The Basics of ASiM

TM410

Introduction

Requirements

Training modules:

TM210 The Basics of Automation Studio TM400 The Basics of Drive Technology

Software:

Automation Studio 3 or higher

Har dware:

B&R drive system (controller, netwo rk, ACOPOS, B&R motor)

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Introduction

Table of contents 1. INTRODUCTION 1.1 Training guide objectives 2. DRIVE DESIGN 2.1 Drive hardware 2.2 Software concept 3. THE FIRST PROJECT 4. DRIVE CONFIGURATION SECTIONS 4.1 Configuration modules 4.2 Motion system settings 5. INITIAL STARTUP AND DIAGNOSTICS ENVIRONMENT 5.1 5.2 5.3 5.4 5.5 Com mand interface Param eter management Display of axis information Trace function Checklist for initial startup 4 5 6 7 10 13 15 16 22 23 27 30 32 35 41 44 44 44 45

6. SIMULATION OPTIONS 6.1 Axis simulation 6.2 Motor simulation 7. SUMMARY

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Introduction

1.

INTRODUCTION The B&R drive concept is fully integrated in Automa tion Studio. The result is a simple and uniform tool for develop ing projects as well as implementing control and po sitioning tasks. This training module explains step-b y-step how to create a drive configuration in an Automation Studio project. It then provides detailed descriptions of comp onen ts that can be use d to ma nag e 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.

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1.1

Training guide objectives You will learn how to se t 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 pa ram eter s for servo drives Use motion diagnostic tools Simulate a ser vo drive

Fig. 2: Overview

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Drive design

2.

DRIVE DESIGN The following section deals with the system architecture of the B&R drive sol ution. Our goal is to establish a basic understanding of the pr ocedures 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 comp onents must be correctly app lied to the different configurations. Thes e settings are made using Automation Studio. Software generation: For controlling the drive and implementing the positioning sequences using an app lication pr ogram. For the B&R drive solution, the software is gener ated using the PLCopen motion control library. Diagnostic and testin g tools: Automation Studio and the System Diagnostics Manag er provide the user with a variety of diagnostic and testing possibilities. Processes (e.g. positioning) can be acc urately adjusted and values can be recorded for analysis. Simulation of motors and servo drives is supported by Automation Studio. The comp onents required for a drive configuration are shown in the figure abo ve. In ord er to unde rstand how this work s, we will first take a closer look at the individual components and then the shared interfaces.

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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. Com munication between the controller and the drives take s place either via X2X or POWERLINK.

Fig. 4: Hardw are 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 method s and po wer regeneration via regeneration choke. ACOPOSmulti SafeMC Also offers expanded safety fun ctions in add ition to the system properties of the ACOPOSmulti series (e.g. Safely Limited Spee d) ACOPOSmicro Ideal application in the lowest power range s for servo and steppe r motor app lications. ACOPOSinverter Broad performance range for cost-effective applications without po sitioning tasks.

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Drive design

X20 / X67 SM Step per motors Up to two step per motors can be op erated using a single module from the X20 or X67 series. MM Motor bridge modules Up to four DC motors can be oper ated 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 manu als.

Drives use two type s of internal parameters: Parameters for the hardware configuration The se rvo drive must be configured according to the conne cted hardware: Characteristics of the motor and holding brake (if present) Plug-in cards (encoder and network cards) Parameters for positioning sequences The se rvo drive pr oces ses parameters that are used to control and check positioning sequences: Mo vement parameters, commands and status values Monitor functions We will take a closer look at the process es in the ser vo drive in the section "Software concept".

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Drive design

Control and communication The drive is oper ated with the help of parameters. Data is exc hanged 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 op erating system on the ser vo drive.

Fig. 5S : Drive control and communication

There are two types of data to be exchanged: Parameter data and commands are sen t from the controller to the ser vo drive. Status data is sent from the servo drive to controller. The system provides global struct ure for op erating and setting the parameters for the respective drive. Com mands are sent to the NC Manager using simple fun ctions. The NC Manager then communicates with the NC operating system to execute the respective actions.

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Drive design

2.2

Software concept The software concept is extremely simple because it works the sa me way for all types of drive technology. The application specifies set values, which are then forwarded to the configured hardware via selected fun ction types. NC objects are created for motion control, CNC and rob otics.

Fig. 6: Software concept

These objects are access ed via a global operating structure. The following objects are available: Real axis Virtual axis CNC system Robotics These objects are manag ed via the NC Manager. It transfers the control commands and their define d parameters from the object to the corresponding drive. It also ens ures that the corresponding status values are returned to the structure of the respective object. The flexibility of the software concept mak es it possible to use the sa me app lication for different drive types.

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Real axis This NC object is us ed to ope rate a real drive with a motor and a position encoder.

Virtual axis In addition to the real axes, ACOPOS also offers the option of op erating a virtual drive. This drive works solely as a type of "set value generator" (i.e. generates values for position and spee d) and is operated identically to a real axis. It can be use d for various app lications such as linking a real axis to the position of a virtual axis.

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Drive design

CNC system A CNC system is an application in which multiple ax es are linked with each other and perform defined movements. The CNC sy stem handles the man age ment and coordination of the individual CNC axes.

Robotics A rob otics system is an application in which multiple axes are linked with each other and perform defined movem ents. Unlike a CNC system however a rob otics system is base d on kinematics.

The operating struct ure for NC objects differs according to the type of app lication in which they are used. For example, a virtual axis requires fewer op erating parameters than a real axis because it doe s not have encode r or control parameters.
Automation Studio Help: Motion / Reference manual / ACP10 / NC objects

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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 tes t 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

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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 ap plication

Note: The "Getting Started" examples can also be accessed directly via the Automation Studio Help system.

Automation Studio Help: Automation Software / Getting Started

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Drive configuration sections

4.

DRIVE CONFIGURATION SECTIONS A variety of settings and pa rameters are required for a drive configuration. These are managed via hardware-independent access. This pre vents any limitations from occ urring due to the drive technology being used. For example, this means that replacing a ser vo drive with a stepp er motor will not cause any prob lems. The drive configuration consists of the following components: Configuration modules Motion system settings

Fig. 8: Drive configuration components

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Drive configuration sections

4.1

Configuration modules The modules created when add ing 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 nam e and is specified by the user . It is used for linking betwe en the app lication and the physical drive. Each drive can be assigned an NC Init module and an ACOPOS parameter table via the NC mapping table.

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Drive configuration sections

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

Fig. 10: Opening the NC mapping table

Automation Studio Help: Motion / Configuration / Motion Control / Configuration modu les / NC mapping table

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Drive configuration sections

NC Init module The NC Init module contains basic axis para meters 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 wh er e the initialization para meter s can be changed.

Fig. 11: NC Init module

Automation Studio Help: Motion / Configuration / Motion Control / Configuration modu les / NC Init module

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ACOPOS parameter table Unlike the NC Init mod ule, specific axis par ameters are defined in the ACOPOS parameter table. This can be started by double-clicking on the ACOPOS param eter table in the Logical View (".apt" file extension).

Fig. 12: ACOPOS parameter tab le

Automation Studio Help: Motion / Configuration / Motion Control / Configuration modu les / ACOPOS parameter table

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Drive configuration sections

Task: Searching parameter IDs (ParIDs) Use Automation Studio Help to search ParIDs for the following parameters: Temperature of the temp erature sensor (current motor temperature) Motor torque (current torque) DC bus voltage Cooler temp erature - Temp erature sensor on the po wer element

Procedure: Start the Automation Studio Help system Select the Motion folder from the Help system Select the hot spot "Parameter IDs Drive Fun ctions"

Search required parameters

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NC Error Text module The NC Error Text mod ule contains the text groups for the drive, which mak es it possible to ge nerate clear text error message s. When using the Motion Wizard, the nam e and language must first be specified. This can be started by double-clicking on the NC Error Text mod ule in the Logical View (".ett " file extension).
Automation Studio Help: Motion / Configuration / Motion Control / Configuration modu les / NC Error Text module

NC Manager configuration / NC configuration The NC Manager is configured using the NC Manage r configuration. These settings are se parate from the actual hardware. For more information on this, please see the section "Motion system setting s".

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Drive configuration sections

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 Manage r. For example, the user can define the buffer size for the network comm and trace or the restart behavior of the drive.

Fig. 14: Motion system settings

Note: Com munication 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 commun ication should be re-established automatically.

Automation Studio Help: Motion / Configuration / Motion Control / Configuration modu les / NC Manager configuration

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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 app lication. This involves the following sections SDM System Diagnostics Manager NC Test Possibilities: Send comm ands Access the drive's parameters Display status parameters Record real-time data on the network

Add itionally, 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 spe ed or limit switch po sitions. This can be acces sed using a standar d web browser. Other fun ctions are also provided such as starting a trace recording and then uploading the resulting data or the network comm and trace. Note: Automation Studio Version 3.0.90 or higher is required in order to use the specific SDM fun ctions for motion.

Automation Studio Help: Di agnosti cs and service / System Diagnostics Manager

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Initial Startup and diagnostics environment

NC Test Unlike the SDM, Automation Studio is required for the NC Test environment. A number of fun ctions and pa ram eter s are included that are used for startup and diagnostics. These include: Com mand interface Parameter man age ment 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.

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Openi ng NC Test The mapping table is opened by double-clicking on the ACOPOS instance in the hardwar e tree. The NC Test can be op ened by right-clicking on the corresponding axis object in the mapping table and selecting Test.

Fig. 16: Opening NC Test

The following dialog box ap pears when the Test window is op ened:

Fig. 17: NC Test mode

The user can decide whether the NC Test should access the axis parallel or exclusively. In exclusive mo de, the app lication com mands are not forwarded to the axis. Instead, operation take s place exclusively via the NC Test.

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Initial Startup and diagnostics environment

NC Test wi ndow appearance The NC Test consists of the following four sections: Command interface (1) Param eter windo w (2) NC watch (3) NC trace (4)

Fig. 18: NC Test window structure

If the NC Test window is closed during an active movem en t, then the user must choose whether the movement should be stopp ed or not.
Automation Studio Help: Motion / Diagnostics / NC Test

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5.1

Command interface The comm and interface is used for controlling an axis.

Fig. 19: Comm and interface

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

The comm and interface is divided into the following sections: Preparation Basis movement Limits Service interface Motor simulation Setup

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Initial Startup and diagnostics environment

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" comm and. A basis movement can then be executed. The "Initialize" comma nd can be used if pa ram eter s 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 wh er e the parameters are located and how to change them.

Basis movement After being prep are d, the drive is then read y to perform basis movements. These are the moveme nt procedures that can be implemented in an app lication using PLCopen fun ction blocks. They are performed by selecting the corresponding movement. Note: A detailed description of the movement procedures can be found in the respective PLCopen fun ction blocks. The "Positive" and "Negative" mo vements 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 rea d ("Read drive parameters") or write ("Write drive parameters") individual parameters from the drive. Some examples include: Motor temperature, torque limitation, etc.

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Limits The comm and "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 param eters can be man age d and changed.

Motor simulation Simulation for a motor can be enabled using "Switch on" in the even t that a mo tor 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 fun ction is no longer nee ded.

Setup The Setup area is used for tuning a motor.

Task: Read ParIDs Determine the following drive param eters: Motor ambient temperature Actual po sition

Procedure: Search ParIDs in the Automation Studio Help system Read-out values using the Watch window Results The values of the specified ParIDs wer e determined right on the drive.

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Initial Startup and diagnostics environment

5.2

Parameter management The drive par ameter s are managed in the par ameter windo w.

Fig. 20: Parameter windo w

The param eter struct ure contains param eters for the INIT parameter module.

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Values that are change d manually are compa red 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 the INIT parameter module (individually for each group of parameters) using the menu command Test / Save Parameter Group. A dialog box ap pears whe n exiting the NC Test if there is no explicit mem ory command. This is where the user can choos e whether or not the changed INIT values will be saved in the INIT pa rameter module.

Fig. 22: Exiting the NC Test

Automation Studio Help:Diagnostics \ NC Test \ Parameter window

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Initial Startup and diagnostics environment

5.3

Display of axis information The NC Watch shows the user the current status of an NC object. The NC Watch wi ndow 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 op ening the NC Test, Sele ction: Watch).

Automation Studio Help: Di agnosti cs \ NC Test \ NC Watch

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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 app ears as follows:

Fig. 25 : Watch: Prob lem with the communication

After the connection has been established success fully and the drive has been prepar ed, the object states appear as follows:

Fig. 26 : Watch: Status icons

The traffic light icon (far right) is use d for switching to and from the NC Watch window. This is neede d 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 ap pears below the icons.

Fig. 27: Error text

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Initial Startup and diagnostics environment

The button in the Watch command area can be used to acknowledge pending errors. Multiple er rors caused simultaneously by an action will be acknowledged in order.
Automation Studio Help: Di agnosti cs \ 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 comm and Fig. 29: Selecting the comm and

The desired elements are selected from the NC object operating struct ure subgr oups in the corresponding dialog box. The selected entries are then adde d to the NC Watch. In general: The list of the pa rameters displayed in the parameter windo w is saved (without the par ameter values) wh en the NC Watch windo w is closed. This list is restored the next time the NC Watch is opened.

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5.4

Trace function The target system provides two different trace fun ctions. One is the NC Trace, which mak es it possible to record real-time data right on the drive. The other is the netwo rk comm and trace, which can be used to log com mands at the network level.

5.4.1 NC Trace Real-time data is record ed directly on the drive. The recor ded data is loaded to Automation Studio from the ACOPOS device via the PLC and displayed graphically. Among other thing s, the trace provides the followi ng 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 parame ter trace

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Initial Startup and diagnostics environment

A numb er of different tools can be used for detailed analysis of the data. Note: Like NC Watch, the Trace fun ction can be ope rated independent of the NC tes t 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 by right-clicking in the NC Trace window and selecting "Save Chart Data".

Fig. 31: Saving trac e data

Automation Studio Help: Motion \ Diagnostics \ NC Trace

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5.4.2 Ne twork command trace The netwo rk 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 recorde d entries.

Fig. 32: Ne twork comm and trace

Amo ng other things, this fun ction can help check the ord er in which commands will be sen t by the tasks to the PLC. The procedure is traceable and any errors that might occ ur can be found quickly and easily. The netwo rk com mand trace is an expansion of the NC Trace and is therefore also opened in the trace environment. The netwo rk com mand trace is op ened 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 co mm and trace

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Initial Startup and diagnostics environment

The netwo rk com mand 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, rightclicking and select Load Data from Target.

Fig. 34: Loading the records

The netwo rk com mand trace shows a list of entries. These entries provide information about the pa rameters 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 netwo rk comm and trace

More detailed information can be found in the Automation Studio Help do cumentation.
Automation Studio Help: Motion \ Diagnostics \ Network Command Trace

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Task: Record lag errors using the trace function Set up a recording for an additive mo vement using NC Trace. Determine the average spee d 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 sp eed / set spee d Lag error Start recording Execute additive movement After finishing the recording, se t the measure ment cursors for the current sp eed 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 betwe en the measurement curso rs by making a simple cha nge to the chart properties.

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Initial Startup and diagnostics environment

Task: Recording the deceleration ramp Use a trigger to start recording the deceleration ramp. The following parameters must be recorded: Actual sp eed / set spee d Lag error The trigger should have the following conditions: Set spe ed is within the range v_max and v_max 10% Com mand 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.

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5.5

Checklist for initial startup This section provides step -by-step instructions for starting up a hardware configuration with drives. The following points need s to be taken into account: Safety It is particularly important to test the safety features. This includes the 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.

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Initial Startup and diagnostics environment

Jolt time The use of a jolt time is recom mende d to pre vent placing unnecessary load on the mechanical compo nents. This is set up using the param eter t_jolt.

Tuning Tuning is ne cessary in orde r 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 wa ys to do this.

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

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

Task: Startup parameters Change the following param eter s and check their functionality. Parameters: Jolt time (t_jolt) Lag error Direction of motor rotation (coun t_dir)

Procedure: Find and change the pa ram eter s in the parameter window Save and transfer the changed values Initialize the servo drive Start mo vement and trace Evaluate trace data Results The mo tor rotates in the opposite direction. The jolt time as well as the lag error were changed.

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Simulation options

6.

SIMULATION OPTIONS Automation Studio supports two types of software simulation.

6.1

Axis simulation If the "PC-based software simulation" is use d as a controller, then axes can be adde d and configured for this configuration. This is done by right-clicking on Slot MO1 in the Physical View and selecting "Insert". A dialog box ap pears indicating where the MotionIF is selected. To insert an axis, open the MotionIF and select the SimACOPOS by rightclicking and choosing "Insert". The sam e 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 fun ctionality 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 windo w using the comm and interface under "Motor Simulation". The comm and "switch on" is use d to start and "switch off" to stop the simulation.

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Summary

7.

SUMMARY Drives are manage d and configured centrally in Automation Studio. The NC Manager uses the controller to comm unicate with the NC operating system on the ser vo drive over an entire network. The NC Manager is the contact point for controlling the drives. It handles the transfer of param eter s and commands to the drive as well as the status information upd ates 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.

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