D

; . 2-J.

SPINDLE ORIENTATiON
by ENCODER
TYPE DL-AE
P

MAINTENANCE MANUAL
h

MITSUBISHI
ELECTRIC
c
 ----a-.-w CONTENTS ~~~~~~~

1. INTRODUCTI(-jN ______-_--_-_____-_----_____-_____-~~~~~~~~----

2.
l
SpECIFICATI(-jN ________-_---_--_-____________________________

3. COMPOSITION ____-________-____------------------------------

4. PRINCIPLE ~-~~~~_____----_-_--____________________~~~_~~~~--

5. INTERFACE ________---_--______--------_------_-_----_____---

6. APPEARANCE AND DIMENTEIONS

6.1 Card arrangement ---------------------------~------------- 7

6.2 gncorder outline dimensions -----~~--~~~~~-~~~------------ 8

7. INSTALLATION AND ADJUSTFNT

7.1 Instaration _-________--_--_--------~----~~~~~~~--~~-~~-~~ 9

7.2 Wiring __________-__----___-_-------_---------_~__-------_ 9

7.3 Setting befor making the circuit ------------------------- .+ 9

7.4 Test run ---_________________--~-----------~--~-----~-~~~~ 11

7.5 Adjustment --__________________~~~-~~~-~-~-~----------~~~- 11

a. CHECK TERMINALS/LEDs LIST ---_______________________________ 14

9. REPLACEMENT OF PARTS ------_---__-_--_----_------~---_~~~~-- 17

9.1 Removal of card

9.2 Adjustment at replacement of orient card

9.3 Replacement of encorder

10. TROUBLE-SHOOTING ~~---~~~~--~~_~~~~_____-_-__-------------_~ 19

11. ELEMENTARY DIAGRAM ___________________________-_____________ 22

c
 1. INTRODUCTION

This Instruction Manual describes optional card "DGAE" used for con-

trol of encoder type spindle orientation device.

.
2 SPECIFICATION

(1) Mechanical Specification

(a) Spindle speed: Max. 6000rpm

(b) Gear ranges: 3 speeds (HIGH, MID, LOW)

(c) Speed llH/Llf gear ratio: 3/l- 10/l

(d) Load GD" Shall be equivalent to or less

than the load to the motor.

(e) Backlash Max. 1.0' (converted into PLG shaft)

(Between PLG and mzr) It is desirous that backlash

is small enough to prevent occur-
rence of gear sound.

(2) Photoelectric rotary encoder

(a) Model: RFH-1024-22-l-68 (NIPPON KOGAKU

(b) Ambient temperature: o-5o"c

(c) Permissible thrust load: lkg

(d) Permissible radial load: l-kg
(e) Input shaft torque: Max. lkg-cm

(f) Inertia: 1.6 x lo-'kg cm.sec"

(g) Permissible speed: 6,OOOrpm

(h) Power source: Y&5%, Max. 250mA

(i) Coupling: Max. runout: O.O2mm, 0.03'

(3) Performance and accuracy

(a) In-position signal: iO.088' x (2 - 128)

(b) Positioning accuracy: +O.l" (depends on the lost motion

(Target value) of the machine)
 (c) Position&g time: Max. 3 sec. (depends on load GD2
and motor)

(d) Orientation speed: 50*30Orpm (At spindle)

(preset Low speed)

3. C O M P O S I T I O N

Controller
r----I
' Sequence

r- Ml9

I+
v106
/
i____1
Orient
(Option)
D L-AE I !-‘-’command ]
,Orient

Orient position command

I
((l&bit binary))
i_-_

Spindle

-2-
 4. PRINCIPLE

The following Time Chart shows the pattern of operation.

Speed depending on positioning

amlifier gain

Motor speed

Orient command
(ORCl-COM)
'
tip-to orient speed,

Reference

In-position output
(ORA1+XlA2)
-l-l-2OOmb

Time Chart

(1) When orient command is given, the motor speed changes to "orient

speed".

(2) When the motor speed reaches orient speed, the detection speed

level at which speed is detected by comparator steps up.

(3) When a mark pulse is given after the up-to orient speed steps

UP, the desired orient position signal delivered from external

source in 12-bit binary is read and at the same time counting

starts. The speed at this step of operation remains at the

orient speed.

(41 When the spindle reaches at approximately 90" before the resired

orient position, the control loop changes from "speed loop" to

"positioning loop" and the motor speed changes from the orient

c -3-
 speed to the speed that depends on the gain of the positioning

amplifier.

(5) The linear zone of positioning loop starts at about 11’ before

the orient position.

After that, the motor speed goes down and the motor stops at the

orient position.
i.
(6) k,f6regoing by setting
"IN POSITION" signal occurs at a positio

value of CSl from the orient position and "fN POSITION" signal

output contacts close in 200mS after the occurrence of the signal.

(7) When the orient command is canceled, the motor speed returns to

the speed specified by “S command". 3

(8) When the orient command is given again while the spindle is

under orient position, the orientation is realized in one turn of

the spindle. ” ~

However, depending on the desired orient position signal and the

setting of CS2, CS3 and CS4 for the position shift, the spindle

may rotate over one turn.

 NTERFACE

: TB4 in the diagram indicates the

Controller
re4(Note) Specification for the c&troller.

Orient command
'7
TB4
CTL "L" gear select
(Closes at low gear)
T04
C$lE#$ORLK)
"M" gear select
(Closes at medium gear)

30V DC
0.2A In-poisition,signal
ORA (String for customer use.)

1
CON4
I
PA

<181 I
<<c
(191
<<R

xP5l-l
LO1-03)
OH kK
1(20) y_________________Y
OG (Cable connector
MR-20LF not furnished)
c
CON5 (Same as CON 4) I
WTo NC
!
(For application to
c R-20L F
synchronous feed)
MR-20RhlA
i

-5-
 Controller
kient position data
CON6

(151 _\2048
12Ha MSB
. (16) _\1024
11Ha
foH-_cn
. (171 _\

_B,
09H -_EII

08H-_c=D
. ,(19> _ q,
15V DC
,GJO> u
5.6~~ 07H--c71 .. -

,d (2) - v
06H_r=a
- u,
05Ha-
04Ha I. -u,

03Ha . , -u,

02H-_I=o ,(6) - u
l

OlH-_cID a ,(7) -U’LSB

r Y __-___--_-____
(14)
OL
t
'Cable connector
MR-20LM
(Not furnished) ..

CON4,5
Pill arrangement

CON6

Pin sr&ngement

-6-

I
 6. A P P E A R A N C E A N D D I M E N S I O N S -
In-position range
6.1 Card Arrangement setting switch
I
Orient direction In-position range Orient position
setting pin setting jumper shift switch
/ I / /

DL-AE
Orient speed
setting

Counter
Gain setting contents
display
LED

Offset .
adjustment

I- Test
pushbutton,
. .
Operation
Test mode
status
,display LEC display
LED
f Test mode -
settingpin

f-- .
. I

5V
I
supply jumper
ficoder/m\otor running
direction setting

Size: 180 x 280 x 25

Weight: About 3OOg
c -7-
6.2 Encoder outline dimensions

Key way dimension

CANNON connector
MS3102A20-29P
Output terminal arrangement MS3106A20-29s

MS3057-12A
(Cable connc>ctor is not
furnished)

'[Reversktg signal
 7. INSTALLATION AND ADJUSTMENT

7.1 Installation

Install the encoder to the machine using care not to exert large

force to the shaft.

\

7.2 Wiring

Since the encoder outputs faint signal that is liable to catch ex-

ternal noises, use twisted and shielded wires for wiring of the en-

coder. The wires should be laid down remotely from the high

voltage circuits, and not extend over 20m.

The orient position signal is also faint signal. Be sure to use

a bound, shielded cable not extending over 5m for wiring of the signal,,

7.3 Setting before making the circuit

Item Symbol of Selec- Description

device tion

Orient PIN 1 LCK Orientation is always in the direction

direction preset by PIN 2.
PRI Orientation is in the direction in which
motor ran before orientation is commanded

PIN 2 ccw Orientation starts in counter-clockwise

direction of the motor.
cw Orientation starts in clockwise direction
of the motor.

Direction of PIN 4 FWD The motor runs in the same direction as does
rotation of the encoder.
encoder REV The motor runs in reverse direction to the
rotation of the encoder.
"If the rotation of the encoder is reversed,
spindle rattles largely and cannot stop.

Range of
IN-POSITION CS 1 0 IN-POSITION within 2 pulses
1 IN-POSITION within 4 pulses
2 IN-POSITION within 6 pulses
3 IN-POSITION within 8 pulses

c -9-
 Symbol Selec- Description
Item of device tion
Range of cs 1 4 IN-POSITION within 10 pulses
IN-POSITION 12 pulses
5
6 14 pulses
7 16 pulses
8 \ 18 pulses
9 20 pulses
A 22 pulses
B 24 pulses
cf.
C 26 pulses
0.088"fpulse
D 28 pulses
E 30 pulses
F 32 pulses
F 64 pulses However, jumper is discon-
nected between G and G.
F 128 pulses However, jumper is discon-
nected between H and H
Jumper G-G may be connected,
or disconnected.

Encoder Jumper Discon- Since the standard model has no incorporated

power supply S-S nect 5V DC source, use the power supply from the
N/C.
For special model equipped with 5V DC supply,
a jumper is provided.
When power supply from the NC is used, dis-
connect the jumper.

- 10 -
 7.4 Test Run

I Note: B e f o r e s t a r t i n g t h e a d j u s t m e n t , m a k e sure all settings are in

compliance with the instruction “ADJUSTMENT DATA”.

Step Item Symbol of Setting escription

device 9

1 R EADY (PRQARA- PIN 3 TEST Remove PIN 3 from DRIVE and then
TION) set into TEST before the line
power supply is given.

2 POWER ON LED 16 Red LED denoting "TEST" mode will

light.

'; ORIENT PB 1 When PBl is depressed after the

machine sequence is set up for
operation, orientation (operation
,- at orient speed) starts.
When PBl is released, orient po-
sitioning takes place.

4 RESET PIN 3 DRIVE Turn off the power source end

return PIN3 to DRIVE position.

5 VERIFICATION LED 16 Turn on the line power supply and

make sure that red LED "TEST" not
does not light.
1
c
7.5 Adjustment
Symbol of
S tep Item Description
device

1 "HIGH" range VRl Start the orientation and adjust VRl so

Orient speed that the spindle stops smoothly and rapidly
as shown by the graph below.

If VRl is turned in --* excessively,

the spindle will stop with overrun.
NSA
f If VRl is turned in ' .L excessively,
time taken for positioning (orient posi-
tion) delays.
Orient----
speed
c -t
I
2'
Overrun

- 11 -

-
 Symbol of
tep Item device
Description

2 "H" range. +t This variable resistor will have been set

Gain adjust- ‘JR4
ment by manufacturer.

3: After VR4 is turned, be sure to perform

the following of set adjustment:
'\
Hunting occurs making impossible orient
stop if VR4 is turned in fl direction
excessively. If VR4 is turned in n
direction excessivly, servo lock torque
decreases and stopping accuracy will worsen

Set VR4 at a position about one grade

turned in n direction where overrun or
hunting is about to occur.

3 "H" range. VR7 By depressing 'TEST pushbutton or entering

Offset Ml9 in MD1 repeatedly, adjust VR7 so that
adjustment LEDs 1 - 8 all light and go out.
Orient positioning display Position error corresponding to 1 pulse occur:
LED1 0 0 LED1
from lighting to going out of the LEDs.
LED2 0 0 LED2
LED3 0 . LED3 Therefore, the offset adjustment with MO3
LED4 0 or . LED4
LED5 0 . LED5 command is not correspondingly applicable
LED6 0 . LED6
LED7 0 0 LED7 to M04.
LED8 0 . LED8
. . . Lights.
z **-Does not light.

4 "Medium" range Shift the spindle gears to "Medium" position

VR2 and se-b the potes in the same manner as for

Orient speed
"H" range. This range is not provided in
Gain VR5
two gear range ("H"/"L") machine.
Offset VR8

5 "Low" range Shift the spindle gears to 'lLOW't position

ad set the potes in the same manner as for
Orient speed VR3
VR6 "H" range.
G&l
Offset VR9

- 12 -

I
 h

Symbol of Description
Step Item device
6 Orient position Orientation occurs at 'IL" range speed.
shift
Error from comm ded (specified) posi-
tion should be Ta justed by CS2, 3 and
4.
cs 2 . . . . 256 pulses/notch (22.5'/notch)
cs 3 . . . . 16 pulses/notch ( l.A'/notch)
cs 4 .... 1 pulse/notch (O.OSS'/notch)
When CS 2, 3 or 4 is turned under orient
control, the spindle turns correspondingly,

_-

c‘ .

c
8. C H E C K TERMINACS/LEDs LIST
Check ter- Function Standard value or wave form Remskrs
Symbol minal No.

ORAl CHl In-position Closes at corn letion

contact r*ac\ 1
ORA CH2 'L_*CH2
LNZ CH3 Linear zone tl5V within ill0 from the orient
position
OV at other position .I
POS CH4 Positioning At stop of orientation
amplifier 0~ i2OmV
output

DRP CH.5 D/A conver- (1) During usual continuous operation, the
ter output output varies +30% at +sV.

q-+_:q

(2) At stop of orientation

0 - +25OmV
(3) Position loop gain can be obtained from,

Gp=510* CH4 Voltage (SW

-1 )
CH5 Voltage *KG
o Read voltages at CH4 and CH5 when
voltage at CH5 is within a range from
0.3 to 0.7V.
o KG is gear ratio (Spindle gear/Motor
gear)

RI CH6 Speed COII+ (1) At usual operation

mand vol- +lOV/Max. speed
tage
(2) The voltage is same as at CH4 when the
spindle stops (orient stop).

P CH7 count
pulse
Jygi-3 2.5 rus

- 14 -
 l-
Check ter- Standard value or wave form Remarks
Symbol Function I
minal No.

U/D CH8 Pulse of addi- OV at subtraction

tion
At addition wlT[
about
. 5/(s
r-
READ CH9 Data reading (1) Pulse generates at
reading

(2) Short-circuit across the following

terminals to make possible data read-
ing for checking of D/A converter
characteristics.
CH3 - CHll
I CH9 - CHll
cs3 cs4 LED D/AUUtput
When CS3, CS4 112 13 I 4 1 5 1 6 17 18 cCH5)<v
sre changed 0 0 l lololololo~o~~’ Oc)
g
with CON 6
disconnected,
the indication 6 1 F
I I I
changes as 7 1 A
listed to the
right.
l : LED does
not light.
o: LED lights .

CP CHlO Clock pulse

P15 CHll t15v DC supply

c‘
N15 CH12 -15V DC suPPly

COM CH13 OV Common line

I I
P5 CH14 t5V DC supply 4-5~0.5V To make encoder
c for encorder compatible with
the NC, discon-
nect jumper JP3
(S-S) andob-
tain 5V source
from the NC.
c
-
- 15 -

I
8.2 LEDs
‘* .I

Symbol LED No. Function Description ,

LED 1 Counter contents Conunecontents are displayed in

t ,
8 bits.
LED 8 -.
ZED 8 is a sign bit.
’ ,
For details, refer to the previous page.
*
IN-POS LED 9 In-position The LED lights at the same time when
orientation ansel-back signal is output.

SERV.IN LED 10 Servo In The LED lights while the position servo
loop is formed.
The LED starts lighting at 90' before
crient position.

ORIENT LED 11 Orient command The LED lights when orient command is
input.

M. GEAR LED 12 "M" gear selection The LED lights when M range is selected
for spindle speed and its signal is given.

L. GEAR LED'13 "L" gear selection The LED lights when L range is selected
for spindle speed and its signal is given.

PULSLA LED 14 Encoder "A"-phase The LED lights when A phase pulse signal
pulse is output from the encoder.
,
PULSE-B LED 15 Encoder "B"-phase The LED lights when B phase pulse signal
pulse is output from the encoder.

TEST LED 16 Orientation test The LED lights when the short pin is
/
set to "TEST". ?’ ‘4

I For usual operation, set the short pin“:

‘,‘,
in "DRIVE" position.
;:
,.I I, ’
c
.I
‘4
‘I 4,

“4
,!C

- 16 -
 .,

9. REPLACEMENT OF PARTS

9.1 Removal of Card \

The orient card is installed to card spacer

Card as shown to the left.

Press down the lugs at the top of the spacer

by pliers and remove the card

9.2 Adjustment at replacement of orient card

(a) There are two types of card, namely, DL-AE (without 5V power sup

ply) and DGAEl (with 5V power supply).

Identify the type before replacement.

(b) Set the VRs, short pin, jumper wire and select svitches as they

are set on the previous card.

(c) Perform orientation at each gear range and make offset adjust-

ment. (See para. 7.4.)

(d) Repeat orientation with command MO3 and MO.4 and adjust the orient

speed, gain and offset so that smooth orientation is assured. .

i\ (See para. 7.4.)

9.3 I Replacement of encoder

For encoder, use that of balance (Deferential signal) type, 1024P/rev.

ep1ac.e the encoder using care not to exert excess force to the

c' coder, shaft and body .

' I (c) Perform orientation and adjust the position by CS2, 3 and 4.
8 (In the case of machining center)
‘*
c , * Remove the drive key from the spindle, perform tool
,
i,’
change (Mob) and set Cs2 - 4 so that the key slot is
i 1

- 17 -

_ ~_~_ .-
 properly positioned.
Since backlash in gearing mechanism, runout of tool change
arm and structural deflection affect positioning accuracy,
repeat orientation in CW and CCW directions(M03, M04) and
repeatedly change tools to properly position the key
slot.

(In the case of lathe)

Perform orientation and adjust CS2 - 4 to establish the
orient position.
Since backlash in gearing mechanism affect positioning ac-
curacy, perform orientation in CW and CCW directions to
set CS2 - 4 SO that the orient position comes to the
center CT the range of backlash.
 10. T R O U B L E S H O O T I N G

10.1 Appearance
Visually check:
- Appearance
- Parts for damage
_ If forein matter is found
- Connectors for looseness

10.2 DC supply voltage

Measure the following voltages using a DC voltmeter:
- CH14 . . . . . +5v+10%

.- - CHll . . . . . +14.5@3.5v

- CH12 . . . . . -14.5QO.5V
For common terminal, CH13 is used in this measurement.

10.3 Troubleshooting

(1) Motor operation does not change although orient command (M19,
M06, etc.) is given (orientation is impossible).
c
Cause Remedy
Orient command signal is not If LEDlldoes not light, signal is not
given to the card. received. ’ Remedy so that command
signal is produced.

(2) When orient command signal is given, the motor continuously runs
at a-orient speed of about 200rpm.

Cause Remedy

1. Pulse signal from the en- When pulse is input, all LEDs 14 and
c coder is not output. 15 on the card light during rotation
of the spindle.

- 19 -
 Note: When speed amplifier gain control VRL+, VR5 or VR6 (VRll, VR12

for DL-SDZ) turns, be sure to make offset adjustment.

(5) Orientation occurs in correct position, but IN-POSITION signsl

is not output...
,-

Cause Remedy

Offset is out of adjust- Perform offset adjustment.

ment.

(6) When ATC arm clamps tool, In-position signal goes out causing

stop to the ATC action.

Cause Remedy
c
1. Because offset is out of - Perform offset adjustment.
adjustment, position moves
- Check if the ATC arm is displaced.
when tool is clamped,
canceling IN-POSITION sig-
c nal.

2. Because orient position is - Perform orient position adjustment.

out of adjustment, position
I- - Check if the spindle is distorted
moves when tool is clamped,
canceling IN-POSITION sig- by collet chuck at unclamping.

nal.

- 21 -
0

I
 4 r,
.

I
I 1 I 2 I 3 I 4 I 5 I 6 I 7 I 8

DP

Eli

CONS-2

e
 /
f P
P
_-
I_
- 24 - D L - A E 3/4