Motrona CT 701.04 User manual

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CT 701.04
Motion Control Firmware for
Rotary “Guillotine” Shears
with MC700 Controllers
Easy parameter setting instead of sophisticated programming, immediately ready to
work with minimum commissioning time
Synchronous cutting process, with cosine-compensated motion profile during
penetration of the cutting tool
Particularly suitable for “flying cut” of steel plates, sheet metals and profiles
High dynamic response by means of short cycle time
High cutting precision due to
400 kHz of feed-back frequency
Suitable for “stand-alone” operation as well as for connection to field bus systems
(CANBUS, PROFIBUS etc.)
Operating Instructions

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Safety Instructions
This manual is an essential part of the unit and contains important hints about
function, correct handling and commissioning. Non-observance can result in
damage to the unit or the machine or even in injury to persons using the
equipment!
The unit must only be installed, connected and activated by a qualified electrician
It is a must to observe all general and also all country-specific and application-
specific safety standards
When this unit is used with applications where failure or maloperation could cause
damage to a machine or hazard to the operating staff, it is indispensable to meet
effective precautions in order to avoid such consequences
Regarding installation, wiring, environmental conditions, screening of cables and
earthing, you must follow the general standards of industrial automation industry
- Errors and omissions excepted –
Version:
Description:
CT701 04A/ TJ/ Feb. 2006
Outputs “Homing Done” and “Automatic Operation” added;
Diagnosis output “Ana Out 1” added
CT701 04B/ TJ/ Aug. 2008
Motrona version

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Table of Contents
1. Preamble: .................................................................................................... 4
2. General remarks about functions of this firmware ....................................... 5
3. Download Procedure.................................................................................... 7
4. How to use the operator software ............................................................... 9
4.1. I/Os (Inputs and Outputs) ......................................................................................9
4.2. General Parameters.............................................................................................12
4.3. Parameter Blocks.................................................................................................13
4.3.1. Circs/ Pulses..................................................................................................................13
4.3.2. Index Settings: ..............................................................................................................14
4.3.3. Ramps............................................................................................................................14
4.3.4. Control Loop ..................................................................................................................14
4.3.5. Jog/Home......................................................................................................................15
4.3.6. Alarms ...........................................................................................................................15
4.3.7. Diagnosis.......................................................................................................................15
4.3.8. Communication settings: ..............................................................................................15
4.3.9. Setup Settings:..............................................................................................................17
5. Function of the LED indicators ................................................................... 18
6. Steps for Commissioning ........................................................................... 19
6.1. Preparations ........................................................................................................20
6.2. Directions of Rotation .........................................................................................20
6.3. Tuning the analogue output ................................................................................21
6.4. Setting of the proportional Gain .........................................................................21
7. Process data (actual values)....................................................................... 22
8. Hints for controller type MC720 with integrated operator terminal............ 23
8.1. Setting of parameters and registers ...................................................................23
8.2. Display of actual process values.........................................................................23
9. Parameter Tables....................................................................................... 25

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1. Preamble
This document provides all information about the CT701 firmware, including parameters,
variables and hints for commissioning.
To implement this application, you will need:
1) A motion controller hardware of type MC700 or MC720
2) A PC with operating system Windows 95, 98, NT, 2000 or XP
3) The motronaCD containing the PC operator software OS5.1, the firmware file CT701xxx
and the pdf files for the manuals MC700xxx.pdf (hardware description, connections,
specifications) and CT701xxx.pdf (description of the firmware as actually at hand)
All of above files are also available for free download from our homepage:
www.motrona.de
1. MC700 / MC720 Hardware
OS5.1 PC software,
CT 701 firmware
2. PC
Documentation (PDF-files)
3. motrona CD
Firmware,
Parameter
Test functions
Moreover, on the Applications site of above homepage you can watch a short demo movie
showing a typical application of the firmware described here.
Please note, the CT701 firmware is liable to payment of a license fee. The license key
necessary for setup will be delivered upon remittance of the licence fee.

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2. General remarks about functions of this firmware
This firmware is suitable, together with motrona controllers of type MC700 or MC720 and an
appropriate servo drive, to generate and control an optimized speed profile for rotary guillotine
cutting systems.
Encoder1 Encoder2 Encoder3 Encoder4
(Line) (Cutter) (N.C.) (N.C.)
0-10V
0-10V
0-10V
Speed reference
Diagnosis
Torque
Ana.Out1
Ana.Out2
Ana.Out3
Reset
Start
Print Mark
Cutting Pulse
Jog Forward
Jog Reverse
Home
Virtual Master
Flying Cut
Clear Torque Mem.
Length Select
In1
In2
In3
In4
In5
In6
In7
In8
In9
In10
In11
Ready
Speedtoohigh
12hposition
HomingDone
Autom.Operat.
Out1 Out2
Out3 Out4
Out5 Out6
Out7 Out8
Line encoder and measuring wheel
Motor, Encoder
Servo drive
MC700/MC720
Communication
Serial
CAN-Bus
PROFIBUS
These cutting systems require the horizontal speed of the cutting tool to be synchronous to the
material at any time of the penetration of the tool, whereas outside of the penetration zone, it
is the cutting length and the active radius of the rotation that determine the speed profile.
The subsequent drawing explains the principle of a rotating puncher, the principle of a rotating
shear, and also the geometric basis of the process. It is easy to understand that, during the
penetration of the tool, both applications require an angular correction of the rotational speed,
as soon as the difference between the inner radius ri and the outer radius ro is no more
negligible.

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12 3
rori
Zone c
rori
12 3
Zone c
VLine VLine
VLine VLine
Vcirc
Vcirc
V=circ VLine
cos
ß
ß
Also it is required to have a smooth profile with no angles and edges, where all values of
acceleration and deceleration are reduced to the possible physical minimum.
As a result of these requirements we find a speed profile as follows:
Line speed
V
L
Speed profile
-1/2 L 0+1/2 L
(a) (a)(b) (b)(c)
Typical profile of the rotational speed with a cutting cycle at cutting length "L"
Zone (a) results from the ratio between the cutting length and the active rotating circumference
of the tool.
Length > circumference reduces the speed of this zone (with respect to line speed) and may
include temporary standstill.
Length < circumference however increases the speed of this zone. Zone (b) is an over swing
zone, necessary to allow an edge-free transition from zone (a) to zone (c).
Zone (c) is the penetration zone of the tool, and the shape of the profile is ruled by the
geometry of the machine, requiring a reciprocal cosine curve in this situation.
The CT701 firmware continuously calculates an optimized speed profile from the
geometric properties of the machine with consideration of actual cutting length
and momentary line speed.
Very short control loop cycles combined with the smart algorithms of profile
calculation provide excellent accuracy, efficiency and performance.

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3. Download Procedure
Ex factory, all MC 700- and MC 720 controllers have loaded the MCBase firmware, which was
used for factory testing purposes.
To download an application firmware, please take the following steps:
Connect the PC to the controller, using a
RS232 cable (see 3.8 of the hardware
manual). Apply power to the controller and
start the OS5.1 PC software. Select
“Download Firmware” from the “File”
menu.
The screen now indicates the firmware
which is actually loaded to the unit, in
general “MCBaseXX.bin”
Click to “Open File” and select drive and
file name of the download firmware
(BY701xxx.bin).
Then click to “Connect”.
(Pictures beside use screenshots of firmware
WR70101a.bin)

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The PC now requests you to set the
controller to the “boot mode”. To do this,
slide the front switch from the “Run”
position to the “Program” position and
push the Reset button located behind the
front plate, by means of a pen or a small
screw driver
Click „OK“ to start the download
The download uses several loading steps.
The progress is displayed on the screen.
After successful conclusion of the
procedure
a. click to “Exit”
b. slide the switch back to the “Run” position
c. activate the Reset button for new
initialization of the controller
Finally you must input the license key:
a. Select “Input license key”” from the “File”
menu
b: Input the license key and click to
“connect”

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4. How to use the operator software
The OS5 software uses a clear structure of register cards and the contents automatically adapt
to the firmware of the controller.
4.1. I/Os (Inputs and Outputs)
This register card shows the logical state of all digital inputs and outputs.
4.1.1. Inputs
Inputs which are in use for the current application are marked with text, and unused inputs are
marked with “Command …” only.
Indicator boxes in the column marked “X6” shine blue, when the associated input signal on
screw terminal strip X6 is HIGH. LOW state is white.
Indicator boxes in the columns marked “RS” shine blue when the associated input signal has
been switched on via serial link. White box means “signal off”. You can switch on and off every
input from your PC by clicking to the corresponding indicator box in the “RS” column.
Indicator boxes in the column “BUS” shine blue, when the associated input signal has been
switched on via CANBUS. White box means again “signal off”. All input signals follow a logical
“OR” conjunction and the input is in “ON” state when one or several boxes shine blue.

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On the connector plate of the MC700 hardware, the inputs are accessible via terminals “In1” to
“In16” and the sequence from up to down corresponds to the same layout as visible on the PC
screen.
Meaning and function of the input signals:
= static operation
= dynamic operation, rising edge
Ser/Bus = Activation by serial command or by field bus only.
In01
Reset
Resets all functions and counters
In02
Start
LOW = automatic operation OFF
HIGH = automatic operation ON
In03
Print mark
Prepared for connection of a print mark sensor. Actually not
used yet
In04
Cutting pulse
Sensor input for HTL cutting pulse. For definition of the knife
position, the controller needs one index pulse with every cut,
which can be generated either by a remote sensor or from the
marker pulse of the encoder.
(See register “Index Mode”)
In05
Jog forward
Moves the cutter drive forward (manual operation)
In06
Jog reverse
Moves the cutter drive reverse (manual operation)
In07
Home
Starts a homing cycle and sets the knife to a defined home
position
In08
Virtual Master
Switches the „virtual master axis“ on, which allows to run the
shear without material. The command must switch on while
the Start input is LOW
In09
Flying cut
Starts an immediate „flying cut“
In10
Clear Torque
Memory
Clears the record register for the torque
In11
Length Selection
Selects one of the two preset cutting lengths:
LOW = Length1
HIGH = Length2
In12
…
In16
X6 –Pin 13
…
X6 –Pin 17
Not in use