MOOG ANIMATICS Class 6 SmartMotor Installation manual

Installation &
Startup Guide
Class 6 SmartMotor
Technology

Copyright Notice
©2014–2015, Moog Inc., Animatics.
Moog Animatics Class 6 SmartMotor™Installation & Startup Guide, Rev. 03 - PRELIMINARY,
PN: SC80100006-001.
This manual, as well as the software described in it, is furnished under license and may be
used or copied only in accordance with the terms of such license. The content of this manual is
furnished for informational use only, is subject to change without notice and should not be con-
strued as a commitment by Moog Inc., Animatics. Moog Inc., Animatics assumes no respons-
ibility or liability for any errors or inaccuracies that may appear herein.
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ing, or otherwise, without the prior written permission of Moog Inc., Animatics.
The programs and code samples in this manual are provided for example purposes only. It is
the user's responsibility to decide if a particular code sample or program applies to the applic-
ation being developed and to adjust the values to fit that application.
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www.animatics.com

Table Of Contents
Introduction 5
Purpose 6
Safety Information 6
Safety Symbols 6
Other Safety Considerations 6
Motor Sizing 6
Environmental Considerations 7
Machine Safety 7
Documentation and Training 8
Additional Equipment and Considerations 8
Safety Information Resources 9
Additional Documents 10
Additional Resources 10
SmartMotor Overview 13
SmartMotor Introduction 14
SmartMotor Features and Options 15
Class 6 M-Style Motors 15
Fieldbus Options 17
EtherCAT Fieldbus Protocol 17
PROFINET Fieldbus Protocol 17
SmartMotor Theory of Operation 18
Getting Started 21
Unpacking and Verifying Your Shipment 23
Installing the SMI Software 23
Installation Procedure 23
Installation Verification 26
Accessing the SMI Software Interface 26
Understanding the Power Requirements 28
Power Requirements 28
CPU, I/O and Communications Power 28
CPU Power Requirements 29
I/O Power Requirements 29
Communications Power Requirements 29
Drive Enable Power 29
Connecting the System 30
Minimum Requirements 30
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Motor Connectors and Pinouts 31
Power and RS-485 Com Multidrop 32
USBConnector and Cable 32
Industrial Ethernet Cable Diagram 34
Maximum Cable Length 35
Moog Animatics Industrial Ethernet Cables 35
M-style to M-style Ethernet Cable 35
M-style to RJ45 Ethernet Cable 36
Ethernet Cable Schematic 36
Understanding the Status LEDs 37
Status LEDs 37
Detecting and Communicating with the SmartMotors 38
Understanding the Detection and Configuration Options 38
Using the Find Motors Button 38
Using the Detect Motors Feature 41
Checking and Clearing the Status Bits 43
Polling the Motor 44
Clearing the Overtravel Limits and Fault Bits 45
Moving the SmartMotor 46
Making the Motor Move 46
Setting and Reporting Torque 47
Checking the Motor Position 48
Viewing the Motor Position with a Report Command 48
Viewing the Motor Position with the Motor View Tool 48
Other Class 6 Changes 50
Features not Available in Class 6 50
EOBK(exp) Command Limitations 50
Status Bit for Ethernet in Status Word 2 50
I/O Control Details 50
I/OControl Examples 51
Scale Factor Calculation – Sample Rates 51
New Commands for Class 6 52
Commands That Have Changed 52
Commands Not Currently Supported 53
For Further Information... 53
Troubleshooting 54
Class 6 M-Style Connector Pinouts 56
Moog Animatics Class 6 SmartMotor™Installation & Startup Guide,Rev. 03 - PRELIMINARY
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Introduction
Introduction
This chapter provides information on the purpose of the manual, safety information, and addi-
tional documents and resources.
Purpose 6
Safety Information 6
Safety Symbols 6
Other Safety Considerations 6
Motor Sizing 6
Environmental Considerations 7
Machine Safety 7
Documentation and Training 8
Additional Equipment and Considerations 8
Safety Information Resources 9
Additional Documents 10
Additional Resources 10
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Purpose
Purpose
The Class 6 SmartMotor™ Installation & Startup Guide provides an overview of the Class 6
SmartMotor, along with information on unpacking, installation and start up. This guide is
meant to be used in conjunction with the SmartMotor Developer's Guide, which describes the
SmartMotor features, SMIsoftware, programming, commands, and other topics related to
SmartMotor application development.
The information in this guide is meant to be used by properly trained technical personnel only.
Moog Animatics conducts classroom-style SmartMotor training several times per year, as well
as product seminars and other training opportunities. For more information, please see the
Moog Animatics website or contact your Moog Animatics representative.
Safety Information
This section describes the safety symbols and other safety information.
Safety Symbols
The manual may use one or more of the following safety symbols:
WARNING: This symbol indicates a potentially nonlethal mechanical hazard,
where failure to follow the instructions could result in serious injury to the
operator or major damage to the equipment.
CAUTION: This symbol indicates a potential minor hazard, where failure to fol-
low the instructions could result in slight injury to the operator or minor dam-
age to the equipment.
NOTE: Notes are used to emphasize non-safety concepts or related information.
Other Safety Considerations
The Moog Animatics SmartMotors are supplied as components that are intended for use in an
automated machine or system. As such, it is beyond the scope of this manual to attempt to
cover all the safety standards and considerations that are part of the overall machine/system
design and manufacturing safety. Therefore, the following information is intended to be used
only as a general guideline for the machine/system designer.
It is the responsibility of the machine/system designer to perform a thorough "Risk Assess-
ment" and to ensure that the machine/system and its safeguards comply with the safety stand-
ards specified by the governing authority (for example, ISO, OSHA, UL, etc.) for the locale
where the machine is being installed and operated. For more details, see Machine Safety on
page 7.
Motor Sizing
It is the responsibility of the machine/system designer to select SmartMotors that are prop-
erly sized for the specific application. Undersized motors may: perform poorly, cause excess-
ive downtime or cause unsafe operating conditions by not being able to handle the loads
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Environmental Considerations
placed on them. The Moog Animatics Product Catalog, contains information and equations that
can be used for selecting the appropriate motor for the application.
Replacement motors must have the same specifications and firmware version used in the
approved and validated system. Specification changes or firmware upgrades require the
approval of the system designer and may require another Risk Assessment.
Environmental Considerations
It is the responsibility of the machine/system designer to evaluate the intended operating
environment for dust, high-humidity or presence of water (for example, a food-processing
environment that requires water or steam wash down of equipment), corrosives or chemicals
that may come in contact with the machine, etc. Moog Animatics manufactures specialized IP-
rated motors for operating in extreme conditions. For details, see the Moog Animatics Product
Catalog.
Machine Safety
In order to protect personnel from any safety hazards in the machine or system, the
machine/system builder must perform a "Risk Assessment", which is often based on the ISO
13849 standard. The design/implementation of barriers, emergency stop (E-stop) mech-
anisms and other safeguards will be driven by the Risk Assessment and the safety standards
specified by the governing authority (for example, ISO, OSHA, UL, etc.) for the locale where
the machine is being installed and operated. The methodology and details of such an assess-
ment are beyond the scope of this manual. However, there are various sources of Risk Assess-
ment information available in print and on the internet.
NOTE: The following list is an example of items that would be evaluated when per-
forming the Risk Assessment. Additional items may be required. The safeguards
must ensure the safety of all personnel who may come in contact with or be in the
vicinity of the machine.
In general, the machine/system safeguards must:
lProvide a barrier to prevent unauthorized entry or access to the machine or system. The
barrier must be designed so that personnel cannot reach into any identified danger
zones.
lPosition the control panel so that it is outside the barrier area but located for an unres-
tricted view of the moving mechanism. The control panel must include an E-stop mech-
anism. Buttons that start the machine must be protected from accidental activation.
lProvide E-stop mechanisms located at the control panel and at other points around the
perimeter of the barrier that will stop all machine movement when tripped.
lProvide appropriate sensors and interlocks on gates or other points of entry into the pro-
tected zone that will stop all machine movement when tripped.
lEnsure that if a portable control/programming device is supplied (for example, a hand-
held operator/programmer pendant), the device is equipped with an E-stop mechanism.
NOTE: A portable operation/programming device requires many additional
system design considerations and safeguards beyond those listed in this sec-
tion. For details, see the safety standards specified by the governing author-
ity (for example, ISO, OSHA, UL, etc.) for the locale where the machine is
being installed and operated.
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Documentation and Training
lPrevent contact with moving mechanisms (for example, arms, gears, belts, pulleys,
tooling, etc.).
lPrevent contact with a part that is thrown from the machine tooling or other part-hand-
ling equipment.
lPrevent contact with any electrical, hydraulic, pneumatic, thermal, chemical or other
hazards that may be present at the machine.
lPrevent unauthorized access to wiring and power-supply cabinets, electrical boxes, etc.
lProvide a proper control system, program logic and error checking to ensure the safety
of all personnel and equipment (for example, to prevent a run-away condition). The con-
trol system must be designed so that it does not automatically restart the machine/sys-
tem after a power failure.
lPrevent unauthorized access or changes to the control system or software.
Documentation and Training
It is the responsibility of the machine/system designer to provide documentation on safety,
operation, maintenance and programming, along with training for all machine operators, main-
tenance technicians, programmers, and other personnel who may have access to the
machine. This documentation must include proper lockout/tagout procedures for maintenance
and programming operations.
It is the responsibility of the operating company to ensure that:
lAll operators, maintenance technicians, programmers and other personnel are tested
and qualified before acquiring access to the machine or system.
lThe above personnel perform their assigned functions in a responsible and safe manner
to comply with the procedures in the supplied documentation and the company safety
practices.
lThe equipment is maintained as described in the documentation and training supplied by
the machine/system designer.
Additional Equipment and Considerations
The Risk Assessment and the operating company's standard safety policies will dictate the
need for additional equipment. In general, it is the responsibility of the operating company to
ensure that:
lUnauthorized access to the machine is prevented at all times.
lThe personnel are supplied with the proper equipment for the environment and their job
functions, which may include: safety glasses, hearing protection, safety footwear,
smocks or aprons, gloves, hard hats and other protective gear.
lThe work area is equipped with proper safety equipment such as first aid equipment,
fire suppression equipment, emergency eye wash and full-body wash stations, etc.
lThere are no modifications made to the machine or system without proper engineering
evaluation for design, safety, reliability, etc., and a Risk Assessment.
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Safety Information Resources
Safety Information Resources
Additional SmartMotor safety information can be found on the Moog Animatics website; open
the file "109_Controls, Warnings and Cautions.pdf" located at:
http://www.animatics.com/support/moog-animatics-catalog.html
OSHA standards information can be found at:
https://www.osha.gov/law-regs.html
ANSI-RIA robotic safety information can be found at:
http://www.robotics.org/robotic-content.cfm/Robotics/Safety-Compliance/id/23
UL standards information can be found at:
http://www.ul.com/global/eng/pages/solutions/standards/accessstandards/
catalogofstandards/
ISOstandards information can be found at:
http://www.iso.org/iso/home/standards.htm
EUstandards information can be found at:
http://ec.europa.eu/enterprise/policies/european-standards/harmonised-standards/
index_en.htm
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Additional Documents
Additional Documents
The Moog Animatics website contains additional documents that are related to the information
in this manual. Please refer to the following list:
lSmartMotor™ Developer's Guide
http://www.animatics.com/support/download-center.html
lSmartMotor™ Product Certificate of Conformance
http://www.animatics.com/download/Animatics_SmartMotor_Servida_Class_5_Declar-
ation_of_Conformity_CE_Rev_1.pdf
lSmartMotor™ ULCertification
http://www.animatics.com/download/MA_UL_online_listing.pdf
lSmartMotor Developer's Worksheet
(interactive tools to assist developer: Scale Factor Calculator, Status Words, CAN Port
Status, Serial Port Status, RMODE Decoder and Syntax Error Codes)
http://www.animatics.com/support/download-center.html
lMoog Animatics Product Catalog
http://www.animatics.com/support/moog-animatics-catalog.html
Additional Resources
The Moog Animatics website contains additional resources such as product information, doc-
umentation, product support and more. Please refer to the following list:
lGeneral company information:
http://www.animatics.com
lProduct information:
http://www.animatics.com/products.html
lProduct support (Downloads, How To videos, Forums, Knowledge Base, and FAQs):
http://www.animatics.com/support.html
lSales and distributor information:
http://www.animatics.com/sales-offices.html
lApplication ideas (including videos and sample programs):
http://www.animatics.com/applications.html
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Additional Resources
EtherCAT is a common standard maintained by EtherCAT Technology Group (ETG):
lEtherCAT Technology Group website:
http://www.ethercat.org
PROFINET is a common standard maintained by PROFIBUS & PROFINET International (PI):
lPROFIBUS & PROFINET International website:
http://www.profinet.com
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SmartMotor Overview
SmartMotor Overview
This chapter provides an overview of the design philosophy and functionality of the Moog Anim-
atics SmartMotor. It also provides information on SmartMotor features and options, and
where to find related documents and additional resources.
SmartMotor Introduction 14
SmartMotor Features and Options 15
Class 6 M-Style Motors 15
Fieldbus Options 17
EtherCAT Fieldbus Protocol 17
PROFINET Fieldbus Protocol 17
SmartMotor Theory of Operation 18
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SmartMotor Introduction
SmartMotor Introduction
The Moog Animatics SmartMotor™ servo is an industrial servo motor with motion controller
integrated into a compact package. Its design is based on the following objectives:
1. Reduce development time
2. Lower machine-production cost
3. Simplify the machine, machine build and support
Class 6 M-Style SmartMotor
The SmartMotor is powerful and unique because of its ability to control an entire machine. The
combination of programmability, networking, I/O and servo performance is unmatched. The
SmartMotor brings savings and value to the machine builder by removing complex and costly
elements in the machine design, such as PLCs, sensors, I/O blocks, cabinets, etc.
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SmartMotor Features and Options
SmartMotor Features and Options
All SmartMotors offer the following features:
lFull floating-point math and trigonometric functions with 32-bit precision results
lDual trajectory generators enabling relative and absolute position moves or velocity
moves on top of gearing or camming
lAdvanced gearing allowing preset traverse and take-up winding parameters including
dwells and wrap counts
lAdvanced camming including cubic spline interpolation and dynamic frequency and amp-
litude changes.
lStand-alone, multi-axis linear interpolation with as many as 120 SmartMotors at a time
lVirtual-axis mastering into camming through gearing, which enables stand-alone,
multi-axis coordinated motion
lProgrammable and non-programmable protection features (both hardware and soft-
ware)
A note about SmartMotor part numbers:
The SmartMotor uses a coded part number, which contains characters that describe the motor
number, frame style and options. For details on decoding the SmartMotor part number, refer
the Moog Animatics Product Catalog at this address:
http://www.animatics.com/support/moog-animatics-catalog.html
and select the file: 14_Understanding Part Numbers.pdf.
Class 6 M-Style Motors
The Class 6 SmartMotor is available in an M-style configuration. All Class 6 M-style SmartMo-
tors have:
lSmartMotor command access through RS-485 or USB
lPorts: Two industrial Ethernet (IE) ports for real-time daisy chain
lLEDs: Bi-colored LED indicators to show error codes, provide network status and com-
munications activity
lCommunications: RS-485, micro USB, and industrial Ethernet
lSMIsoftware: Used for application development and debug
lMotor feedback: Supported
lMotor sample rate: 16 kHz
lEncoder: 4000 counts per revolution
lPosition Capture Register from signal-ended, ground-referenced external input (non-dif-
ferential)
lExternal Encoder input: Differential A-quad-B
lA or B channel input frequency up to 100 kHz
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Class 6 M-Style Motors
For a product-specific list of features, specifications, torque curves and more, see the cor-
responding SmartMotor datasheet for your motor. SmartMotor datasheets are available from
the Products menu on the Moog Animatics website.
The following industrial (Fieldbus protocol) communications options are available on the Class
6 motors. (Availability varies by model number; see the Moog Animatics Product Catalog for
details.)
lEtherCAT option
lPROFINET option
All firmware options include:
lModbus Remote Terminal Unit (RTU) Slave (RS-485 COM 0)
The M-style motors are available in the following NEMAframe sizes:
lNEMA 23
The following figure shows the connector and LED location for the Class 6 M-style SmartMotor.
For details on the motor connectors, see Connecting the System on page 30. For details on the
LED functions, see Understanding the Status LEDs on page 37.
LED 2: (Network specific**)
LED 0: Motor Drive LED
LED 5: Link LED
LED 3: (Network specific**)
LED 1: Motor Busy LED
LED 4: Link LED
Power Input
Communication
I/O
Industrial Ethernet
USB Active LED
Micro USB
**Refer to the Status LED description in the corresponding SmartMotor fieldbus guide
Class 6 M-Style SmartMotor Connectors and LEDs
CAUTION: When daisy-chaining SmartMotors for an EtherCAT network, you
must connect the OUT port (right-hand port) of the upstream motor to the IN
port (left-hand port) of the downstream motor.
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Fieldbus Options
Fieldbus Options
This section details the Fieldbus communications protocol options that are available on certain
models of SmartMotors.
EtherCAT Fieldbus Protocol
NOTE: This fieldbus protocol is optionally available on Class 6 M-style motors.
The EtherCAT fieldbus protocol provides the following features:
lCommand/Response Codes for SmartMotor commands
lCiA 402 Motion Modes: Profile Position (PP), Profile Velocity (PV), Torque (TQ), Cyclic
Sync Position (CSP), Cyclic Sync Velocity (CSV), Cyclic Sync Torque (CST)
lDynamic PDOmapping
lConfigurable Sync Manager 2 and 3 assignment
lDC-Sync Subordinate Mode with SYNC0 and SYNC1
lDC-Sync Slave
lSelectable Homing modes (with or without index pulse)
lSelectable Interpolation modes (spline or linear)
lTouch Probe function allows the motor's position to be captured on a specific event
For the EtherCAT connector diagram and pinouts, see Connecting the System on page 30.
For more details on the EtherCAT protocol implementation, see the SmartMotor EtherCAT
Guide.
PROFINET Fieldbus Protocol
NOTE: This fieldbus protocol is optionally available on Class 6 M-style motors.
The PROFINET fieldbus protocol provides the following features:
lCommand/Response Codes for SmartMotor commands
lUse of on-board I/O through PROFINET, SmartMotor program, or RS-485 commands
lThe Moog Animatics communications profile over PROFINET is intended to integrate well
with a PLC that continuously transmits and receives cyclic data; the command and
response codes achieve this through a handshaking mechanism
lCertain configuration data is held in nonvolatile storage in the SmartMotor; therefore,
the motor data EEPROM must be correctly initialized before PROFINET operation
For the PROFINET connector diagram and pinouts, see Connecting the System on page 30.
For more details on the PROFINET protocol implementation, see the Class 6 SmartMotor™
PROFINET Guide.
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SmartMotor Theory of Operation
SmartMotor Theory of Operation
The Moog Animatics SmartMotor is an entire servo control system built inside of a servo
motor. It includes a controller, an amplifier and an encoder. All that is required for it to oper-
ate is power and either an internal program or serial commands from outside (or both). To
make the SmartMotor move, the program or serial host must set a mode of operation, state a
target position with/or a maximum velocity at which to travel to that target, and a maximum
acceleration. After these three parameters are set, and the two limit inputs are properly
grounded or deactivated, a "Go" command starts the motion profile.
The core functional areas of the SmartMotor are:
lMotion Control Functions (see Motion Details in the SmartMotor™ Developer's Guide)
lSystem Control Functions (see Program Flow Details in the SmartMotor™ Developer's
Guide, also see System Status in the SmartMotor™ Developer's Guide)
lCommunication Functions (see Communication Details in the SmartMotor™ Developer's
Guide)
lI/OFunctions (see I/O Control in the SmartMotor™ Developer's Guide)
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SmartMotor Theory of Operation
The following block diagram illustrates the relationship between the functional areas in the
SmartMotor.
Trajectory 1
MP MV MD
Trajectory 2
MC MFR MSR
Pe KP
IKI edt
Cam
function1,2
Follow
Prole
MFA
MFD
MFSLEW
MFSDC 1
VT= AT= DT=
PT= PRT= ADT=
ENC1
ENC0
External
Encoder
+
G, X, OFF, S
MTB
PWM
Commutation
Motor
Encoder
KV
KA
Vel
Control
on/o
RPC
RPA
+ e
–
Accel
DKD
KS
KL
KG
+
+
+
+++
Hall sensor
de
dt
SRC(2)
SRC(1)
SRC(0)
SRC(-1)
SRC(-2)
filter
*
*
*
*
*
Internal
Clock:
1 tick per
PID cycle
-1
*
Null
-1
*
RCTR(1)
RCTR(0)
1. MFMUL and MFDIV commands do not have an eect on dwell time or distance. Dwell is strictly based on raw master encoder counts selected by the
SRC( ) command specifying internal virtual or external master count source.
2. When feeding a Cam table with a gearing prole, changes to MFMUL and MFDIV will aect the time it takes to move through a Cam table but will not
aect dwell time, as specied in the previous note.
NOTES:
Current
sensors
Current
control
KII KPI
Torque
command
MDC
MDS
MDE
MDT
Not supported on
D-series motors
SmartMotor Theory of Operation Diagram
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