demo case are tuned for improved performance

2) Manually orient the slave shear axis (right axis) such that the arrow points up. Flip SI5 switch on and off to set

that position as the home position for the slave axis. The position at which the master (left axis) is will be set as

its zero position too. The orientation of the master axis does not matter in this step.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095

Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming

July 13, 2009 Page 9 of 21

Figure 8: Demo case controls for sample program

3) Enable the servos using DI0. Leave DI0 on

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095

Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming

July 13, 2009 Page 10 of 21

4) Flip DI1 on and off. This is to home the slave axis. On starting up, the slave axis is already in its home

position.

5) Turn on DI2. This will start the master axis jog. The master axis will jog at 90 degrees /second. To stop the

master jog, turn DI2 off.

6) When DO2 lights up, it is an indication that the controller program is ready for registration.

7) Flip SI4 on the first row on and off. This simulates a part or registration mark. DO2 will turn off. The slave axis

will wait for the master axis to turn 180 degrees (distance from sensor to shear’s home) from where the mark

was seen and then start the cam profile. The slave axis travel one way is 250 mm or 2.5 revs on the demo.

When the slave passes 30 mm travel, DO2 turns on and indicates that the system is ready for another mark.

DO2 will be on until the window is closed (240 mm on the slave). The slave’s shift in profile during the travel back

to home will depend on when the registration was seen in the cycle. If the part was detected early (closer to 30

mm), the move back on the slave will be rapid. If the part was detected later (closer to 240 mm), the move back

will be slow.

If a part is not detected while the slave is synchronized to the master and the window is over (DO2 turns off), the

slave cams out and stays at the home position until the next part comes along. The system will be ready for

registrations (DO2 on) as soon as the cam out is done.

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