YASKAWA MP2000iec Administrator guide

Doc#: EM.MCD.09.095 Copyright Yaskawa Electric America ©2009 July 13, 2009
Page 1 of 21
Example Code Manual
Example Code Manual for Linear Flying Shear on MP2000iec
Sigma-5 demo using Camming
Applicable Product: MP2000iec, MotionWorks IEC
Yaskawa Electric America
2121 Norman Drive South
Waukegan, IL 60085
1-800-927-5292

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 2 of 21
Application Overview
This document explains how to demonstrate the linear flying shear application with camming on the MP2000iec –
Sigma-5 demo box. The algorithm and core program elements are explained in detail.
Application Highlights:
Industry: Automation industry using electronic camming for registration based applications
Major Features: Electronic camming, cam shifts on the fly based on high speed registration
Products Used:
Component
Servopack
Motor
Controller
Software MotionWorks IEC, CamTool
Product and Model Number
Sigma-5 MECHATROLINK II Rotary type
SGMAV, SGMJV
MP2000iec

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 3 of 21
Application Explanation
The sample code explained in this manual simulates the linear flying shear application as shown in Figure 1
below. The conveyor is the master. The ball screw unit is the slave that cams to the master axis based on a
registration mark. The cutting axis shown in the figure has not been incorporated into the sample code.
Figure 1: Linear Flying shear unit
The relation between the master and slave is given by the following profile (figure 2).
Figure 2: Stages of slave cam profile

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 4 of 21
Figure 3: Critical positions on the cam master slave profile
Figure 3 details the critical points on the master and slave profiles. The algorithm followed to execute the linear
flying shear is shown in Figure 4. The algorithm starts with the shear axis (slave) at the home position and the
master axis running at a constant velocity. The slave axis waits for a registration mark from a part or on the
master axis. This triggers a shift in the master position such that the start of the cam cycle comes by when the
registration mark reaches the slave home position after covering the sensor to start distance (SSD). Once the
slave cams in and is synchronized, the window for capturing next registration latches opens up (when the slave
passes 30 mm of travel in the forward direction). If a registration is captured when the window for capture is
open, the position is stored and the calculation for phase and master distance is performed. The shift cannot
start immediately because when the shearing process is in progress, the slave and master need to be in tight
sync. Only after the shear is done, can the shift for the next part start. This is determined using a dead man area
on the slave’s position profile (user defined).

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 5 of 21
Figure 4: Linear flying shear algorithm

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 6 of 21
The phase is calculated by noting the difference in two consecutive latches on a 360 degree cycle. The master
distance is calculated as (SSD – (SSP – Master shifted position)) where SSD is distance the part has to travel to
get to the shear home position. SSP is the shift start position which is the position on the master from where the
shift can start. This is shown in Figure 5.
Figure 5: Implementation of cam shift
Figure 6 is an illustration of continuous part registration at unequal intervals. Shift one is executed for the first
latch (registration) seen in figure 6. Since the second registration was very early in a cycle, the shift to get the
slave back to home position is very large. This large shift over a small distance causes the slave to return back to
home in a very fast move on the return stroke as can be seen from shift 2. Since the third registration happens
almost at the end of the window, the phase shift is small and it has more distance over which to implement the
shift. It can be seen from Figure 6 that the third shift does not cause a major change in the cam profile.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 7 of 21
Figure 6: Multiple continuous registrations at unequal intervals
Figure 7 is an illustration of a first part detection or part detection after a cam out. It can be seen that at part
detection, the master position is 32 degrees. Sensor to home distance is 180 degrees. This means that the cam
cycle will have to start when the actual master position is 32 + 180 = 212 degrees. This first part shift can be
seen in Figure 7. If a part is not detected in the window area, a cam out is commanded and after the cam out is
done, a phase shift to negate all cumulative phase shifts is carried out so that the total shift becomes zero and
the master position and shifted master position match up as can be seen at the end of the profiles in figure 7.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 8 of 21
Figure 7: First part detection or part detection after a cam out
Demo Instructions:
The master axis (Left axis) is configured to be in rotary mode with a 360 degree cycle. (1 rev or motor = 360 user
units). The slave axis is configured as a linear axis with 1 rev of the motor = 100 mm of linear travel.
1) Make sure the servo axes on the demo case are tuned for improved performance
2) Manually orient the slave shear axis (right axis) such that the arrow points up. Flip SI5 switch on and off to set
that position as the home position for the slave axis. The position at which the master (left axis) is will be set as
its zero position too. The orientation of the master axis does not matter in this step.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 9 of 21
Figure 8: Demo case controls for sample program
3) Enable the servos using DI0. Leave DI0 on

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 10 of 21
4) Flip DI1 on and off. This is to home the slave axis. On starting up, the slave axis is already in its home
position.
5) Turn on DI2. This will start the master axis jog. The master axis will jog at 90 degrees /second. To stop the
master jog, turn DI2 off.
6) When DO2 lights up, it is an indication that the controller program is ready for registration.
7) Flip SI4 on the first row on and off. This simulates a part or registration mark. DO2 will turn off. The slave axis
will wait for the master axis to turn 180 degrees (distance from sensor to shear’s home) from where the mark
was seen and then start the cam profile. The slave axis travel one way is 250 mm or 2.5 revs on the demo.
When the slave passes 30 mm travel, DO2 turns on and indicates that the system is ready for another mark.
DO2 will be on until the window is closed (240 mm on the slave). The slave’s shift in profile during the travel back
to home will depend on when the registration was seen in the cycle. If the part was detected early (closer to 30
mm), the move back on the slave will be rapid. If the part was detected later (closer to 240 mm), the move back
will be slow.
If a part is not detected while the slave is synchronized to the master and the window is over (DO2 turns off), the
slave cams out and stays at the home position until the next part comes along. The system will be ready for
registrations (DO2 on) as soon as the cam out is done.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 11 of 21
Program Explanation:
The various POUs in the sample project are explained in this section.
Initialize: This POU runs for the first scan and initializes the axis IDs and other relevant application parameters
like sensor to start distance, shift start distance and cycle.
Enable: The Enable POU controls the enabling of the two axes. There is a reset alarms control in this PO.
Monitor: The Monitor POU has function blocks that monitor parameters like master position, slave position,
master shifted position and unmodularized (raw) master position
Home: The Home POU controls how the user defines the home position for the slave. Home position for the
master is not significant because the master is a rotary infinite axis. After a home position is set once in a run,
the slave axis can be commanded to go to that home position at any instant using a MC_MoveAbsolute block.
Production:
Figure 9: Master move control

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 12 of 21
Master axis move can be controlled using a MC_MoveVelocity FB. The velocity can be adjusted on the fly using
the velocity variable. The master is brought to a stop using MC_Stop.
Figure 10: Cam file select and window for registration
The cam profile for the shear axis (slave) is loaded as a csv file from the controller memory to the ProconOS

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 13 of 21
memory for cam calculation using Y_CamFileSelect. Window for registration is defined based on actual position
on the shear axis using GE blocks.
Figure 11: Logic for executing registration latch

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 14 of 21
Figure 11 is a screen shot of the logic that executes the MC_TouchProbe FB to capture a registration. The three
scenarios in which it needs to be triggered are
a) when the machine is started the first time (master in velocity)
b) When the cam is engaged but the window feature is active
c) When the cam is active but no part was detected in the window and cam out is executed
Figure 12: Trigger abort block
The touch probe functionality is aborted as soon as a part is detected, or if the master stops its move or if the
window is over.
Figure 13: Capturing the raw position of the registration latch

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 15 of 21
As seen from Figure 13, parameter 1031 is used to capture the raw master position when the latch was
triggered.
Figure 14: Calculating the modular master position corresponding to the raw master position
The modular master position is required to make a shift when a part is detected when the slave is not
synchronized and at home. (In order to start a new cam relation). This is shown in Figure 14. The bit ‘calculate’ is
used to trigger this calculation.
The shift for the first part detected is different for parts detected while the slave is in sync with the master. The
phase shift and distance calculation are as shown in Figure 15

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 16 of 21
Figure 15: Calculating the master distance and phase shift for the first part in production.
Figure 16 details the logic for executing the cam shift block for the first part. Figure 17 is the cam in function
block to engage the cam at the start location after a shift has been done to the master position.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 17 of 21
Figure 16: Cam Shift for the first part
Figure 17: Cam in function block

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 18 of 21
Figure 18: Logic to decide on cam disengage
Figure 18 shows the logic to determine if a cam out needs to be executed. A cam out is executed if no part is
detected within the window of an existing cam cycle. If no part is detected, a cam out is issued and a shift back is
commanded such that there is no phase shift in the master’s position after the cam out is done. This is shown in
Figure 19.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 19 of 21
Figure 19: Total phase shift back to cancel accumulative shifts
If a part is detected when the slave is in the window area, the phase shift is calculated based on the difference
in master position between two adjacently detected parts on the scale of one cam cycle. This position difference
will be the shift to be incorporated in such a case. This is shown in Figure 20. Figure 21 illustrates how the
master distance and phase calculations are done when the slave is in sync and a shift has to be performed for a
new registration. Figure 22 describes the logic to decide when the shift should be executed for a new registration
while the slave is cammed.

Subject: Example Code Manual Product: MP2000iec Doc#: EM.MCD.09.095
Title: Example Code Manual for Linear Flying Shear on MP2300Siec Sigma-5 Demo using camming
July 13, 2009 Page 20 of 21
Figure 20: Phase shift if part detected while slave is in sync
Figure 21: Master distance and phase for shift while slave is in sync
Figure 22: Logic to activate shift while slave is in dead man area