Emerson PCM-22 User manual

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PCM-22 Rotary Knife
Controller Operators
Manual
Information furnished by EMERSON EMC is believed to be accurate
and reliable. However, no responsibility is assumed by EMERSON
EMC for its use. EMERSON EMC reserves the right to change the
design or operation of the equipment described herein and any
associated motion products without notice. EMERSON EMC also
assumes no responsibility for any errors that may appear in this
document. Information in document is subject to change without
notice. P/N 400274-01
Revision: A2
Date: 1/15/96

ii
Customer Services:
EMERSON EMC offers a wide range of services to support our
customers’ needs. Listed below are some examples of these services.
Service Support (612)-474-8833
Emerson Electronic Motion Control’s products are backed by a team
of professionals who will service your installation wherever it may
be. Our customer service center in Minneapolis Minnesota, is ready
to help you solve those occasional problems over the telephone.
Our customer service center is available 24 hours a day for
emergency service to help speed any problem solving. Also, all
hardware replacement parts, should they ever be needed, are
available through our customer service organization.
Need on-site help? Emerson EMC provides on-site service, in most
cases, the next day. Just call Emerson EMC’s customer service
center when on-site service or maintenance is required.
Training Services (612)-474-1116
Emerson EMC maintains a highly trained staff of instructors to
familiarize customers with Emerson EMC products and their
applications. A number of courses are offered, many of which can be
taught in your plant upon request.
Application Engineering
An experienced staff of factory application engineers provide
complete customer support for tough or complex applications. Our
engineers offer you a broad base of experience and knowledge of
electronic motion control applications.
EMERSON BBS [phone].
PCX Software updates can be obtained from the Emerson BBS. 300 -
9600 Baud, N, 8, 1.

iii
Table Of Contents
CUSTOMER SERVICES:...................................................................................II
Service Support (612)-474-8833 ..................................................................ii
Training Services (612)-474-1116 ...............................................................ii
Application Engineering..............................................................................ii
EMERSON BBS [phone].................................................................ii
TABLE OF CONTENTS...................................................................................III
Overview............................................................................................1
Features....................................................................................................... 1
THEORY OF OPERATION................................................................................2
PCM-22 Terminology.................................................................................. 3
Installing Your PCM Module .........................................................6
Input Wiring................................................................................................6
Output Wiring .............................................................................................7
SENSOR SETUP..............................................................................................7
Follower Sensor........................................................................................... 7
Master Sensor..............................................................................................7
Programming The PCM-22.............................................................8
MASTER AXIS DESCRIPTION........................................................................ 11
Master Axis Setup ..................................................................................... 12
MASTER CYCLES ........................................................................................ 16
Master Cycle Number................................................................................ 16
Master Cycle Length.................................................................................. 16
Master length upper limit .......................................................................... 17
Master length lower limit........................................................................... 17
Master phase distance................................................................................ 17
Master Cycle Defined by Sensor................................................................. 17
Cycle Length Averaging............................................................................ 17
FOLLOWER CYCLES .................................................................................... 19
Follower Cycles Screen.............................................................................. 20
Inputs/Outputs................................................................................25
INPUT FUNCTIONS....................................................................................... 25
OUTPUT FUNCTIONS.................................................................................... 34
Executing Follower Cycles...........................................................38
CREATING A MOTION PROGRAM................................................................. 39
Time Base (Indexes And Homes)............................................................... 41
Programming Functions............................................................................. 41
SUSPEND/RESUME FUNCTIONS..................................................................... 49
Encoder Operation.........................................................................52
MULTI AXIS SYNCHRONIZATION.................................................................. 53

PCXWin Operators Manual
1
Overview
This manual provides setup and programming information for the
PCM-22 Application Module. It is important that you become
familiar with the FX Drives manual (P/N 400282-00) which provides
the background information needed to setup and configure the FX
amplifier using PCX 6.X software.
The PCM-22 has the drive setup parameters stored in the PCM
module which allows it to be transferred to another FX amplifier (of
the same size) without losing your setup parameters. Firmware
updates are done on the PCM module eliminating the need to replace
EPROM's on the FX amplifier.
Features
Not all of the features available with the PCM-22 will be used in
every application. For example, there are 15 programming functions
available with the PCM-22, however, a typical rotary knife program
will use only a few of them. The features provided by the PCM-22
Rotary Knife Controller included:
•Programmed with easy-to-use PCX software.
•Allows an FX Drive to accurately position and match speed based
on data received from a master axis.
•Calculates cycle profile based on user defined parameters while
maintaining position and velocity.
•Parameters can be changed "on-the-fly".
•Two internal counters for each cycle: Product cycle counter and
product batch counter.
•Stores up to 16 cycle motion profiles in memory to be called up
for execution.
•93 user assignable I/O functions.
•Expands I/O line capacity of FX Drive with eight optically
isolated input lines and four optically isolated outputs.
•Stores parameters in non-volatile memory to allow the unit to be
moved to another FX Drive of the same size without losing data.
Firmware Revision
The firmware revision on a PCM-22 module necessary for all of the
programming features in this manual is A4 or higher. You can find
the revision number of your module by looking at the serial number
sticker located on the side of the module.

PCXWin Software
2
Theory Of Operation
The PCM-22 allows an FX Drive to monitor a product's position (with
respect to its motor position) and produce uniformly spaced cuts or
perforations on the product. The object of Rotary Knife Control is to
cause the follower axis (defined as the rotary knife) to produce one or
more cycles of motion for every cycle of motion produced by the
master axis (defined by an encoder).
Figure 1PCM-22 Rotary Knife System Example
Referring to Figure 1, in order to maintain proper synchronization
between the two axes, the FX Drive monitors the start points of both
the master and the follower axes. The follower axis will slightly
speed up or slow down as each registration mark passes a sensor. If
both the follower and the master axis are in sync, no speed correction
is made.
The PCM-22 can "learn" new parameters based on sensor
information which allows it to automatically compensate for new
product lengths on the fly. For example, if the distance between
registration marks on the master axis increases from 8.25" to 8.45",
the PCM-22 will adjust the follower axis parameters to compensate
for the increase.

PCXWin Operators Manual
3
PCM-22 Terminology
The terms used in PCX to define the system parameters and how the
knife (perforator or crimper) operates are described below.
•Working Segment Width: Referring to the motion profile below,
the cutting portion of the rotary knife profile is termed the
"Working Segment". During the working segment the blade is in
contact with the material that is being cut.
•Working Ratio: The Working Ratio defines how fast the blade
moves relative to the product when the cut is being applied.
Usually this ratio is close to 1:1. The "working segment" is a
length during which the Working Ratio is applied. Figure 2
shows a typical motion profile for a PCM-22 Rotary Knife
System.
Figure 2PCM-22 Motion Profile Example
•Variable Segment: The PCM-22 will automatically calculate the
motion profile needed for the remaining portion of the cycle in
order to be properly positioned for the next cut. This portion is
called the “Variable Segment”.
•Master Length: Referring to Figure 3, the Master Length, in user
units is the distance that the master axis (encoder or upstream
drive) moves during each master cycle.
•Follower Length: Referring to Figure 3, the Follower Length, in
user units, is the distance the follower axis (DX motor) moves
during each follower cycle.
•Working Segment Offset: The Working Segment Offset is the
distance that the follower sensor or zero point lags behind the
center of the working segment (cut point).
•Master Zero Point: The master zero point is defined by the
master sensor and is usually the leading edge of a product or a
registration mark.
The master length, follower length, their respective phase relationships
and offset positions and the working segment, can all be changed during

PCXWin Software
4
operation using inputs. The working ratio can also be adjusted using
PCX software or with serial commands.

PCXWin Operators Manual
5
When any of these parameters are changed, the PCM-22 calculates and
completes the profiles necessary to accommodate the new parameters.
Any changes made before the center of the working segment will take
place during the next cycle. During the working segment the working
ratio will always be maintained.
If parameters are entered that either cannot be accommodated within
one cycle or cannot be accommodated at all, the cycle limit reached
output (if assigned) will be activated until the limit has been solved.
Figure 3Rotary Knife System
•Master Phase Distance: The master phase distance parameter
(located in the Master Cycles screen) defines the distance from
the sensor to the center of the follower working segment (cut
point).
In Figure 3 the master phase distance may be greater than the
master length. If the cut point is on the registration mark, the exact
length from the master sensor to the master cut point may be
entered as master phase distance.
In this example the rotation of the rotary knife is counterclockwise and
the product movement is from left to right.
This parameter is critical to system operation and must be entered
properly. The remainder of the master phase distance divided by the
master length is the actual phase offset.
If you want the beginning of the master length at a position other
than at the beginning of the master length, you must factor in the
distance from the center of the working segment to this parameter.
Lengthen the sensor distance to move the center of the working
segment before the start point of the product; shorten the distance to
move the center of the working segment after the start point of the
product.