Pilz PMotion User manual

Motion Control PMC
PMotion
User Manual – No. 21472-EN-11

1General Information
Page 2 User Manual for PMotion
1 General Information
1.1 Copyright
Copyright 2012 Pilz GmbH & Co.KG. All rights reserved.
All rights reserved. The implementation of technical changes which improve the performance of
the product is subject to change without prior notification! The product or parts of the content
may be reproduced or transmitted in any form (by printing, photocopying, microfilm or any other
method) or stored, processed, copied or distributed by electronic means without the written
permission of Pilz GmbH & Co. KG.
1.2 Notice
Pilz GmbH & Co. KG reserves the right to make amendments to this document at any time.
The examples given serve only as illustrations. No guarantee is given for their suitability in
particular applications. Although the utmost care has been taken in the production of this
document, no liability can be accepted for any mistakes that it may contain. We welcome any
suggestions for the improvement of our products, or documentation.
We reserve the right to make technical changes, which lead to the improvement of the product!
1.3 Previously published editions
V
ersion Notes
V1-28-06-2002 Initial version: valid from software version 2.03
V2-06-12-2002 Revised version: valid from software version 2.04
V3-10-06-2003 Revised version: valid from software version 2.05
V4-12-05-2004 Revised version: valid from software version 2.06
V5-23-02-2005 Revised version: valid from software version 2.07
V6-23-08-2005 Revised version: valid from software version 2.08
V7-15-11-2005 Revision
V8-11-10-2007 Revised version: valid from software version 3.1
V9-05-02-2008 Revised version: valid from software version 3.2
V10-02-03-2010 Revised version: valid from software version 3.3
V11-02-04-2012 Revised version: valid from software version 3.4

2Contents
User Manual for PMotion Page 3
2 Contents
1General Information 2
1.1Copyright ................................................................................................ 2
1.2Notice ..................................................................................................... 2
1.3Previously published editions ................................................................. 2
2Contents 3
3Abbreviations and Symbols 5
3.1Abbreviations.......................................................................................... 5
3.2Symbols.................................................................................................. 5
4Safety Guidelines 6
5About this manual 7
6Introduction 8
6.1Installation under Microsoft Windows ..................................................... 8
6.2Hardware requirements .......................................................................... 8
6.3General Description................................................................................ 9
6.3.1Designations........................................................................................... 9
6.3.2Motion Generator Overview.................................................................... 10
7PC based Motion Generator PMotion 12
7.1Introduction............................................................................................. 12
7.2Menus..................................................................................................... 13
7.2.1Menu "File" ............................................................................................. 13
7.2.2Menu "Edit"............................................................................................. 13
7.2.3Menu "View" ........................................................................................... 14
7.2.4Menu "Create" ........................................................................................ 15
7.2.5Menu "Programs" ................................................................................... 16
7.2.6Menu "Window" ...................................................................................... 16
7.3Toolbar ................................................................................................... 17
7.4Map Settings........................................................................................... 18
7.4.1Property Page „Map“ .............................................................................. 18
7.4.2Property Page “Master” .......................................................................... 19
7.4.3Property Page “Slave” ............................................................................ 20
7.4.4Property Page "Machine Parameters" .................................................... 21
7.5Edit Segment parameters....................................................................... 22
7.6Create a map.......................................................................................... 24
7.6.1Map Table .............................................................................................. 24
7.6.2Map Sequence ....................................................................................... 24
7.7Example of using the PC based Motion Generator PMotion .................. 25
8Internal Motion Generator 28
8.1Commands for Internal Motion Generator .............................................. 28
8.2Messages displayed in terminal and in status variable $MSTATUS....... 29
8.3Example of using the internal Motion Generator..................................... 30
9Segment Types 32
9.1Segment Type "Constant Position"......................................................... 33
9.2Segment Type "Constant Velocity"......................................................... 34
9.3Segment Type "Constant Acceleration".................................................. 35
9.4Segment Type "Sine-Squared Velocity" and "Cycloidal" ........................ 36
9.5Segment Type "Modified Trapezoidal" ................................................... 37
9.6Segment Type "Modified Sine" ............................................................... 38
9.7Segment Type "Triple Harmonic" ........................................................... 39
9.8Segment Type "Sinusoidal" .................................................................... 40
9.9Segment Type "Polynomial" ................................................................... 41
9.10Segment Type "Ramp" ........................................................................... 43

2Contents
Page 4 User Manual for PMotion
9.11Segment Type "Throw"........................................................................... 44
9.12Segment Type "Quadratic Spline" .......................................................... 45
9.13Segment Type "Cubic Spline"................................................................. 46
9.14Segment Type "Sine-Constant-Cosine".................................................. 47
9.15Segment Type "Simple Harmonic" ......................................................... 48
10Motion Generator: Features and Functions 49
10.1Start and End Percentages of a Segment .............................................. 49
10.2Summary of Segment Constraints.......................................................... 50
10.3Summary of Segment Types and their Parameters................................ 52
10.4Technical Information about the Motion Generator................................. 53
10.4.1Maximum number of segments .............................................................. 53
10.4.2Variable names used by the internal Motion Generator......................... 53
11Index 55

3Abbreviations and Symbols
User Manual for PMotion Page 5
3 Abbreviations and Symbols
3.1 Abbreviations
Meaning
CE Communité Europeenne
COM Serial interface for a PC
DIN Deutsches Institut für Normung
ISO International Standardization Organization
MB Megabyte
PC Personal Computer
RAM Volatile memory
UL Underwriter Laboratory
VDE Verband der Elektrotechnik Elektronik Informationstechnik e.V.
3.2 Symbols
Meaning
This symbol indicates a possible danger, hazard, risk to life and/ or
health. Ignorance may seriously affect health and cause dangerous
injuries.
This symbol indicates an important hint regarding the correct use
of the product. Ignorance may affect the performance of the
machinery and/or the surrounding.
This symbol indicates special user tips and/or important useful
information. These will support optimum use of the product and
functions.
•
Emphasis indicator
⇒
See page (cross reference)

4Safety Guidelines
Page 6 User Manual for PMotion
4 Safety Guidelines
Caution!
When commissioning, you must ensure that neither the controllers nor the amplifiers present
any risk to persons, plant or machinery.
A
ppropriate protection and precautionary measures must be put in place.
To avoid personal injury and material damage, only qualified, trained personnel should work on
the devices.
Only specialist staff with extensive knowledge of drive technology and control engineering
should be permitted to program a running drive online.
Data stored on data media is not protected from unintended changes by third parties. Data
must be checked for accuracy before it is loaded on to the hardware.
Attention!
The installation and operating instructions must be read carefully and all safety
regulations observed before installation and initial operation as danger to personnel and
damage to machinery may be caused.
•Only qualified and well-trained specialists who are familiar with the transportation,
installation, initial operation, maintenance and operation of the units as well as with the
relevant standards may carry out the corresponding works.
•Technical data and indications (Type tag and documentation) are to be kept absolutely.

5About this manual
User Manual for PMotion Page 7
5 About this manual
This manual explains how to use the PMotion program, a software tool used to generate
motion curves for the control systems
•PMCprimo 16+,
•PMCprimo C,
•PMCprimo Drive2 and
•PMCprimo Drive3
from Pilz. The Motion Generator, which operates internally within the control systems, is also
described.
Knowledge of the Microsoft Windows operating system and the use of a PC is assumed.
You must follow the safety, installation and commissioning instructions in the installation
manual for the servo amplifier that is used.

6Introduction
Page 8 User Manual for PMotion
6 Introduction
6.1 Installation under Microsoft Windows
The software is installed using the installation program on the "Motion Control Tools".
The CD-ROM contains an installation program which makes it easier for you to install the
software on your PC. The CD-ROM also has an "AutoPlay" function: once the CD-ROM has
been inserted, a dialogue box will open automatically, showing various selection options
(program installation, manuals, etc.). This function can also be started manually by calling up
the program minstall.exe.
Install:
Place the CD-ROM in the CD-ROM drive of your computer. After a few seconds the setup
function starts automatically, if "Autoplay" is enabled. Otherwise please start minstall.exe.
Choose "Install Motion Control Tools" and follow the on-screen instructions.
6.2 Hardware requirements
Minimum specification for the PC:
Operating system Windows 2000, XP, Vista or 7
Hardware Minimum requirements of operating system
Interface
one free serial interface
Ethernet interface (optional)

6Introduction
User Manual for PMotion Page 9
6.3 General Description
The Motion Generator is a software tool which allows the machine designer to create, modify
and implement custom positional mapping between two machine axes. It can be used as a tool
to design and implement machine cams, but without the limitations of a mechanical cam.
When using the Motion Generator each custom machine motion is called "Map" (one axis is
mapped to another). There are a number of terms and phrases associated with the Motion
Generator which have specific meanings. Look at the following description (Chapter 6.3.1).
This manual describes the Motion Generator, which operates internally within the controllers,
and the PC-based motion generator PMotion, a tool available with the "Motion Control Tools".
•The motion generator interface PMotion runs on the PC and is part of the "Motion Control
Tools" software package that operates under Windows. This component was developed to
enable the graphical generation of movements between two axes for a machine on which
the controllers’ axes are regulated. This graphical construction of a motion curve can be
loaded and stored on control systems in the form of position mapping (a table of
Master/Slave positions). The position mapping can also be loaded into control systems as
an executable program (sequence) and can be calculated there using the internal motion
generator.
•The motion generator that operates internally within the control systems can be purchased as
an accessory. This internal motion generator is a program which reads information about
defined variables from special map sequences and can use the values from these
variables to calculate tabular values for position mapping in the controller.
6.3.1 Designations
Map Shape The name for the curves displayed on the monitor, for the data stored on the PC and the list of
variables for the internal controller calculation. A map shape is the description of a Master/Slave
relationship consisting of a series of segments with the relevant additional parameters for each
segment. The data from a map shape can be used to calculate the corresponding slave position
for each stated master position.
Map Table The name for a series of position co-ordinates (for Master and Slave), which correspond to the
curves on the PC and originate from the motion generator. The controller uses the position co-
ordinates to set up the relative positional relationship between Master and Slave (the points
between the co-ordinates are calculated through linear interpolation).
Map Sequence The name for a sequence with which a map can be calculated by the internal Motion Generator
of the controller.
Segment A single section of the map shape. A segment will have a type to define its shape and may
have certain additional parameters which affect its shape.

6Introduction
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6.3.2 Motion Generator Overview
The Motion Generator provides the ability for the user to create complex position mappings
between one axis and another. Before using the Motion Generator a number of issues need to
be understood:
•You are designing a map shape which relates the position of the slave axis to the position
of the master axis at any point along the master axis. This is essentially a cam, although
you can do things that a cam could not. During the design of the map shape you will
determine the map shape using segments, and setting parameters for these segments.
•Certain restrictions have been applied, by default, to the segment to segment boundaries
to ensure that the generated map shape is physically achievable:
Default segment boundary conditions:
Slave Derivative Segment nn to Segment nn+1 boundary conditions (defaults)
Position Match with previous: The start position of segment nn+1 will match
the end position of segment nn. This cannot be altered.
Velocity Match with previous: The start velocity of segment nn+1 will
automatically be adjusted to match the end velocity of segment nn.
This may have the effect of modifying the shape of segment nn+1
which can lead to unexpected segment shapes. (For certain segment
types it is possible, but not advisable, to break this matching.)
Acceleration No value specified: For all segment types excluding polynomial and
cubic spline acceleration at the beginning of segment nn+1 is
determined by the segment type. Therefore there may be a step
change in acceleration across the nn to nn+1 segment boundary.
Match with previous: A polynomial segment and the cubic spline
segment automatically matches their start acceleration to the end
acceleration of segment nn. For the polynomial segment alone this
matching can be broken.
Jerk No value specified: The jerk value at the beginning of segment nn+1
is determined by the segment type. Therefore there may be a step
change in jerk across the nn to nn+1 segment boundary.
For the polynomial segment alone it is possible to change this to
match with previous or specify the required value.

6Introduction
User Manual for PMotion Page 11
•The map shape wraps round. In other words the last segment connects to the first
segment. However the continuity laws across this segment to segment boundary are, by
default, different from those on all other segment to segment boundaries:
Last to first default segment boundary conditions:
Slave Derivative Last segment to first segment boundary conditions (defaults)
Position Specified value: The end position of the last segment and the start
position of the first segment can both be specified. Therefore there can
be a step change in position across this boundary. You can manually
align the end position of the last segment to match the start position of
the first segment if required (linear slave axis).
Velocity Match with previous: Normally the start velocity of the first segment
will be automatically adjusted to match the end velocity of the last
segment.
The one exception to this rule is when all segments inherit their
velocity from the previous segment: the first segment will then start
with zero velocity. In this case use a constant velocity segment to
create any required velocity offset.
Acceleration No value specified: For all segment types excluding polynomial and
cubic spline the acceleration at the beginning of the first segment is
determined by the segment type.
Match with previous: If the first segment is either a polynomial or
cubic spline segment then it automatically matches it's start
acceleration with the last segment's end acceleration. For the
polynomial segment alone this matching can be broken.
Jerk No value specified: The jerk value at the beginning of the first
segment is determined by the segment type. For the polynomial
segment alone this can be changed to matching or start jerk specified.
•At no instance does a map shape or map table contain any time dependent information.
The velocity and acceleration of the slave axis at any point will depend upon the velocity of
the master axis.
For the PC based Motion Generator PMotion only: to enable you to develop a map shape
that is within the physical constraints of your machinery it is possible to enter the number of
cycles per minute required. This sets the master velocity at a constant value and allows the
motion generator to put figures on the slave velocity and acceleration shapes.
•The default segment type is polynomial. This segment type is the most configurable of all
the available types and should be used in preference to another type whenever possible.
With the exception of the start of segment position parameter (which must always match
the end of the previous segment) it is possible to modify the boundary constraints for all the
derivatives at both the start and end of the segment. This means that it can be configured
to provide a smooth transition between known points.

7PC based Motion Generator PMotion
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7 PC based Motion Generator PMotion
7.1 Introduction
PMotion is part of Motion Control Tools, which can be used for graphically design of custom
machine motions between two machine axes.
Screen layout:
The Motion Generator window presents the current map shape as a series of segments. In the
above picture position, velocity, acceleration and jerk are being viewed. The currently selected
segment is highlighted in red and the position of the mouse pointer is given in map coordinates
in the status bar.
When PMotion is first started a map consisting of a single segment is displayed. This map can
then be edited as required, or a previous session can be loaded from the PC disk.
The following sections detail all the menus, dialogue boxes and actions associated with the
Motion Generator.

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7.2 Menus
7.2.1 Menu "File"
New Creates a new map with the default segment type "Polynomial".
Open Loads a map from the PC disk.
Close Closes the current map file. If the file has been changed, the user will
be indicated to save the changes.
Save Saves the current map to the PC disk.
Save as Saves the current map on using a different file name.
Print Prints the current map. In a dialogue box you can choose the printer.
Print Preview Preview a print – see what your program will look like when printed.
Printer Setup Printer configuration.
Send Send the current map via email.
Exit Quits PMotion.
7.2.2 Menu "Edit"
Undo You can undo the last change of your map you are working on.
Segment left Selects the segment on the left side of the currently selected segment.
Segment right Selects the segment on the right side of the currently selected
segment.
Insert Segment Inserts a segment to the left of the currently selected segment. The
new segment will be 1000 counts long and of a polynomial type. The
master cycle length will be stretched automatically.
Split Segment Splits a Segment into two parts.
Append Segment Adds a segment to the end of your map shape. The new segment will
be 1000 counts long and of a polynomial type. The master cycle length
will be stretched automatically.
Delete Segment Deletes the currently selected segment. You cannot delete the
segment if it is the only one in a map shape.
Segment parameters Opens a dialogue bar on the left side of the view, where you can
configure the currently selected segment settings.

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Map Settings Opens a dialogue box, where you can configure the map shape
settings.
Map variables Shows a dialogue box in which you can edit the map variables.
Colours and Lines Adjustment of colours and lines for the motion view.
Show comparison mapShow/Hide a further map in the motion view. Select a map in the
following dialog to compare it to the current map.
7.2.3 Menu "View"
Position Shows or hides the view „Position“.
Velocity Shows or hides the view „Velocity“.
Acceleration Shows or hides the view „Acceleration“.
Jerk Shows or hides the view „Jerk“.
Toolbar Shows or hides the toolbar.
Status bar Shows or hides the status bar.

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7.2.4 Menu "Create"
Create Map Table Creates the current map shape as a map table in a ptf-file (ptf = PMC
text file). With the text editor PEdit you can download this map to the
controller.
Create Map Sequence Creates the current map shape as a map sequence in a ptf-file (ptf =
PMC text file). With the text editor PEdit you can download this
sequence to the controller. The internal Motion Generator on the
controller is able to generate maps from this sequence during runtime.
Download map table Downloads the current map shape as a map table directly to the
controller.
Download map sequence
Downloads the current map shape as a controller sequence directly to
the controller. The internal Motion Generator on the system is able to
generate maps from this sequence during runtime.
Import map
Active map from system
Imports the last map sequence to be executed (XS command) from
the connected controller.
Map sequence from system
Imports a map from a map sequence saved on a controller.
Map sequence from file
Imports a map from a map sequence saved in a ptf file.
If values in the map sequence are defined as variables, you can
enter a value for these during import for showing the map.
Export map as FB for SoftPLC
Exports the current map (map table or map sequence) as a function
block for the system integrated Software PLC.

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7.2.5 Menu "Programs"
PTerm Starts the terminal program PTerm.
PDrive Starts the setup software PDrive.
PScope Starts the scope function PScope.
PEdit Starts the text editor PEdit.
7.2.6 Menu "Window"
New window Opens a further window for the current document.
Cascade Arranges all the windows you are editing in a neat, cascaded, pile.
Tile Tiles all the windows you are editing horizontally across the screen.
Arrange icons Arranges all icons in the bottom area of the window.

7PC based Motion Generator PMotion
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7.3 Toolbar
With the toolbar you have direct access to important functions of the program.
Creates a new map.
Opens an existing map.
Saves the current map file.
Displays full pages of the current map before printing.
Prints the current map.
Selects the segment on the left side of the currently selected segment.
Selects the segment on the right side of the currently selected segment.
Inserts a new segment to the left side of the currently selected segment.
Splits a segment into two parts.
Adds a segment to the end of your map shape.
Deletes the currently selected segment.
Opens a dialogue bar on the left side of the view to configure the segment settings.
Creates a map table in a ptf-file (ptf = PMC text file).
Creates a map sequence in a ptf-file (ptf = PMC text file).
Downloads a map table to the controller.
Downloads a map sequence to the controller.
Starts the terminal program PTerm.
Starts the setup software PDrive.
Starts the scope function PScope.
Starts the text editor PEdit.
Opens the “About” dialog.

7PC based Motion Generator PMotion
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7.4 Map Settings
The map settings dialogue is presented when the menu option "Edit" -> "Map Settings"
is chosen.
The dialogue consists of four property pages:
7.4.1 Property Page „Map“
Map Name: Each map has its unique name on the controller. The name consists of an alphanumeric
expression with a maximum of 20 characters. This identifier will be used for the map table
when it is downloaded into the controller.
Number of
Steps:
When a map shape is turned into a map table the Motion Generator needs to know what
resolution you require. The more map steps the greater the resolution of the map table, but
also the larger the memory space for saving the table in the Flash EPROM. The maximum
number of steps is 65536.
Cycle Length
(Master):
The master length is the length of the map shape along the master axis (horizontal) in position
units. If this value is changed the whole map is scaled and all the master and slave positions
are affected. The length of the master axis and the machine’s cycle speed are used to calculate
the curves.

7PC based Motion Generator PMotion
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7.4.2 Property Page “Master”
Scaling / Unit PMotion can work with user defined units. Therefore it needs the name of the chosen unit and
the scaling factor (numerator and denominator) for the conversion between the new unit and
the standard encoder counts. This factor is necessary, because the internal position values of
the controller must be defined in increments (encoder counts).
Offset A offset of master position can be entered to shift the map horizontally.
Attention: The offset will not be transmitted to the motion control system. Use the command
“MB” to shift a map on the system.

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7.4.3 Property Page “Slave”
Scaling / Unit Like the master axis user defined units are also possible on the slave axis. Therefore PMotion
needs the name of the chosen unit and the scaling factor (numerator and denominator) for the
conversion between the new unit and the standard encoder counts. This factor is necessary,
because the internal position values of the controller must be defined in increments (encoder
counts).
Show
maximum
values
The maximum values for position, velocity, acceleration and jerk can be defined. These
maximum values will be displayed as horizontal lines in the diagrams. The colour can be
changed in the dialog box “Colours and lines”.