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User manual
Index ver. Date Changes description
V3.xx 9th July 14 Add sections 1.2, 1.3, 1.4 and 12.1.
Corrections:
Corrected return after changed cutting length
Revised ramp at removal of run cmd
Corrected ClearAlarm
Corrected negative mechanical ratios
Additions/Changes:
Selection of motor encoder and measurement
wheel based on IPA 5310 (Enc src sel)
Configuration of drive functions and I/O at boot
and load default
Addition of ErrPosSpeed (11358) limit parameter
in Gains
EnableCut initial default On Remove zero cycle
with cam plus encoder index
Addition of MaxMotorSpeed (11270) parameter in
MechRatios
Eliminated GetCutTimeCmd
Changed fieldbus mapping
V1.00 4th March 2014
------------------------------------------------------------------------------------------------------------------------------
To make it easier to search for parameters in the various menus, these are shown as follows:
“FLYINGSHEAR \MechRelations\MetricWheelSel”. The name includes the list of the menus in which the
parameter is situated. In this case the menu is FLYINGSHEAR followed by MechRelations and lastly the
parameter name MetricWheelSel.
Characteristics
• Controls entire cutting system with only 2 bits via field bus. Enable and RunCmd. Extremely simple
control via PLC.
• Gap/Overspeed function to retract blade from material after cutting
• Cycloidal ramps on forward acceleration and reverse deceleration for smooth control of the system.
• Change of cutting level while machine is running
• Calculation of maximum line speed based on set cutting measurement.
• Virtual Master function to commission the machine without material
• Serial control function for commissioning via PC.
• Modbus communication as standard; CANbus and Profibus with addition of optional card.
• Easy commissioning with use of GF_eXpress Configurator for setting motor and inverter parameters
and Shear application.
A simulation tool on the PC lets you start from mechanical data to calculate the required motor speed and
torque. You can also check theoretical system performance (line speed based on cutting length). The
entered data can then be used for configuration in the field.
As with all products in the ADV200 series, the oscilloscope for commissioning is a thing of the past:
SoftScope is a serial oscilloscope suitable for the entire commissioning process.
For each position of the material from zero up to the cutting length and according to other mechanical
parameters, the application produces the carriage position and therefore the blade position.
The speed profile is the relationship between the material speed and the carriage speed, see figura 1.
The speed profile consists of:
• A waiting phase where the material slides under the still carriage;
• A second phase called acceleration forward. During this phase the carriage reaches the speed of the
material;
• The third phase is synchronization. The carriage proceeds synchronized with the material to reduce
as much as possible any positional error between the carriage and the material;
• The cutting phase follows. Once the synchronization zone with the material is reached, the
application supplies the indication of ReadyToCut and CutSignal allowing the start of the cutting
operation. The application proceeds in synchronization with the material up to the end of the cutting
space;
• At this point the application returns the carriage to its start position and immediately starts the waiting
phase.
NB.:
1) The length of each phase is measured in terms of space. The space used for each phase is calculated
according to the maximum speed allowed for the material.
2) Even if the material flows slowly, each phase uses the same space. This means that, at the end of the
cutting phase, the carriage always advances to the same point regardless of the speed.
3) The space used by the carriage and maximum speed vary depending on the set cutting length. These
parameters are found in the FLYINGSHEAR\FlyingShear menu.
Red = acceleration
Yellow = speed
S_ShapedAcc = On
To be smoother, acceleration should not be varied stepwise (i.e., linear acceleration), but instead should
reach maximum level on a ramp (also called limited jerk ramp).
By doing this, to keep the same acceleration time, maximum acceleration must be greater than the value
needed with linear acceleration.
Its effect is shown in the above picture:
• la The upper image display the acceleration
• The bottom one shown the speed
• In yellow is the linear acceleration, in magenta the rounding due to OveAcc = 1.2.
The acceleration reach its maximum value which is 1.2 times the linear acceleration. Some time is used to
reach the maximum acceleration smoothly.
Spazio Gap
Init
4
2 3
0 1 5 6 7 8 12 13
TSincro Ttaglio
Ready To Cut
Cut Completed
(Ok, No Fault)
Lama Bassa
The cutting sequence starts. The blade can start its motion. If a gap is foreseen (an increase in speed of the
carriage to distance the blade from the material), this starts when a Low Blade signal is given. No indication
is given if this signal is not present, however if Gap is enabled, an error signal is present with a positional
skip at the end of the cycle.
The High Blade signal is controlled at the end of the synchronization speed section. Before deceleration
takes place, a check is made to make sure that the blade has left the material. If this has not happened, the
system passes into an application alarm situation, giving code CUT_NOTCOMPLETED_ALARM (on
FLYINGSHEAR \DriveStatus\ApplAlarmCause menu ) and stops on FLYINGSHEAR \Ramp\FastStop menu.
If the blade up position has been reached correctly the carriage returns to the home position. The time it
waits in this position depends on the set cutting length. For short cuts the waiting time is practically zero. It
increases for longer cutting lengths.
Sensor On
Lama
Blade
Sensor Off
Lama Alta
Blade in Up
position
Lama Bassa
Blade in Low
position
ReadyToCut
Lama Alta
Blade in Up position
Lama Bassa
Blade in Low position
In case is necessary to have a cut command with a defined duration use CutSignal. It last according to the
TimeCutSignal value.
CutSignal may work in two different ways:
• with TimeCutSignal different from zero at cutting time it goes high for TimeCutSignal then back to low
state
• with TimeCutSignal set to zero at cutting time it goes high. It return to low after detection of BladeUp
equal zero and following transition of BladeUp to high state.
3.2 FastStopCmd
When the command turns to ON, the drive passes into speed control mode with reference speed 0. The
ramp used is FLYINGSHEAR \Ramp FastStop Ramp.
When the FastStop command is ON, a message in ApplicationAlarmCause is generated. To restart, the drive
must be disabled. We advise using the ClearAlarm command to reset the ApplicationAlarmCause value.
Note: This command is logical OR for FastStopDig (from digital input not allowed), FastStopBus (from field
bus) and FastStopSer (from serial).
When EnableSerCmd is set to OFF FastStopSer is set to FALSE.
When the Bus control is disabled FastStopBus is set to FALSE.
3.3 VirtualMstStartCmd
Start/Stop of the Virtual Master.
It is used to test the machine without material. The material measurement signal is generated by the
application itself.
3.4 ZeroQualifier
Zero qualifier input. Only from digital input. The zero qualifier indicates when the system has reached the
home position. Depending on the zero cycle setting, once the qualifier has been reached, the carriage is
moved to find the first zero index of the encoder or stopped and the position that is reached is the zero
position.
3.5 VirtualEnableCmd
Drive enable from field bus (VirtualEnableCmdBus) or serial (VirtualEnableCmdSer).
The command is active on the edge.
The drive enable is given by an AND between VirtualEnableCmdBus, VirtualEnableCmdSer and the DI0
digital input.
When the Bus control is disabled, VirtualEnableCmdBus is set to TRUE.
3.6 SysClearAlarm
Zeros the drive alarms. Active to 1. The command is only effective if RunCmd is set to zero and the drive is
disabled.
3.8 SetCutTimeCmd
If field bus is being used, it is possible to program the cutting time value through processing channels.
The new value can be accepted when:
• The drive is disabled (DriveStatus = Disabled);
• On the climbing front of SetCutTimeCmd;
If setting is refused due to a drive state not equal to disable or because the value is too low, the
CutTimeRefused flag becomes high. CutTimeRefused remains high until a value is accepted.
The parameter FLYINGSHEAR \Miscellaneous\ImageFromBus\CuTimeViaBus shows the time value sent via
the bus.
3.9 ImmediateCut
Works in the Camming state. Activates immediate cutting regardless of the length that has been
reached. The carriage is synchronized and the cut is performed.
Note: if the command is sent during the wait phase or during the tracking phase (before the cut), the
system makes the shortest possible cut and returns rapidly to zero.
If the command is sent after the cut, the machine goes rapidly to zero. Give the command again to
start an immediate cut.
3.10 RunCmd **
It is the command that automates the use of the drive. When it passes from 0 to 1, a series of operations are
carried out.
1. Checks to see if the zero sequence has been done. If negative, the zero sequence is carried out;
otherwise it passes to point 3.
2. Zero sequence
3. A Move is done to position 0. The zero position is the found Index position added of ZeroOffset value.
This is the zero reference for the system.
4. Wait of 0.5 sec
5. Cutting command.
6. Wait of 0.5 sec.
7. Starts to follow the material.
Removing the RunCmd command, the carriage stops with StopRamp slope. If the carriage stops (limits) are
exceeded an OverLimitPosition error is issued stopping with the FastStop ramp.
The operation state corresponds to FLYINGSHEAR \DriveStatus\RunCmdState
Camming is the state in which it terminates, when initialization is OK. At this stage the line can be started.
Code RunCmdState
0 DriveStatus not equal to Stop
1 Stop
2 Move to
3 Zero + Move
4 Wait
5 Cut
6 Waiting end of cutting
7 Camming
8 Alarm
10 Waiting steps 4 or 6
SysEnableStatus = False
Stato_Alarm
AND Stato <> Disabled
INIT (5)
SysSystemAlarm = 0 Reg_v e
RifV=0
Stato_Disabled
(0) EnableCmd AND MovePosCmd=1 SysSystemAlarm = 1
Reg_v e RifV=0 sysEnableStatus AND
ZeroCycleStatus =1
Stato_AllarmeParac
arro (7)
Reg_v e RifV=0
Disabled Stato_Stop
(1) Stato_MovPos
JogCmd+ OR (6)
JogCmd- = 0 Reg_v e
RifV=0 Reg_pos
Stato_Jog
(2)
Reg_v e RampTime =
RifV=JogRef JogCmd+ OR FastStopRamp
JogRamp JogCmd - = 1 Reg_V, RifV=0
CammaCmd =1
RampTime = AND
RampTime =
StopRamp ZeroCycleStatus =1
FastStopRamp
Reg_V
Reg_V, RifV=0
RifV=0
FastStopCmd=0
MovePosCmd=0
OR
ZeroCycleStatus =0
JogRamp, StopRamp e
Macchina Stati Camma
FastStop Ramp sono
Rnc 30 Ott 08 Stop Ramp tempi di rampa
Rnc 09 Ago 05 Rev PlastiBlow
Rnc 08 Lug 05 Prima versione
FLYINGSHEAR\Gains\PosFFWDGain
FeedForward gain of system position loop.
FLYINGSHEAR\Gains\MeasureWheelFilter
Low pass filter on the measurement wheel. If the value is too high it may cause an error during cutting
when starting-up and stopping the line. Approximate value up to around 4 msec.
During the cutting phase it may be necessary to increase the time constant of the filter on the metric wheel.
This prevents vibrations due to blade/sheet metal interference from affecting carriage movements. The two
parameters shown below can be used for this purpose:
FLYINGSHEAR\Speed Gains\EncFiltTauInCut
Filter constant applied during cutting.
FLYINGSHEAR\Speed Gains\TauInCutDuration
The time for which the filter is applied starting from the ready to cut signal. It must be long enough to
allow the blade to leave the sheet metal.
The direct speed of the metric wheel encoder is shown in blue; The filter eliminates the disturbance on the filtered measurement
Green: filtered metric wheel and thus on the movement of the carriage
Yellow carriage speed
Disturbance due to cutting is seen on the metric wheel and affects
the carriage
When using the additional filter, working with a constant line speed during cutting is recommended to avoid
measurement and movement errors. To guarantee this condition, stop the line acceleration ramp at the start of the
forward movement, indicated by the StartCycle bit (see StatusWord), until the blade down signal is raised.
Warning
CutPGain
Cutting length control gain. This value is used in the cutting length control system. It moves the
carriage forward or back with respect to the material to obtain a correct cut. Values range from 0.5 to
2%.
To carry out the following and cutting profiles, the state must correspond to Camming. The cycle is started
with the command RunCmd.
1. Checks to see if the zero sequence has been done. If negative, the zero sequence is carried out;
otherwise it passes to point 3.
2. Zero sequence
3. A Move is done at position 0. The zero position is the found Index position added of ZeroOffset value.
This is the zero reference for the system.
4. Wait of 0.5 sec.
5. If the “InitialCutting” parameter equals one, a cut is commanded each time RunCmd passes from 0 to
1. If this parameter equals zero, the initial cut is made only at the first butt cut.
6. Wait of 0.5 sec.
7. Starts to follow the material. At this stage the line can be started.
RunCmd set to 0. The motor runs at zero speed with the JogRamp time. This is the condition that is normally used.
Activate RunCmd again to repeat the above sequence.
FastStop command. The system stops with the FastStop ramp. the commands RunCmd must be removed.
Otherwise the system could restart incorrectly to follow the material.
Warning
If an alarm occurs, the commands RunCmd must be removed.
Otherwise the system could restart incorrectly to follow the material.
Nota: When starting and the RunCmd procedure is not used, the zero position must be checked by reading
the MotorPosition parameter. If the carriage position is not the same as the zero position, the carriage
will move towards the zero position quickly.
5.2 ImmediateCut
Available in the Camming state. Activates immediate cutting regardless of the length that has been reached.
The carriage is synchronized and the cut is performed.
Note: for more information, see Errore. L'origine riferimento non è stata trovata.,
Note: In order to enable the drive the terminal must also be connected.
Initially VirtualEnableCmd and RunCmd are both set to zero. First VirtualEnableCmd is set to high, and the
drive is enabled. Next RunCmd is sent. The system executes the zero cycle if necessary. This only happens
when the machine is switched on.
The butt cut is performed. When that has been done RunCmdState turns to 7 and the line can start.
The line can change speed, even to zero, and restart with no problem.
RunCmd and Enable must only be set to zero if operations are to be performed on the material.
When RunCmd is removed the carriage stops with the Jog ramp.
Alarm
StatusBit Word AND 0002 = 0002
OR
ApplicationAlarmCause <> 0
Init
VirtualEnableCmd = 0
RunCmd =0
Init
SysClearAlarm =0
VirtualEnableCmd = 0
RunCmd =0
VirtualEnableCmd = 1
VirtualEnableCmd = 0 VirtualEnableCmd = 1
RunCmd =0
RunCmd =0 RunCmd =0
SysClearAlarm =1
Wait
Wait
100
100
Wait msec
msec
VirtualEnableCmd = 1
VirtualEnableCmd = 0
RunCmd =1
RunCmd =0
Stop Line and Disable
TimeOut
StatusBit Word AND 003C = 001C
6.1.1 Jog
The Jog state can be reached by using the commands JogCmd+ and JogCmd- when in the Stop state. The
motion is at the speed JogSpeed and ramp JogRamp.
See paragraph 4.
When the new length is received, the carriage returns with maximum acceleration
(FLYINGSHEAR\FlyingShear\MaxAcceleration) and speed FLYINGSHEAR\MechRelations\MaxRetSpd at
zero position. It then waits for the new cut at the new length.
If the carriage is accelerating to go to cutting phase, these operations are postponed until the cut is finished.
CutLengthAccepted goes to zero when a new cutting dimension is given. Goes to 1 when the dimension is
confirmed active. The next cut will be carried out with the new dimension. NB. If the dimension is not
accepted, the signal remains equal to zero and the word ApplicationAlarmCause indicates an error.
To be sure that cutting is active for the next cycle, it is recommended to send a new dimension when
StartCycle = 1. This gives more time for the processor to make the calculation.
The CutLengthAcqDly parameter can be used to delay reading of the CutLength value sent by the field bus.
If the CutLength value changes, the value on the bus is considered valid after this delay time. This can be
useful if the value is set using a combination of relays. Any instability of the contacts can be ignored.
In case a new length is sent with the machine in Camming condition the return to home is executed also if
the line speed is zero.
This movement can occour also also with line stopped (line speed equal zero). Pay attention. No operator
Warning must be close to machine also at line speed zero.
If, when back to zero position, the cutting dimension has already been exceeded
an FLYINGSHEARAlarm CutLengthTooShort error is issued and the machine stops.
The line speed should be decreased beforehand if necessary.
If the dimension is not accepted, the signal rests at zero and the word ApplicationAlarmCause indicates the
Warning error. cCALCOLICARRO_ALARM
Yellow: Speed
CutLengthAccepted
For this reason a series of metric wheel motion controls have been implemented. These can be divided into
two types:
• Checking that the motion of the metric wheel is within the correct acceleration and speed ranges and
that the wheel does not move backwards;
• Checking that the speed of the metric wheel is close to the line speed read by the PLC.
8.1 Checking that the motion of the metric wheel is within the correct acceleration
and speed ranges and that the wheel does not move backwards
The parameters are in the FLYINGSHEAR \MWControl\MWLimitTest menu.
To facilitate evaluation of acceleration values and of the limits to be set, two parameters indicate the
maximum value of accelerations measured during movements. The operator must reset these and write their
value as zero. During the movement these store the maximum measured value.
Another variable displays the current acceleration value. The acceleration value used for all the tests is
mediated to 200 msec.
When the speed of the wheel exceeds the limit this is indicated in:
N.B.:
Exceeding of the limits does not result in any direct action by the drive. The event is indicated in the
ApplicationAlarmCause word. The PLC decides what action is to be taken. See chepter 11.
Messages indicating that limits have been exceeded can be excluded by raising the limits to values that
cannot be reached..
8.2 Checking that the speed of the metric wheel is close to the line speed read by
the PLC
The parameters are in the FLYINGSHEAR\MWControl\MWvsLineSpd menu.
The line speed can be sent to the drive, via fieldbus, to check whether the line speed and metric wheel
speed correspond. The drive verifies that the speed measured by the wheel is within a percentage range
calculated with respect to the LineSpeed value received by the PLC.
When the line speed that is received falls to more than 20% less than the maximum line speed allowed the
range is calculated with respect to 20% of this.
If the speed of the metric wheel remains outside the range for more than the time set in MWOutRangeTime,
this is signalled. The out of range time is set to zero each time the speed returns to within the limit.
Exceeding of the limit does not result in any direct action by the drive.
The event is indicated in the ApplicationAlarmCause word. The PLC decides what action is to be taken. See
chapter 11.
The test is enabled with EnbMWLineSpdChk via parameter or with CommandReg via Bus.
Unit of
Name Value Note
Measure
MechRelations/MetricWheelDisp
(Metric wheel circumference) [mm]
MechRelations/MetricWheelRev
Metric wheel revolutions to have the
circumference given (usually 1)
MechRelations/CarriageDisp
Carriage displacement [mm]
MechRelations/MotorRev
Motor revolutions to have CarriageDisp
FlyingShear/CarriageLength
Carriage length [m]
FlyingShear/MaxCarriageVelocity
Maximum carriage speed [m/s]
FlyingShear/MaxAcceleration
2
Maximum acceleration [m/s ]
FlyingShear/MaxDeceleration
2
Maximum deceleration [m/s ]
FlyingShear/SyncTime
Synchronization time before cutting [s]
FlyingShear/CutAndGapTime
Time used for cutting and Gap execution [s]
FlyingShear/GapLength
[m]
Gap length
FlyingShear/GapTime
[s]
Gap Time
MechRelations/Max position
[m]
MechRelations/Min position
[m]
FlyingShear/MaxCarriageVelocity
Maximum carriage speed [m/s]
MechRelations/MaximumSpeed
Maximum motor speed [rpm]
MechRelations/MaxRetSpd
Maximum return speed [rpm]
10.2 Encoders
You have to define the encoder mounted on the motor via IPA 5310: Encoder Sel Source. The other
mounted encoder is used as a measurement wheel.
The fieldbus is configurable. The suggested configuration is set with the load default command.
FieldBus M->S
FieldBus S->M
11.3 cLENGTH_TOO_SHORT
When home position is reached after a change in cutting length, not enough material has advanced to
execute the cut at the requested length.
12.1.1 Requirements
To install the application you must have a PC, version 1.6.5 or higher of the Gefran GF Express software
with Catalog, the drive RS485 - PCI COM connection kit and the set-up CD.
The application set-up CD contains an automatic procedure that copies the required files in the specific
folders of the GF Express catalog.
Through GF Express is possible to use "Download firmware" command on the toolbar. This command will
open a drop-down menu where all the downloadable applications are listed (compatible with the drive fw).
By choosing the desired application, the window "Download firmware" will open with the field: "File to
download" and the indication of all the applications that are compatible with the drive used.
If you have not installed applications (only the PID is installed by default as application 1) Download
Firmware window will be empty. The user will need to manually select the file ". Fl2" to download.
- Check the connections, paying particular attention to shielding (see standard wiring diagrams) in order
to reduce interference to a minimum, especially on encoders.
- Set the IPA 558 Application Select parameter to the application where you wish to load the
application (Application 1 or Application 2).
- If the application firmware is not already installed, download it using the GF-Express "Download
firmware" utility.
- Files called "filename___A1fl2" enable the firmware to be downloaded to Application 1, files named
“filename___A2.fl2” enable the firmware to be downloaded to Application 2.
Note!
The ADV200 drive is supplied with the PID application installed in Application 1; to keep this application, we
recommend downloading the firmware to Application 2.
- Send a "Drive reset" command.
- Open the drive parameters file containing the application parameters (.gfe).
- Send the “Load default drive values” command from the configurator Parameters menu to load the
default parameters.
- First send a “Save parameter into target” command, then “Drive reset”.
Attention! when installed for the first time, the application automatically activates for 300 hours, after
which the application will NO LONGER be active and the “Key Expiring” message will be
displayed.
If you have the cd-rom ADV200 Flying Shear Application, code 1S3E30, do steps 1 and 2.
If you do not have the cd-rom, do step 3.
Step 1) Entering the enable key (if you have cd-rom 1S5E30)
• Select the parameter IPA 572 Application key (menu 4 - DRIVE CONFIG) from the keypad or PC
with GFeXpress (see fig. 2).
• Enter the unlock key written on the back of the ADV200 Flying Shear Application cd-rom, code
1S3E30 (see Fig 2).
• Run the parameter IPA 550 Save parameters (menu 4 – DRIVE CONFIG) and reset the drive (switch
the drive off and then back on or, from GFeXpress, run the RESET DRIVE command - see fig. 3).
Fig.1 Fig.2
Fig.3
Contact Gefran’s Sales Department to purchase the enable key: you will be asked the serial number of the
control card (see below) and the serial number and model of the inverter (shown on the external data plate).
Fig.4 Fig.5
The procedure describes Start up with a single metric wheel connected to the XER input.
If you want to use two metric wheels, see paragraph 12.3.3 “Checking the value set for metric wheel
circumference.”
The connection diagram proposed is as follows:
If necessary the commands can be made to pass via the PLC (e.g. to allow manual control of the cutting
unit).
The physical limit switches must be managed by external control units. This is because when engaged they activate
the Stop state and the carriage cannot be moved.
The FastStop command must be removed by means of an appropriate sequence controlled by the operator.
Caution
12.3.1 Self-setting
By means of two parametrs the source of some parametrs is set. The source may be Serial port or Field Bus
Setting Bus_enable OFF and EnableSerialCmd ON data are set trough serial port.
Setting Bus_enable ON and EnableSerialCmd Off the CutLength, CutTime and CmdRegister(sysFBRxw7)
came via field bus.
FLYINGSHEAR\5-MechanicalRelations
Name Meaning Note
MetricWheelSel
MetricWheelDisp Material advancement in RevMst revolutions of If RevMst = 1 then DeltaDispMst is the material
the measurement wheel. advancement per revolution of the measurement
wheel.
MetricWheelRev Number of measurement wheel revolutions with
which the material advances by DeltaDispMst
MetricWheelDisp2nd Material advancement in one revolutions of the
second measurement wheel
CarriageDisp Carriage advancement in RevSlv revolutions of If RevSlv = 1 then DeltaDispSlv is the carriage
the motor shaft. advancement per revolution of the motor shaft.
MotorRev Number of motor shaft revolutions with which
the carriage advances by DeltaDispSlv
MaximumSpd Maximum motor speed If this level is exceeded the speed is limited. An
appropriate ApplicationAlarmCause value
signals this condition
ReverseMasterDirectio Master direction inversion (measurement wheel) The master must always increase. If the wheel
n measurement decreases, set
ReverseMasterDirection to On
MaxRetSpd Motor return speed during the cutting length
change phase.
MaxPosition Maximum Carriage Position Limit switch
MinPosition Minimum Carriage Position Limit switch
EnablePosLimit Enable the limit switch control Set it on
ActiveMetricWheel Active metric wheel selection Off XER metric wheel
On EXP o XFI metric wheel
MasterSelection VirtualMaster This configuration is used to test the machine without material. The material
advancement is simulated internally
CarriageDisp 580.616 Saw carriage advancement
MotorRev 28.28 Number of motor revolutions for one revolution of the slow shaft
MetricWheelDisp 400 Metric wheel circumference
MetricWheelRev 1
MetricWheelDisp2nd
MaximumSpd 1800 rpm This speed is set to about 20% above the maximum motor speed reached.
This speed must keep in mind the Gap and the return speed. If this level is
exceeded, the ApplicationAlarmCause value signals an error.
MaxRetSpd 1500 rpm Motor return speed during the cutting length change phase.
ReverseMasterDirection See below
MaxPosition Off. The main metric wheel is selected. XER connector
MinPosition -10 (to verify with carriage movement)
EnablePosLimit 1010 (to verify with carriage movement)
ActiveMetricWheel On
JogRamp is the ramp used in Jog mode. (See Figure 3: Drive states).
SpazioArresto is the stopping space in meters, (the unit of measure is between []):
( MaximumSpd[rpm] ⋅ DeltaDispSlv[mm])
V max Carro = Maximum carriage speed in m/s
60'000 ⋅ Re vSlv
2 ⋅ SpazioDiArresto[m]
TempoDiArresto = Stopping time in seconds
VMaxCarro[m / s ]
MstStep is the speed of the virtual master. This simulates the metric wheel during the test without material.
The virtual material speed is expressed in mt/s.
VirtualMstRamp is the ramp applied to the variations of MstStep inside the cycle. Suggested value 1 s.
Note:
If the value of MstStep is modified, the internal cycle ramp is changed. The new cycle starts immediately with
the final value. Change MstStep gradually.
MoveToSpeed. Using the command RunCmd, the saw proceeds to the zero position before cutting the butt
and starting to follow the material. The speed at which it travels to the zero position is MoveToSpeed, the
ramp is JogRamp. See Figure 3: Drive states
The controls will be passed integrally to the serial line. To enable this set Bus_enable to OFF and
EnableSerialCmd to ON. These are found in the Miscellaneous menu.
On the command page of the configurator, all useful measurements are shown.
Have an emergency push button available to disarm the system if necessary. This push button must be easily
reached.
The operation described can be (must be) initially carried out with the motor disconnected from the machine.
Once the functions have been tested, the operations can be repeated with the motor connected to the
machine.
Jog forwards and backwards. Check for movement in the correct direction. With Jog forward the carriage
advances in a positive direction and the MotorPosition increases.
Otherwise set DeltaDispSlv to negative.
Select ZeroType:
0=Cam+EncIndex;
1=CamOnly;
2=actPos-> zero.
As soon as the drive reaches the Camming state, remove RunCmd (set it to red). The drive stops in Enabled
state.
Note:
When passing to camming, an initial butt cut is carried out. If the high blade and low blade sensors are not
connected, the drive will go to an alarm state, with FLYINGSHEARAlarmCasue = Cut not completed (code
64).
To modify the zero position change the ZeroOffset value and repeat the RunCmd. The carriage will move to
the new zero position.
E.g.:
Difference between the two Motor Positions = 600 mm
Carriage distance travelled = 590 mm
DeltaDispSlv = 0.580 m
N.B.
Both the wheel must count in the same direction. The ReverseMasterDirection flag acts on both.
Cesoia
LunghezzaUtileCarro
Posizone di
Zero
Spazio Gap
Init
4
2 3
0 1 5 6 7 8 12 13
TSincro Ttaglio
Ready To Cut
Cut Completed
(Ok, No Fault)
Lama Bassa
If the required cutting length is not compatible with the other data, it is refused and the last value is
maintained.
CutAndGapTime (Cutting Time): It is the time used for cutting and gap execution. The time starts when the
ReadyToCut signal is given. Keep this in mind when taking into account Plc delays and
various actuators.
GapLength is carried out in GapTime (Sec). GapTime is usually less than blade up time (about half of cutting
time).
N.B.
The cutting system is made up of several elements with times related between each other.
It is therefore possible to adjust the various timing intervals and decrease some of them. This must be done
after due consideration.
MaxCarriageVelocity [m/s]:
VelocitàMotore[rpm] ⋅ CarriageDispl[mm]
Is given by the formula: V max Carro[ m / s ] =
60 ⋅1'000 ⋅ Motor Re v
MaxAcceleration: is the acceleration used to calculate the motion profile. This acceleration is obtained
when the system works at the calculated VlineaMax value.
The value can be supplied by the manufacturer or can be found empirically with the drive
connected, as follows:
Cutting state: varies depending on the blade and ready to cut positions. A value of 99 indicates an error
state.
OverallMstTrip, OverallSlvTrip ViaggioTotaleMst and Slv: Are the distance covered by the metric wheel
(equal to the cutting length) and the total distance of the carriage (about zero). They are
present only for checking..
UsedCarriage SpazioAndata*: Space used by the carriage to carry out the cut
MaxLineSpeed VlineaMax*: Maximum line speed possible with respect to the data inserted. The line can
have a higher value. Timing and acceleration will not be respected.
InUseCutLength LtaglioInUso: Cutting length in use. It could be different than the one set, if calculation
errors are present.
Ramp\MstStep is the speed of the virtual master. This simulates the metric wheel during the test without
material.
The value is inserted in mt/s.
DriveStatus,
MetricWheelPos,
MotorPosition,
BarLength,
RealCutLength.
Set:
RunCmd OFF
Enable Drive
Check for any irregular movements, the space used (equal to UsedCarriage) and RealCutLength length
(equal to the required cutting length).
Having done the above, we can proceed to set the drive, by increasing the cycle speed (increasing the
MstStep value).
S_Shaped On
S_ShapedRet Off
S_ShapedRet and
S_Shaped are both On
The resolution of the metric wheel part must be equal or higher of the one of the carriage part.
In other words the ratio between the carriage displacement for motor revolution and motor encoder ppr must
be similar to the ratio of the metric wheel length and its encoder.
Supposing to have:
• avanza carriage advance 36 mm per revolution;
• motor encoder 1024 ppr;
SviluppoRuotaMetrica
pprRuotaMetrica = ⋅ ImpulsiGiroEncoderMotore
AvanzamentoCarroPerGiroMotore
Suppose the circumference of the metric wheel is to be written via fieldbus. This is possible using the free
words on the bus. The procedure is shown below.
1) In the MechanicalRel menu, note that MetricWheelDisp is parameter IPA 11132 and float format.
The float format of ADV200 is 32 bit.
2) In the /COMMUNICATION/FIELDBUS M->S menu select Fieldbus M->S4 IPA.
Assign the parameters as shown here:
Note:
For more details, please refer to Profibus card manual (cod.1S5F24_EXP-PDP-ADV_IT/EN) and ADV200 FP
manuals.
In this mode the drive operates in position control with destination position ToGoPositon.
The maximum destination value is +/- xxx mm.
The dimension must be between MaxPosition and MinPosition.
This state is invoked using the command MovePosCmd. To reach the MovePos state, at least one zero cycle
has been carried out (ZeroCycleStatus = 1)
This mode must be used in the Start up phase to check for correct mechanical relationships (mechanical
development mm/motor turns).
See paragraph 5.
5 11374 S_ShapedAcc Boolean On/Off Set the forward Set the forward acceleration
acceleration and and reverse deceleration with
reverse deceleration cycloidal shape
with cycloidal shape
17 12134 sysPosOkState Boolean T/F In MovePos mode The real movement may take
show the reference longer time.
reach the target
position
18 11014 Aux Int16 sector Aux field
18 11016 AuxSet0 Int16 mm Aux Set 0
18 11018 AuxSet1 Int16 mm Aux Set 1
18 11020 AuxSet10 Int16 mm Aux Set 10
18 11022 AuxSet11 Int16 mm Aux Set 11
18 11024 AuxSet12 Int16 mm Aux Set 12
18 11026 AuxSet13 Int16 mm Aux Set 13
18 11028 AuxSet14 Int16 mm Aux Set 14
18 11030 AuxSet15 Int16 mm Aux Set 15
18 11032 AuxSet16 Int16 mm Aux Set 16
18 11034 AuxSet17 Int16 mm Aux Set 17
18 11036 AuxSet18 Int16 mm Aux Set 18
18 11038 AuxSet19 Int16 mm Aux Set 19
18 11040 AuxSet2 Int16 mm Aux Set 2
18 11042 AuxSet20 Int16 mm Aux Set 20
18 11044 AuxSet21 Int16 mm Aux Set 21
18 11046 AuxSet22 Int16 mm Aux Set 22
18 11048 AuxSet23 Int16 mm Aux Set 23
18 11050 AuxSet24 Int16 mm Aux Set 24
18 11052 AuxSet25 Int16 mm Aux Set 25
18 11054 AuxSet3 Int16 mm Aux Set 3
18 11056 AuxSet4 Int16 mm Aux Set 4
18 11058 AuxSet5 Int16 mm Aux Set 5
18 11060 AuxSet6 Int16 mm Aux Set 6
18 11062 AuxSet7 Int16 mm Aux Set 7
18 11064 AuxSet8 Int16 mm Aux Set 8
Id Name
1 1-Application
2 2-Ramp
3 3-DriveStatus
4 4-Miscellaneous
5 5-MechRelations
6 6-FlyingShear
7 7-ShearState
8 8-Gains
9 9-MWControl
10 10-MWLimitTest
11 11-MWvsLineSpd
12 12-Commands
13 13-ZeroCycle
14 14-PosLimits
15 15-ImageToBus
16 16-ImageFromBus
17 17-Reserved
18 18-CamTable
1 1-Application
0 MainMenu
1044 MONITOR
1710 DRIVE INFO
1495 DRIVE CONFIG
1109 REFERENCES
1151 RAMPS
1815 MULTI REFERENCE
1816 MOTORPOTENTIOMETER
1817 JOG FUNCTION
1818 MONITOR FUNCTION
1183 COMMANDS
1129 DIGITAL INPUTS
1130 DIGITAL OUTPUTS
1128 ANALOG INPUTS
1088 ANALOG OUTPUTS
1058 MOTOR DATA
1160 ENCODER CONFIG
1819 SPEED REG GAINS
1198 REGULATOR PARAM
1820 TORQUE CONFIG
1528 VF PARAMETERS
1529 FUNCTIONS
1537 SPEED RATIO
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