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.

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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

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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.

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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.

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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

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

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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.

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Installing Your PCM Module
PCM modules attach to the front of any FX Amplifier with two
locking arms. All electrical connections (except I/O) are made via the
48 pin connector.
All PCM modules are equipped with 8 input lines and 4 output lines,
doubling the I/O capability of the standard FX drive. All inputs and
outputs are optically isolated for +10.5 to +30 vdc operation. Each
input and output line has 2 screw terminals associated with it to
provide for either current sinking or current sourcing operation.
The first 8 pairs of terminals (numbered 13 - 20) are inputs and the
last 4 pairs of terminals (numbered 21 - 24) are outputs. The outputs
are capable of sinking or sourcing 200 mA. You must limit the output
current to less than or equal to 200 mA per line.
Figure 4Installing Your PCM Module
Input Wiring
Inputs require an external voltage source for operation. This voltage
source must be in the range of 10.5 to 30 VDC. The negative (-) lead
of the external power supply must be connected to the enclosure or
safety ground.

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Output Wiring
Outputs are similar to inputs in that they can be connected to either
sinking or sourcing type loads. Outputs require an external isolated
supply voltage, usually the same supply as the inputs. Each output
can sink or source 0.2 amps DC. The negative (-) lead of the external
power supply must be connected to enclosure or safety ground.
If inductive loads such as DC relay coils are connected to the
outputs, a suppression diode must be installed in parallel with the
load coil with its cathode towards the positive end of the external
supply.
Sensor Setup
In a typical rotary knife system the rotary knife will be designated as
the follower axis and the product or material conveyor as the master
axis. A sensor on the knife (or follower axis) can be used if the exact
position of the blade changes due to mechanical configuration of the
system.
Master and follower axes sensors must use FX Drive high speed
inputs 1 and 2 only. Input functions number 45 and 46 (Zero Master
Cycle and Zero Follower Cycle respectively) must be setup to operate
with the appropriate sensors (see Input Functions ) on input lines 1
and 2.
Follower Sensor
In most applications a follower sensor should be used to prevent the
working segment and other parameters from drifting away from it's
desired position due to accumulated length error. When entering
data in the PCX software, certain values such as follower length can
be rounded off which will cause the follower's position to drift over
time. Maintaining follower position is critical in most applications.
The follower zero point must be established after initial power-up by
executing a home cycle that will bring the knife into it's zero position
or by applying a signal to the zero follower cycle input when the
rotary knife is in it's proper zero position. The center of the working
segment is also established at this time.
Master Sensor
In most applications a master axis sensor is critical to maintaining
product registration. Like the follower axis, the master's position
could also drift over time due to accumulated length error. The
master axis sensor can be eliminated in applications where the
number of external encoder steps in the Master Cycle Length is
repeatable. This would mean that there is no product stretch or
shrinkage or slip over time.
Whether the master axis is defined by a sensor or not, it must be
"zeroed" at least once. The zero point can be established anytime by
placing the master in its proper zero position and then applying a
signal to the Zero Master Cycle input. No follower cycle motion will
begin until the master is zeroed.

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Programming The PCM-22
The first step in programming your FX Drive with a PCM-22 is to
configure the drive using the 5 menu options in the Drive
Configuration screen. The Drive Parameters, Limits, Inputs and
Outputs screens are explained in the PCX section of the FX manual
(P/N 400282-00).
The Master Axis screen is where you identify the Signal Source of
the master axis and setup synchronization parameters.
The next step is to define the motion parameters in the Define
Motion screen. The first three menu selections, Jog, Home and
Index, are explained in the PCX section of the FX manual (P/N
400282-00).
The next two selections, Master Cycles and Follower Cycles, define
the relationship between the master and follower axes.
The last step is to Create a program (or programs) that use the "Y"
command (Execute Follower Cycle) with other programming
functions as logical steps within a program.
The menu hierarchy charts on the following pages show, in the
darker boxes, the menus that are added or changed in PCX 6.X
software when a PCM-22 module is employed with an FX Drive.

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Figure 5PCX Hierarchy Diagram #1

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Figure 6PCX Hierarchy Diagram #2
The PCX features necessary to run a Cycle Profile are listed below in
the order in which they should be addressed. Each feature listed
must be set up before you can use them in a Cycle Profile
application.
Individual setup information for each feature is covered on the
following pages.
1. Drive Parameters: The first step in setting up the PCM-22 is to
define the parameters in the Drive Parameters screen. A
description of the parameters in this screen can be found in the
PCX section of the FX Drives manual (P/N 400282-00). The Drive
Parameters screen can be found by selecting Drive Setup, Drive
Configuration then Drive Parameters.

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2. Master Axis (Signal Source): The next step is to identify the
Signal Source of the master axis. In addition to running Cycle
Profiles the PCM-22 also has the ability to run synchronized
indexes. In this screen, only the Signal Source, Signal Polarity,
Signal Interpretation and Signal For Sync Output From
parameters are used by the PCM-22 when running Cycle
Profiles. The Master Axis screen is found by selecting Drive
Setup, Drive Configuration then Master Axis (see page 11).
3. Input and Output lines: The next step is to assign any input or
output functions to the I/O lines on the FX amplifier and the
PCM-22 module. There are several input and output function
used specifically for Cycle Profiles. The input and output function
screens can be found by selecting Drive Setup, Drive
Configuration then either Inputs or outputs (see page 25 for
inputs and page 34 for outputs). For a list of basic I/O functions
see input and output functions in section 1 of the PCX 6.X
manual P/N 400282-00).
4. Master Cycle: The next step is to define the parameters of the
Master Cycle screen. (see page 16).
5. Follower Cycle: The next step is to define the parameters of the
Follower Cycle screen (see page 19)
6. Cycle Profile Programs: The last step is to create a program
using the “Y” programming function, Execute Cycle Profile (see
page 38).
Master Axis Description
This screen is where you identify the Signal Source of the master
axis. In addition to running Cycle Profiles the PCM-22 also has the
ability to run synchronized indexes, however, in this screen only the
Signal Source, Signal Polarity, Signal Interpretation and
Signal For Sync Output From parameters are used by the PCM-
22 when running Cycle Profiles.
An external master axis becomes the time base for motion control of
the follower axis (your FX Drive equipped with a PCM-22). The basis
of operation is determined by the relationship of the external master
axis encoder or drive to the follower axis motor.
The master axis is typically an Emerson SCS series encoder, an
upstream drive or it can be a customer supplied encoder of any line
density yielding the appropriate steps per revolution.
The master axis encoder must not exceed 210KHz (see Master
Maximum Velocity on page 14.
The base number system used for the FX Drive is binary and 12 bits.
The smallest resolution is one part in 4096. Since this number may
be difficult to work with because of units, the drive electronics allow
for a conversion to any number from 200 to 25,000, with the default
being 4000.

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Master Axis Setup
To setup a relationship between the master axis and the follower
axis, select the Master Axis Option from the Drive Configuration
menu.
Figure 7Master Axis Screen.
Signal Source
Select the origin of the signals (drive or encoder) used for master axis
positional information. When a follower axis (PCM-22) is receiving
its synchronization source from an FX drive lead axis, the count
source becomes the binary 4096 counts per turn.
If your master axis is an Encoder, there will be 5 parameters that
you need to setup that pertain to the signal source (see master axis
screen above). If you select Drive for your signal source, the
Encoder Steps Per Revolution parameter will not appear.
Encoder Steps Pre Revolution
This parameter is not
available if the Signal
Source is set to Drive.
This parameter is the number of encoder setps per revolution of the
synchronization encoder. The default value is 4000 steps per
revolution. Minimum value is 0 and maximum value is 65535.
User Distance Pre Revolution
The default value for this parameter is 4000 "user units" per
revolution (see definition of user units in the PCX section of the FX
Drive manual P/N 400282-00). Minimum value is 1 and maximum
value is 65535.

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Signal Polarity
This feature defines the direction of the synchronization encoder that
corresponds to a positive master position change. Clockwise is
indicated with a (+); counterclockwise is indicated with a (-). CW and
CCW motion of the master axis is defined while facing the encoder
shaft.
Figure 8CW Motor Rotation
Signal Interpretation
The signal interpretation feature allows you to define how the
follower reacts to clockwise and counterclockwise motion of the
synchronization encoder.
The recommended signal interpretation mode when using a PCM-22
module is mode #4, COMP +. Signal interpretation modes apply only
to ratio synchronization.
Mode #1 (+ and -): When the master axis moves either CW or CCW,
the follower axis will move in its commanded direction. If the master
axis changes direction the follower axis will continue in the original
commanded direction. The follower axis will not reverse direction.
Mode #2 (+): The follower will only react to synchronization pulses
when the master axis runs in the CW direction. CCW master axis
pulses are ignored.
Mode #3 (-): The follower will only react to synchronization pulses
when the master axis runs in the CCW direction. CW master axis
pulses are ignored.
Mode #4 (COMP +): The follower will only react to synchronization
pulses when the master axis runs in the CW direction. The drive
counts the pulses received in the CCW direction and ignores that
exact number of CW pulses before follower motion in the CW
direction occurs.
This feature compensates for master axis motion in the opposite
(CCW) direction. For example, the master stops, then inadvertently
backs up due to conveyer slack, etc.
Mode #5 (COMP -): The follower axis will only react to
synchronization pulses when the master axis runs in the CCW
direction. The drive counts the pulses received in the CW direction
and ignores that exact number of CCW pulses before follower motion
in the CCW direction occurs. This feature compensates for master
axis motion in the opposite (CW) direction.

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Signal For Sync Output From
If you select motor, your FX drive will output a sync signal to the
next FX drive based on the performance of its own motor. If you
select upstream drive, your FX drive will output a signal that comes
from the motor of the preceding amplifier.
Encoder pulses are passed to all amplifiers in the synchronization
chain. How you answer this question has no effect on the integrity of
the encoder signal. The signal source of the next FX drive and PCM-
22 in the synchronization chin must be set to drive in order to
operate with this signal.
Master Maximum Velocity
The Master Maximum Velocity,
Sync Velocity User Units, and
External Mode Override
parameters are not used by the
PCM-22 when running Cycle
Profiles.
The master maximum velocity is the maximum frequency that the
master axis signal source is expected to produce when running at its’
full speed. To calculate the master maximum velocity, use the
following formula:
However, they would be used if
you were running synchronized
indexes or jogs. Master MaxVelocity MV MS
Sec
Min
=()( )
60
MV = Master Axis Maximum Velocity (RPM's)
MS = Master Steps/Rev
If encoder is master: MS = (Encoder Line Density)*(4)
If drive is master: MS = 4096
For example: The master axis is a 1000 line encoder and rotates at a
maximum speed of 3000 rpm, and, when quadratured, produces 4000
steps per revolution. Then:
( )( Re ) 3000 4000
60 200,000
RPM Steps v
Seconds Steps Per Second=
Maximum frequency into
PCM-22 module cannot
exceed 210 Khz or
steps/second.
This value is the master encoder velocity at which synchronized time
base and real time base are equal. This parameter is used to calculate
actual follower velocity while running in synchronized time base.
Sync Velocity User Units
This parameter sets the units to be associated with all sync
velocities. User units can be any three letter combination, such as
IPS (inches per second), RPM (revolutions per minute), FPM (feet
per minute), etc.
Sync Velocity Scaling (Max RPM Equals)
This parameter sets the sync velocity entry that will produce
maximum velocity of the drive when the master axis signal source is
at maximum velocity. When an index is running in sync time base,
the velocity is specified in user units.
The default value is 1.000. A setting of 0.500 in an index velocity
means the drive will accel to half of maximum velocity.

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External Mode Override
External mode override works in conjunction with input function #38
to override the current mode of operation. When input function #38
is assigned and active, the drive will exit its’ current operating mode
and default to the mode selected with this parameter. There are
three modes of operation, analog velocity, analog torque and bi-
polar sync.
Analog Velocity/Torque
When set to analog velocity or torque mode, the drive will respond to
a conventional 10VDC signal. In either of the two analog modes a
10VDC signal is equated to either (CW) or (CCW) maximum
programmed velocity or maximum full peak torque rating.
If you enable analog torque mode and apply a voltage between 0 and
10 VDC to the command connector the FX drive will attempt to
produce torque equal to:
MaxTorque AppliedVoltage
VDC Actual Torque 10




=
If there is no physical resistance to the torque at the motor shaft, the
motor will very quickly accelerate to maximum speed.
Bi-polar Sync
When set to bi-polar sync, this parameter allows for direct movement
of the FX drive motor ratioed to the sync encoder. This mode moves
the motor shaft in direct response to encoder or drive signals. This
means immediate velocity without ramping in your FX drive. If the
master axis accelerates very quickly, your FX drive (follower axis)
will try to follow just as quickly. Too fast an acceleration by the
master axis could result in “F” (Following Error) faults for the
follower axis.
Encoder Counts Per Motor Rev.
This parameter is the relationship of the follower axis position to the
master axis position. For example, if you set this value to 3, for every
1 count of the master axis there will be 3 counts of the follower axis.
Thus, the bipolar sync ratio would be 3:1.