SEW-Eurodrive MOVI-PLC User manual

Drive Technology \ Drive Automation \ System Integration \ Services
MOVI-PLC
®
Application Solution
“SyncCrane“
Manual
Edition 03/2008
11666617 / EN

SEW-EURODRIVE – Driving the world

Manual – MOVI-PLC® Application Solution "SyncCrane" 3
1 General Information ............................................................................................ 5
1.1 Structure of the safety notes ....................................................................... 5
1.2 Right to claim under limited warranty.......................................................... 5
1.3 Exclusion of liability..................................................................................... 6
1.4 Other applicable documentation ................................................................. 6
2 Description .......................................................................................................... 7
2.1 Fields of application .................................................................................... 7
2.2 Application examples .................................................................................. 9
2.3 Functional principle of indirect positioning and synchronization ............... 10
2.4 Program identification ............................................................................... 15
3 Project Planning................................................................................................ 16
3.1 Prerequisites ............................................................................................. 16
3.2 Functional description ............................................................................... 17
3.3 Scaling the drive ....................................................................................... 19
3.4 Limit switches, reference cams and machine zero ................................... 20
3.5 Process data assignment.......................................................................... 21
3.6 Software limit switches.............................................................................. 25
3.7 Hardware limit switches ............................................................................ 26
3.8 Safe stop................................................................................................... 27
4 Installation ......................................................................................................... 28
4.1 Software MotionStudio.............................................................................. 28
4.2 Wiring diagram MOVIDRIVE® MDX61B................................................... 29
4.3 Bus installation PROFIBUS DHP11B ....................................................... 30
4.4 Connecting system bus (SBus 1).............................................................. 30
5 Startup................................................................................................................ 31
5.1 Prerequisites ............................................................................................. 31
5.2 Preliminary work ....................................................................................... 31
5.3 Starting the SyncCrane program .............................................................. 33
5.4 Parameters/H variables of the MOVI-PLC® ............................................. 49
5.5 Drive inverter parameters ......................................................................... 50
5.6 Group signals............................................................................................ 50
5.7 Program overview of the PLC program..................................................... 53
6 Operation ........................................................................................................... 55
6.1 Starting the drive....................................................................................... 55
6.2 Diagnostics monitor .................................................................................. 56
6.3 Jog mode – unsynchronized ..................................................................... 56
6.4 Referencing mode..................................................................................... 59
6.5 Positioning mode – unsynchronized ......................................................... 60
6.6 Automatic mode ........................................................................................ 62
6.7 Emergency mode...................................................................................... 67
6.8 Additional functions................................................................................... 68
6.9 Cycle diagrams ......................................................................................... 69
6.10 Fault information ....................................................................................... 76

4Manual – MOVI-PLC® Application Solution "SyncCrane"
7 Auxiliary Drive (Auxiliary Axis)........................................................................ 77
7.1 System description.................................................................................... 77
7.2 Project planning for auxiliary drives .......................................................... 79
7.3 Startup of auxiliary drives.......................................................................... 83
7.4 Operation of auxiliary drives ..................................................................... 89
8 Appendix............................................................................................................ 93
8.1 Frequently asked questions ...................................................................... 93
9 Address List ...................................................................................................... 94
Index ................................................................................................................. 103

Manual – MOVI-PLC® Application Solution "SyncCrane" 5
1
Structure of the safety notes
General Information
MOVI-PLC® Appl ication Solution "SyncCrane"
1 General Information
1.1 Structure of the safety notes
The safety notes in these operating instructions are structured as follows:
1.2 Right to claim under limited warranty
A requirement of fault-free operation and fulfillment of any rights to claim under limited
warranty is that you adhere to the information in the MOVIFIT®, MOVIDRIVE®or
MOVITRAC®documentation. Consequently, read the operating instructions and
manuals before you start working with the unit!
Make sure that the operating instructions and manuals are available to persons
responsible for the plant and its operation, as well as to persons who work independently
on the unit. You must also ensure that the documentation is legible.
Symbol SIGNAL WORD!
Nature and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to avoid the hazard.
Symbol Signal word Meaning Consequences if
disregarded
Example:
General hazard
Specific hazard,
e.g. electric shock
HAZARD! Imminent hazard Severe or fatal injuries
WARNING! Possible hazardous situation Severe or fatal injuries
CAUTION! Possible hazardous situation Minor injuries
STOP! Possible damage to property Damage to the drive system or its
environment
NOTE Useful information or tip.
Simplifies the handling of the
drive system

6Manual – MOVI-PLC® Application Solution "SyncCrane"
1Exclusion of liability
General Information
1.3 Exclusion of liability
You must comply with the information contained in the operating instructions to ensure
safe operation of MOVIFIT®, MOVIDRIVE®or MOVITRAC®and to achieve the
specified product characteristics and performance requirements. SEW-EURODRIVE
assumes no liability for injury to persons or damage to equipment or property resulting
from non-observance of these operating instructions. In such cases, any liability for
defects is excluded.
1.4 Other applicable documentation
• This manual does not replace the detailed operating instructions and the
corresponding manuals.
• Installation and startup of the inverter only by trained personnel observing the
relevant accident prevention regulations and the following documents:
–"MOVIFIT
®FC" operating instructions and corresponding manuals
– or "MOVIFIT®MC" operating instructions and corresponding manuals
– or "MOVIDRIVE®MDX60B / 61B" operating instructions and corresponding
manuals
–or"MOVITRAC
®B Basic Unit" operating instructions and corresponding manuals

Manual – MOVI-PLC® Application Solution "SyncCrane" 7
2
Fields of application
Description
2 Description
2.1 Fields of application
The SyncCrane application module is used to implement applications in which drives
move at a synchronous angle to one another permanently or occassionally, such as:
• Lifting devices
•Cranes
•Hoists
• Travel carriages
The IEC program controls up to 8 MOVIDRIVE®individual axes. In Automatic mode, it
sends a virtual master signal to the individual axes switched in synchronous operation.
Control of 4 additional auxiliary drives (e.g. pushers/hydraulic units, etc.) is supported.
2.1.1 Advantages of the SyncCrane application
The SyncCrane application offers the following advantages:
• Only one MOVI-PLC®is required for controlling the individual axes.
• Open IEC programming lets users make application-specific adjustments.
• The software wizard ensures guided startup and comprehensive diagnostic
functions.
• High degree of similarity with "SEW application modules".
• In addition to the motor encoder, external absolute encoders (HIPERFACE®/SSI)
can be connected and evaluated.
• Common setpoint for automatic mode is ensured by controlling the single axis via
virtual encoder.
• Indirect positioning or indirect synchronization allows for safe system operation in the
following cases:
• Different wear of the drive axes
• Slip, for example between drive gear and steel rail
• Design susceptible to vibration
This application solution provides the user with an easy-to-use and guided startup
standard solution based on the principle of "indirect positioning/synchronization".
This solution approach allows the following applications:
• Applications with high requirements on the dynamic properties.
• Applications that are susceptible to vibration due to mechanical conditions (e.g. due
to high elasticity and/or unfavorable load distribution between the drivelines).
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8Manual – MOVI-PLC® Application Solution "SyncCrane"
2Fields of application
Description
2.1.2 Characteristics of positioning mode and jog mode
Characteristics of positioning mode and jog mode:
• Positioning mode based on motor encoder with optional indirect position adjustment
based on external synchronous encoder.
• Override function for reaching the target in an optimized manner by straightening the
linear deceleration ramp.
• Group / individual axis control of the connected axes.
• Software limit switch evaluation
2.1.3 Characteristics of referencing mode
Characteristics of referencing mode:
• Referencing the motor encoder system to the specified reference offset.
• Depending on the reference travel type, referencing is performed to a standstill
position or the axis system is referenced to a cam position via search travel.
• Adjusting the external encoder signal to the specified reference offset.
• Group control for all connected axes.
• Single-axis control when using the "standstill" reference travel type.
2.1.4 Characteristics of automatic mode
Characteristics of automatic mode:
• Automatic alignment of the physical axes with each restart.
• Synchronous operation with automatic indirect synchronization of the external
encoder system to the virtual encoder position.
• Virtual master value processing with jerk-limited ramp specification.
• Group control for all connected axes.
• Automatic interruption of the motion sequence if an axis fails and/or the specified
synchronicity is violated.
2.1.5 Characteristics of emergency mode
Characteristics of emergency mode:
• Jog mode (with motor encoder or without encoder).
• Group / individual axis control of the connected axes.
• Deactivation of the selected absolute encoder detection and monitoring.
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Manual – MOVI-PLC® Application Solution "SyncCrane" 9
2
Application examples
Description
2.2 Application examples
The SyncCrane application module offers a wide range of possible applications. Some
examples are given in this section.
Example 1: Multiple column hoist with positioning and synchronization based on
HIPERFACE®motor encoder.
Example 2: Gantry crane with indirect positioning and automatic slip compensation by
means of absolute encoder evaluation.
511850891
511852427
Slave
Master
Slave
Master
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10 Manual – MOVI-PLC® Application Solution "SyncCrane"
2Functional principle of indirect positioning and synchronization
Description
2.3 Functional principle of indirect positioning and synchronization
2.3.1 The Problem
Existing applications with evaluation of the absolute encoder as IPOS encoder (see
IPOS manual chapter "Position detection and Positioning") limit the control dynamics
due to the properties of the absolute encoder systems and the mechanical conditions
(e.g. mounting of the encoder system).
Due to mechanical feedback, the entire system is susceptible to vibrations, which often
requires complex optimization of the control parameters on site.
The IPOS-based application module "DriveSync" was implemented according to this
principle. Especially when it comes to lifting devices and assembly-hall cranes, where
evaluation of an absolute encoder is necessary in addition, compromises have to be
made in project planning with respect to dynamics.
The SyncCrane application solution simplifies startup and operation.
2.3.2 Conventional solution: Direct position control with absolute encoders
The necessary SHELL parameters are determined during guided startup (SHELL/DIP
startup). Direct position control is part of the firmware. This means no additional
programming is required.
During the positioning operation, the cyclically read-in actual position (absolute encoder/
motor encoder position) is read in by the profile generator and corrected by adjustment
of the n-controller in case of deviations.
Deviations caused, for example, by slip between motor encoder and absolute encoder
thus directly affect the speed profile of the drive.
The following figure shows direct position control with position correction.
536585611
vmax Maximum velocity nC Speed controller
amax Maximum acceleration nact Actual speed
PG Profile generator ABS Absolute encoder
PC Position controller IPOS IPOSplus® program
DIP 11B
PG PC nC
M
–
+
n
act
V
max
a
max
IPOS
–
+
X62
ABS
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Manual – MOVI-PLC® Application Solution "SyncCrane" 11
2
Functional principle of indirect positioning and synchronization
Description
The following figure shows the speed profile (motor encoder) for direct position control.
774628875
[1] Optimal speed process
[2] Real speed process
V [m/s]
t [s]
[1] [2]
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12 Manual – MOVI-PLC® Application Solution "SyncCrane"
2Functional principle of indirect positioning and synchronization
Description
2.3.3 SyncCrane solution with indirect position control
Unlike direct position control, the absolute encoder signal is only evaluated for correct-
ing the specified target position.
During the travel process, the speed profile of the drive is therefore not changed.
Susceptibility to vibration caused by retroactive effects, for example deviations between
the absolute encoder detection and motor encoder detection, are minimized in this way.
The user can optimize time delays in absolute encoder sensing and setpoint processing
by setting an "override". The override causes an early and softer run-in to target, which
suppresses overshoots.
This function is part of the SyncCrane application module.
The following figure shows indirect position control with absolute encoder.
536587275
vmax Maximum velocity POSact Actual position motor encoder
amax Maximum acceleration POSset Setpoint position motor encoder
PG Profile generator ABS Absolute encoder
PC Position controller nact Actual speed
nC Speed controller
Calc
Delta Inc PGMOVI-PLC PC nC
M
Pos
act
Pos
set
n
act
X15 Pos
act
V
max
a
max
DIP 11B
++
––
X62
ABS
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Manual – MOVI-PLC® Application Solution "SyncCrane" 13
2
Functional principle of indirect positioning and synchronization
Description
The following figure shows the speed profile (motor encoder) with override for indirect
position control.
2.3.4 Conclusion
The table below contains a comparison of both solutions and their effects on internal
position control.
Result The following properties do not have an effect on the speed profile of the drive but on
the target position of the position controller if positioning tasks are solved using indirect
position control:
• Slip
• Properties of the absolute encoder
• Mechanical elasticities between absolute encoder sensing and the drive
This leads to a higher dynamic response and thus to improved operating characteristics
for dynamic positioning applications.
This solution with indirect positioning has been successfully implemented at SEW-
EURODRIVE for some time in the area of SRUs with cornering ability, etc.
536580619
V [m/s]
t [s]
Optimal speed process
Real speed process
Direct position control Indirect position control
Mechanical mounting Direct effect No direct effect
Position resolution Direct effect No direct effect
Properties, such as time delay Direct effect No direct effect
Dynamic response that can be
achieved
Low due to summation of nega-
tive effects
High
Startup effort High, since optimum setting has
to be found iteratively
Low
Effort for implementation in the
program
No Only parameter setting effort when
function modules are available.
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14 Manual – MOVI-PLC® Application Solution "SyncCrane"
2Functional principle of indirect positioning and synchronization
Description
2.3.5 SyncCrane solution indirect synchronization to virtual master encoder
Due to the mentioned positive characteristics in relation to indirect positioning, we are
currently testing if this can also be applied to synchronous operation.
We are working on the approach to superimpose a higher-level control loop for slip
compensation on the firmware function "internal synchronous operation".
Internal control loop: Angular synchronous operation of the motor encoder
Angular synchronous operation is ensured by using the "internal synchronous
operation" technology function.
The specified value for the virtual master is created via SBus object from the MOVI-
PLC®. The optimum master value is ensured for the physical axes because the master
value can be specified with limited jerk.
The controller parameters can be set "hard" by direct coupling of the drive trains.
Higher-level control loop: Indirect synchronization
To prevent mechanical strain, e.g. caused by slight differences in the crane wheel diam-
eter of gantry cranes, the actual position value read in via an absolute encoder must be
compared with the position setpoint of the virtual encoder and corrected if necessary.
This is implemented by the higher-level indirect synchronization.
The cyclically calculated difference value triggers a compensation movement if specified
position windows are exceeded (distinction is made between dynamic and static case).
The dynamics of the compensation movement is set during startup.
The following figure shows indirect synchronization.
536582283
X62
Slave
Virt
Encoder
Download
SynchronousState
= MDX_GEAR_OFFSET
SynchronousSpeed
= VESpeed * Raising
SynchronousSpeed= Staticspeed
OffsetCycleValue = DeltaInc
DeltaInc > PosWindowDynamic
(DeltaInc > PosWindowStatic) &&
(DeltaInc < PosWindowDynamic)
DeltaInc
DeltaInc
–
+
DeltaInc
SynchronousState
SynchronousState =
MDX_GEAR_INGEAR
ABS
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Manual – MOVI-PLC® Application Solution "SyncCrane" 15
2
Program identification
Description
2.4 Program identification
You can use the MOVITOOLS MotionStudio®software package to identify the program
that was loaded last into the MOVI-PLC®.
From the menu, choose [Diagnostics]/[MOVI-PLC: Information and Remote Control].
The "Information" tab page shows the current application.
832287115
Part number A loaded SyncCrane application module can be identified by the part number
18219543.xx
Version The current main version of the application module is displayed in this field.
Release The current release of the application module is displayed in this field.
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16 Manual – MOVI-PLC® Application Solution "SyncCrane"
3Prerequisites
Project Planning
3 Project Planning
3.1 Prerequisites
3.1.1 PC and software
The SyncCrane application module is implemented in the MOVI-PLC®as IEC code and
is part of the MOVITOOLS MotionStudio®software version 5.5 and later.
You require a PC with one of the following operating systems to use the MOVITOOLS®
MotionStudio:
• Windows®95
• Windows®98
• Windows®NT 4.0
• Windows®2000
• Windows®XP
You also require:
• MOVITOOLS®MotionStudio version 5.5 or higher.
• Libraries 2020 or higher.
3.1.2 Inverter
MOVIDRIVE®•MOVIDRIVE
®B with encoder feedback.
• Optional absolute encoder evaluation or HIPERFACE®encoder evaluation.
• Firmware 824 854 0.18 or higher.
• Prior motor startup of the individual axes using the SHELL software
• If required, prior startup of the external HIPERFACE®encoder or absolute encoder
using the SHELL software. The IPOS encoder source SHELL parameter 941, IPOS
encoder source must remain set to motor encoder.
• Subsequent configuration of the individual axis for operation with MOVI-PLC®via
DriveStartup. Make sure that different SBus individual addresses are specified.
Assign the numbers in increasing order beginning with 1. It is important that the
communication is set to 1 Mbaud.
• Only PROFIBUS is supported for connection to the bus master with the DHP11B
option.
Connection of motor shaft and load
Positive connection
External encoder is not required
Non-positive connection
External encoder required
External encoder type Absolute encoder Incremental encoder Absolute encoder
Bus type
(required option) PROFIBUS
Additional
MOVIDRIVE®option
required
DEH11B or DER11B
DIP11B / DEH11B /
DER11B

Manual – MOVI-PLC® Application Solution "SyncCrane" 17
3
Functional description
Project Planning
3.1.3 Motors / gear units
• Asynchronous or synchronous servomotors with motor encoder
• Gear unit / additional gear
• Optimum control behavior is only achieved with mechanically identical design of
slave axes (same gear ration, wheel diameter, etc.).
3.1.4 MOVI-PLC®
•T2version
3.2 Functional description
The SyncCrane application has the following functional characteristics:
Jog mode
• The drive is moved clockwise or counterclockwise using two bits for direction
selection.
• Velocity and ramp can be specified via fieldbus as required.
Referencing mode
• Position adjustment is initiated with the start signal of the external encoder.
• Reference travel establishes the reference point (machine zero) for absolute
positioning operations.
• Three different reference travel types are supported.
Positioning mode
• The target position is specified by the process output data words PO4 and PO5. The
speed and the ramp can be varied using the fieldbus. The current actual position is
reported back via the process input data words PI4 and PI5. The program cyclically
queries the target position so that position changes are possible during ongoing
positioning.
• When external HIPERFACE®/SSI absolute encoders are processed, the motor
target position is adjusted during the travel process so that possible slip can be
compensated.

18 Manual – MOVI-PLC® Application Solution "SyncCrane"
3Functional description
Project Planning
Automatic mode
• Automatic mode is used as motion control based on the technology function "Internal
Synchronous Operation" (ISYNC) and is controlled in the inverter. Once automatic
mode is selected, the axis system is adjusted to a common "adjust position" in
positioning mode and the axis system is synchronized accordingly. The axis system
can then be moved using the virtual master encoder.
• Master value specification via virtual encoder is made either in jog or positioning
mode.
• The startup wizard lets you specifiy a jerk time for the virtual encoder.
• Position deviations between virtual encoder position and external synchronous
encoder are compensated cyclically during ongoing movement. This is to adjust, for
example, varying wear on the drive wheels without limiting positioning accuracy.
Emergency mode
• The drive is moved clockwise or counterclockwise using two bits for direction
selection.
• Velocity and ramp can be specified via fieldbus as required.

Manual – MOVI-PLC® Application Solution "SyncCrane" 19
3
Scaling the drive
Project Planning
3.3 Scaling the drive
The drives are always scaled in increments.
3.3.1 Determining the scaling factors for motor encoder/absolute encoder
The objective is to map all actual position values via the determined scaling factors to
the absolute encoder.
These values are:
• Specified positions for positioning operation of the physical axes
• Position setpoints in synchronous operation via the virtual encoder and cyclical
compensation between virtual and absolute encoder
• Feedback of actual positions of the physical axes and the virtual master encoder
For draw-wire encoder:
Encoding scaling factor (SHELL parameter 955), for example, for laser distance
encoder:
ScaleFactorMotEncoder Encoder Resolution Gear Box Numerator =×
×
π DDiameter Gear Box Denominator
Inc
mm
ScaleFactorMotEncoder
×
[]
[]
== ScaleMotEncNum
ScaleMotEncDenom
ScaleFactorAbsEncoder Encoder Resolution Encoder Scaling Fact =×oor Gear Box Numerator
Diameter Gear Box Denominator
Inc
mm
×
××
[]
[]
π
SScaleFactorAbsEncoder ScaleAbsEncNum
ScaleAbsEncDenom
=
ScaleFactorAbsEncoder Encoder Resolution Encoder Scaling Fact =×oor Inc
mm
ScaleFactorAbsEncoder ScaleAbsEncNum
ScaleAbsE
1
[]
[]
=nncDenom

20 Manual – MOVI-PLC® Application Solution "SyncCrane"
3Limit switches, reference cams and machine zero
Project Planning
Conversions The following applies:
This means the motor encoder position is calculated as follows with a specified absolute
encoder position:
As well as the absolute encoder position
3.3.2 Determining the scaling factors for virtual encoder
• Setpoint specification refers to the actual position of the absolute encoder.
• The actual position is displayed in the resolution of the absolute encoder.
• The position setpoint is converted internally into the motor encoder.
• Enter the values determined for the external encoder system as conversion factors.
3.4 Limit switches, reference cams and machine zero
Note the following points during project planning:
• The software limit switches must be located within the travel range of the hardware
limit switches.
• When defining the reference position (position of the reference cam) and the
software limit switches, make sure they do not overlap.
• You can enter a reference offset during startup if the machine zero is not located on
the reference cam.
The following formula applies: Machine zero = reference position + reference offset
This way, you can alter the machine zero without having to move the reference cam.
ScaleFactorMotEncoder
MotEncoderPos
ScaleFactorAbsEncoder
Ab
=ssEncoderPos
MotEncoderPos ScaleFactorMotEncoder AbsEncoderPos
ScaleFact
=×
oorAbsEncoder
AbsEncoderPos ScaleFactorAbsEncoder MotEncoderPos
ScaleFact
=×
oorMotEncoder
NOTE
The user interface limits the scaling factors to 216.