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

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Ser Bus
Command 16
…
Command 28
Not in use
Ser Bus
Store to EEPROM
Stores all actual parameters and variables to the EEPROM
Ser Bus
Adjust Program
Starts the Adjust program for testing and commissioning
(Will be set automatically by PC operator software when you
select “Adjust…” in menu “Tools”)
Ser Bus
Test Program
Starts the Test program for testing and commissioning
(Will be set automatically by PC operator software when you
select “Test…” in menu “Tools”)
4.1.2. Outputs
Outputs which are in use for the current application are marked with a text, and unused outputs
are marked with “output …” only.
The indicator box shines red when the corresponding output is HIGH, otherwise the box
remains white. Outputs on the screen appear in the sequence of their mechanical layout on the
connector panel
Meaning and function of the output signals:
Out1
Ready
Indicates that the unit is ready to work after power-up,
initialisation and self-test. This output, however, is not a
guarantee for trouble-free operation of all functions.
Out2
Speed too high
Goes HIGH when the analogue speed output command
exceeds the preset maximum output value
Out3
12 h position
Generates a pulse with adjustable duration every time the
shear position passes “12 o’clock” position (opposite of the
cutting position)
Out4
Homing Done
Set to on when the homing cycle is finished. Reset to off
when the home position is no more valid and a new homing
cycle should be executed (after Reset, Jog, power down etc.).
Out5
Automatic
Operation
Set to on during automatic cutting operation when input
“Start” is on. When input “Start” is reset to off, this output is
set to off not before the actual cut is finished and the cutting
roll is at standstill.
Out6
X7 –Pin6
Not in use
Out7
X7 –Pin7
Not in use
Out8
Error
An error has occured.

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4.2. General Parameters
This register card holds the essential variable settings of general nature
Length1
Preset of the desired cutting length 1 scaled in length units according to
user definition (active with input “Length Selection” = LOW)
Length2
Preset of the desired cutting length 2 scaled in length units according to
user definition (active with input “Length Selection” = HIGH)
Max Frequency
Expected maximum frequency of the master encoder (Hz). Used for pre-
scaling of the analogue output.
Virtual Master
Speed
Preset speed of the virtual master axis (Hz)
Gap Overspeed
Temporary overspeed after the cut to create a gap
(Added supplementary speed = Actual line speed x register setting)
Min. Length
Lower limit for length preset values (Length units)
Max. Length
Upper limit for length preset values (Length units)

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4.3. Parameter Blocks
This field contains more parameters and machine specifications, separated to clearly arranged
blocks.
4.3.1. Circs/ Pulses
This block defines the mechanical dimensions and associated ppr numbers of the encoders.
Circ1
Circumference of the measuring wheel or the feed roll of the material line
(Master) Scaling: Length units
PPR1
Number of incremental encoder pulses with one revolution of the
measuring wheel, with consideration of the selected quadrature edge
count (x1, x2, x4)
Inner Circ2
Inner active circumference of the rotating knife in length units
(= 2 πx ri , see section 2.)
Outer Circ2
Outer active circumference of the rotating knife in length units
(= 2 πx ro , see section 2.)
PPR2
Number of incremental encoder pulses with one revolution of the rotating
cutter roll, with consideration of the selected quadrature edge count (x1,
x2, x4)
+/-xx.x% Outer
Fine tuning of the profile shape during penetration of the tool, referring to
the radius of the outer circle ro. Normal setting 00.0
+/-xx.x% Inner
Fine tuning of the profile shape during penetration of the tool, referring to
the radius of the inner circle ri. Normal setting 00.0

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4.3.2. Index Settings:
This register card defines origin and evaluation of the index signals
Mode
Currently not used, reserved for future use.
Index Mode
The cutting pulse necessary with every cut (mandatory) and a print mark or
index pulse from the line (optional) can be applied as a HTL/24V signal to
the digital inputs, or as a TTL/RS422 signal to the SUB-D-connector of the
corresponding encoder input:
Ind. Mode:
Cutting pulse source:
Master index source:
0
HTL (Cont.In04, X6 terminal 5)
HTL (Cont.In03, X6 terminal 4)
1
TTL/RS422 (Encoder2, Pin 6/7)
HTL (Cont.In03, X6 terminal 4)
2
HTL (Cont.In04, X6 terminal 5)
TTL/RS422 (Encoder1, Pin 6/7)
3
TTL/RS422 (Encoder2, Pin 6/7)
TTL/RS422 (Encoder1, Pin 6/7)
Slave Index Div.
Impulse divider for cutting pulse. Setting to a value n > 1 evaluates only
every nth cutting pulse
Slave Z Offset
Offset register for virtual displacement of the physical cutting impulse
(generated from encoder index or by proximity). Setting in +/- encoder
increments. This register makes superfluous a precise mechanical
adjustment of the location of the pulse (the virtual cutting pulse must be
located exactly in the peak position of tool penetration)
Time Pulse out
Sets the pulse duration of the 12 o’clock pulse output (x.xxx sec) which the
unit generates exactly in the opposite position of the virtual cutting pulse.
4.3.3. Ramps
This register card is designed for future functions and remains currently unused.
4.3.4. Control Loop
Defines the properties of the closed loop position control:
Gain-Correction
Sets the proportional Gain of the position control loop in relation to
positional errors
Sampling Time
Sampling time of the Master frequency input. Used to smoothen the
analogue output with unsteady input frequencies
Gain Torque
Proportional Gain of the torque analogue output. The torque output voltage
is proportional to the differential error during the cut. When the next cut
begins, the torque output starts with the value that has been stored after
the previous cut. When an error higher than the previous error is detected,
the new value will overwrite the previous value.

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4.3.5. Jog/Home
This register card specifies the Jog and Homing functions:
Jog Speed
Jog speed for manual movement of the cutter drive
Jog Ramp
Ramp time for acceleration and deceleration when using the Jog function
Home Speed Hi
Fast Homing speed.
Every homing cycle will start with this speed.
Home Speed Lo
Slow Homing speed.
A Homing cycle will end with this speed
Home Ramp
Ramp time for acceleration and deceleration with Homing cycles
Home Switchpnt
Distance from the final home position (scaled in length units) where the
homing speed changes over from high speed to low speed.
4.3.6. Alarms
Settings for monitoring functions:
Min. Master
Frequency
When the real master encoder frequency becomes lower than this set
value, the unit substitutes the encoder frequency by this setting. This
prevents the shear from stopping while the tool is penetrated to the
material.
Max. Analogue
Output
When the analogue speed output signal gets higher than this setting, the
“Speed too High” output signal will switch on.
4.3.7. Diagnosis
Settings for diagnosis functions:
Sel. Diag.
Ana Out 1
Selects the actual value (Process Data) that is put out at analogue output
“Ana Out 1”.
The gain of the analogue diagnosis signal is set by parameter “Ana Out 1
Gain”. When set to 10.00, an actual value of 2048 is repre-sented by an
analogue output voltage of 10 V.
4.3.8. Communication settings
This register card sets the communication parameters for the CAN interface and the serial link.
Settings and operation of the CANopen interface are explained separately in the manual CI700,
which is available on our homepage or on our CD-ROM
The serial link uses the following parameters:

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Ser. Unit Address
Serial unit address. Range 11 ... 99.
Address numbers containing zeros like 01, 02, 03, ..., 10, 20, etc. are not
permitted because these are reserved for broadcast messages (collective
addressing of several units)
Factory default address is always 11.
Ser. Baud Rate
0: 38400 bps
1: 19200 bps
2: 9600 bps
3: 4800 bps
4: 2400 bps
Factory setting: 2
Ser. Data Format
Setting
Data bits
Parity
Stop bits
0
7
even
1
1
7
even
2
2
7
odd
1
3
7
odd
2
4
7
none
1
5
7
none
2
6
8
even
1
7
8
odd
1
8
8
none
1
9
8
none
2
Factory setting: 0

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4.3.9. Setup Settings:
These settings define all important hardware properties of inputs and outputs of the MC700
controller.
You must only make settings for these functions that are really used and wired with this
application (see 2.).
Mode Counter
(1–4)
Determines the number of edges counted from the four incremental encoder
inputs:
0 = (x1), 1 = (x2) 2 = (x4)
Dir. Counter
(1–4)
Assigns a counting direction (up / down) to the corresponding encoder
input, depending on the quadrature A/B phase displacement. These
parameters are found out and set best in the Test menu or the Adjust menu
Ana-Out Offset
(1–4)
Sets the zero position of the corresponding analogue output. This parameter
uses a numeric range from
–2047 ... 0000 ... +2047 corresponding to
--100% ... 0000 ... +100% full scale output
Ana-Out Gain
(1-4)
Sets the full scale output of the corresponding analogue output, directly in
volts.
0 –10,00 means 0 –10 volts or 20 mA
Ana-In Offset
(1-4)
Sets the zero position of the corresponding analogue input. This parameter
uses a numeric range from
–2047 ... 0000 ... +2047 corresponding to
--100% ... 0000 ... +100% full scale input.
Ana-In Gain
(1-4)
These parameters remain unused with the application of this firmware..
Index output
Frequency
Output
Dir. Frequency
Frequency Select
Index 1 select
Index 2 select
Index 3 select
Index 4 select

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5. Function of the LED indicators
There are 6 red LEDs mounted to the connector plate of the unit, for display of the actual
positional error of the tool position with regard to the scheduled position. The LEDs are scaled
in encoder increments and the update cycle is less than one millisecond. Therefore, this simple
means of error display provides a good information about the dynamic performance of the
control loop.
With hardware version MC720, also the front LEDs operate in a similar way.
]+/-0
]-08 ... -15
]-24 ... -31
]
]+08 ... +15 +24 ... +31
-01 ... -07
-16 ... -23
< -31
+01 ... +07
+16 ... +23
> +31
Position error in encoder increments

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6. Steps for Commissioning
For setup and commissioning of all drives, the “Adjust” menu is available under “Tools” in the
main menu of the screen.
At this time, all drives must be adjusted to a proper and stable operation over
the full speed range. Slave drives need a maximum of dynamics and response
(set ramps to zero, switch of any integral or differential component of the
internal speed control loop, operate the drive with proportional speed control
only, with the proportional Gain as high as possible).
Before you start the Adjust menu, make sure that all parameters on the required register cards
are set correctly. Where you find the possibility for integration, please switch it off for the first
steps (set “Int.Time” to 000)
The Adjust Program is used to set the directions of rotation of the encoders and to adjust the
analogue output with regard to the output level and the proportional Gain.
For the adjustment procedure, the Slaves uses always the virtual master axis as
a reference

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6.1. Preparations
Before starting the procedure, the following settings should be done:
Frequency Preset:
Set the virtual line speed that you would like to use for adjusting. This setting is directly in
Hz of Master encoder frequency and the default value is 10% of the maximum frequency
you have set before (= recommended speed for adjustments).
Ramp Time:
This ramp time is used for all acceleration and deceleration during the adjust procedure.
Gain-Correction:
An initial setting of 500 is recommended.
Ana-Out-Gain:
Start with the default value of 1000 which corresponds to a maximum analogue output of
10.00 volts.
6.2. Directions of Rotation
Move your Master encoder into forward direction (manually or by means of a remote speed
signal)
Observe the counter in the Master column. It must count up (increment)! Where you find it
counts down, please click to the unchecked direction box of the master column (Forward or
Reverse) to change the direction.
When the master counter counts up while the master moves forward, the definition of the
Master direction is o.k.
Click to the “Up” key to start the slave drive.
It is a must that the Counter in the “Slave” column counts up (increments).
Where you find it counts down, please click to the other direction box (Forward or Reverse)
to force it to upwards count.
Once it counts up, click to the “Down” key to stop the drive again. The definition of
direction of rotation has been stored to the unit now
Only when both counters counts up while the according axis moves forward, the
definition of the Encoder direction is correct!