Motion Analyzer Software

User Manual

Motion Analyzer Software

Version 7.00

Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety

Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1

available from your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/ ) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, Kinetix, MP-Series, ProposalWorks, Rockwell Automation, Rockwell Software, RSLogix, TechConnect, TL-Series, and Ultra are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

New and Updated

Information

This manual contains new and updated information.

Summary of Changes

This table contains the changes made to this revision.

Topic

Removed the Activation Wizard section.

Added Group/Ungroup and Add Drive Group descriptions to the Home Tab section.

Updated Power Data, Shunt, and Energy tab examples for the

Power Supply/Accessories - Single-axis Drive Systems section.

Added Power Supply/Accessories – AC/DC Power Sharing Systems (Kinetix 5500 drives) section.

51

Updated the Output Format Selection dialog boxes in the Export to RSLogix 5000 Wizard section.

65

Added new Explorer View examples and updated the Drives Group Node description.

Updated the Solution List dialog box example.

Added Preferred Product section.

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210

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46

Page

N/A

Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012 3

Summary of Changes

Notes:

4 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Preface

About This Publication

The versatility of Motion Analyzer software lets users of various application complexities and experience levels use one software package to size their systems.

This manual is designed to accommodate basic users, advanced users, and everyone in between.

Who Should Use This Manual

This manual is intended for engineers directly involved in the selecting, sizing, and optimizing of drives and motors or actuators for a motion control system.

Conventions Used in This

Manual

The following conventions are used throughout this manual:

•

Bulleted lists such as this one provide information, not procedural steps.

•

Numbered lists provide sequential steps or hierarchical information.

•

Hyperlinks are embedded throughout this document so that you can easily navigate to and obtain information that is relevant to your particular application.

System Requirements

Motion Analyzer software requires the following operating conditions.

Attribute

Computer hardware requirements

Operating systems supported

Microsoft Office software supported

Description

• Pentium IV processor

• 1 GB RAM minimum

• 1280x800 screen resolution

• Windows XP - 32 Bit (SP2)

• Windows XP - 64 Bit (SP2)

• Windows Vista - 32 Bit

• Office 2007

• Office 2010

• 500 MB free space in the installation directory

• .NET Framework 2.0

• Windows Vista - 64 Bit

• Windows 7 - 32 Bit

• Windows 7 - 64 Bit

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource

Download Motion Analyzer software from: http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software

Kinetix Motion Control Selection Guide, publication GMC-SG001

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Product Certifications website, http://www.ab.com

Description

Comprehensive motion application sizing tool used for analysis, optimization, selection, and validation of your Kinetix® Motion Control system.

Overview of Kinetix servo drives, motors, actuators, and motion accessories designed to help make initial decisions for the motion control products best suited for your system requirements.

Provides general guidelines for installing a Rockwell Automation industrial system.

Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at http:/www.rockwellautomation.com/literature/ . To order paper copies of technical documentation, contact your local Allen-Bradley® distributor or

Rockwell Automation sales representative.


Preface

Notes:


Welcome to Motion Analyzer Software

Chapter

1

Topic

Before You Begin Sizing

Database Updater Program

Welcome to Motion Analyzer

Menu Bar and Quick Access Toolbar

File Tab

Home Tab

Graphical View

Group View

Multiple Profile View

Power Supply/Accessories View

Preferences Tab

Export – Import Tab

Export to RSLogix 5000 Wizard

Bill of Materials (BOM) Tab

Help Tab

Explorer View

65

65

76

76

78

22

26

29

62

16

17

14

15

8

13

Page

8


Chapter 1 Welcome to Motion Analyzer Software

1.1. Before You Begin Sizing

After downloading and starting Motion Analyzer software, you’ll want to update the Motion Analyzer database with the latest Allen-Bradley products available for motion control applications. This section steps you through that process.

TIP Download Motion Analyzer software from http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software .

1.1.1. Database Updater Program

The Motion Analyzer Database Updater program updates your Motion Analyzer software with the latest database available for the version currently installed on your personal computer.

1.

To start the Motion Analyzer database updater program, go to

Start>All Programs>Rockwell Automation>Motion Analyzer 7.00>

Database Updater.

TIP To update the software version, download Motion Analyzer software from http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software .

The Motion Analyzer Database Updater wizard opens.

8

Table 1 - Database Updater Analysis

Description Attribute

Installed Motion

Analyzer version

Installed database version

Indicates the version of Motion Analyzer software currently installed.

Indicates the database version currently installed.

2.

Click Next.

Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Welcome to Motion Analyzer Software Chapter 1

The program checks for database updates.

If the program finds that you already have the current database installed, the following dialog box opens.

3.

Click Finish.



4.

If the program finds that a database update is available, a dialog box opens with the following information:

•

Installed software and database versions

•

Available database version

•

Database download file size

•

Summary of new features and products in the new database

5.

Click Update.



6.

If the database updater program detects that your current version of

Motion Analyzer software is running, a dialog box opens with the following instructions.

7.

If the program finds that a new software version is available, a dialog box opens with the following options:

• Click the link to download the new version of Motion Analyzer software

•

Click Next to skip the download and just update your current database



8.

When the database updater program begins the update, this dialog box opens.

9.

When the database updater program completes the update, this dialog box opens.

12

10.

Click Finish.



1.1.2. Welcome to Motion Analyzer

The Welcome to Motion Analyzer dialog box opens when the software application is launched. Two modes of operation are possible.

Figure 1 - Welcome to Motion Analyzer Dialog Box

Table 2 - Motion Analyzer Modes of Operation

Mode

Size and Select

Just Quote

Description

Intuitive workflow to help size, select, and optimize the motion control system. This mode also creates a bill of materials.

Creates only a bill of materials so no sizing input is required.

Click either of the New option modes to start a new application or click Browse to open a previously configured application.



1.2. Menu Bar and Quick

Access Toolbar

Your Motion Analyzer application file opens and the menu bar appears across the top of the dialog box. Above the menu bar is the Quick Access toolbar.

Figure 2 - Size and Select Dialog Box

Quick Access Toolbar

Menu Bar

The Quick Access toolbar provides shortcuts to commonly used functions.

These functions include New, Open, Save, and Print.

Table 3 - Menu Bar Tab Descriptions

Options

File Tab

Home Tab

Description

Standard File menu options.

Most commonly used actions across different views in Motion Analyzer software.

Preferences Tab

Export – Import Tab

Setting /View user preference option.

All data Export – Import functionality.

Bill of Materials (BOM) Tab

Useful shortcuts for navigating through the Bill of Materials view.

Help Tab

Standard Help menu options.

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76

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65

Page

15

16



1.2.1. File Tab

The File tab is similar to the file menu in many computer applications.

Figure 3 - File Tab Options

Table 4 - File Tab Descriptions (refer to Figure 3

)

Options

New

Open

Save

Save As

Recent Files

Sample Applications

Print

Help

Exit

Description

Click New to go to the Welcome dialog box in Motion Analyzer software.

Click Open to browse folders and open Motion Analyzer applications. Standard Open functionality.

Click to save the running Motion Analyzer application. Standard Save functionality.

Click to launch a dialog box, browse to the path on your computer, and save the current application to an.mba file.

Click for the list of recently opened applications. You can open one of these applications directly from this shortcut.

Lets you open Motion Analyzer sample applications present in the Motion Analyzer installation.

Print Click to print the application data.

Print Preview Click to see a preview of printable application data.

This is similar to the Help Tab on page 76 .

Click to close the running application.



1.2.2. Home Tab

The Home tab contains five sections.

Figure 4 - Home Tab Options

16

Table 5 - Home Tab Descriptions

Option

Views

(label 1 in

Figure 4 )

Clipboard

(label 2 in

Figure 4 )

Edit

(label 3 in

Figure 4 )

Add

(label 4 in

Figure 4 )

Description

Used to access the different views available in Motion Analyzer software.

Graphical View

Group View

Click to open the Graphical view on

Click to open the Group view on

page 17

page 22

.

.

Multiple Profile View

Click to open the Multiple Profile view on

page 26 .

Power Supply/

Accessories View

Identify Your Load

Axis View

Click to open the Power Supply/Accessories view on

Click to open the Axis view on page 82

.

page 29 .

System Bill of

Materials (BOM) View

Click to open the BOM view on page 36

.

Used to access the Cut, Copy, and Paste functions. Click to perform these functions that are common to many software programs.

Used to access these editing functions. Each one works on the entity selected in Explorer hierarchy view.

Rename

Delete

Click to rename the selected entity.

Click to delete the selected entity from the application.

Sort by Power

Allocate

Unallocate

Group/Ungroup

Click to sort the axes in Drives group for Multi Axis Family application by Axis Power. Sort is valid at the Rack, Group, or IPIM level.

Allocate the axis from Un-allocate Axes Group to Drives Group.

Un-allocate the axis from Drives Group to un-allocate Axes Group.

Select multiple axes in Explorer view and click Group to create a Power

Sharing Drive Group. This feature is available only for families that support AC and DC power sharing (Kinetix 5500 drives).

Select Power Sharing Drive Group in the Explorer view and click

Ungroup to ungroup the axes of the selected group.

Used to access these add functions. Each one works on the entity selected in Explorer hierarchy view.

Add IPIM

Add a new IPIM module in the selected Drives Group in Explorer hierarchy view.

Add Axis

Add Drive Group

Add a new axis in the Drives Group/Unallocated Group or IPIM based on user’s current selection in Explorer hierarchy view.

Add a new Drives Group under the Project node in the Explorer hierarchy view. This feature is available only for families that support

AC and DC sharing (Kinetix 5500 drives).

Tools

(label 5 in

Figure 4 )

Motion Analyzer/SolidWorks Integration is used to launch the SolidWorks Integration wizard.



1.2.2.1. Graphical View

The Graphical view applies to multi-axis drive families and provides graphical representation of the current (Bulletin 2093 and 2094) power rail and

Kinetix 6000M integrated drive-motor system configurations.

Figure 5 - Graphical View Example

Table 6 - Graphical View Options (refer to Figure 5

)

Options

Power Rail View

Power Interface

Module View

Description

Displays the graphical representation of the current Bulletin 2093 or 2094 power rail configuration.

Displays the graphical representation of the Kinetix 6000M integrated drivemotor system on the Bulletin 2094 power rail.

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18



1.2.2.1.1. Power Rail View

The Power Rail view displays the graphical representation of the current Bulletin

2093 or 2094 power rail configuration.

Figure 6 - Power Rail View Example

18

Table 7 - Power Rail View Options

Options

Product Rack

Summary

(label 1 in

Figure 6 )

Image view

(label 2 in

Figure 6 )

Module Information

(label 3 in

Figure 6 )

Additional

Module Information

(inside red box)

Description

Part Number Displays the selected power rail catalog number.

Total No. of Slots Displays the total number of slots available in the selected power rail.

Slots Occupied Displays the number of slots currently occupied in the selected power rail.

Graphical representation of the power rail with the drive modules and empty slots are displayed along with the selected catalog numbers. Power rail configurations like Axis – Slot mapping can be configured using options available in this view.

Right-click the modules and choose operations to perform from the menu (refer to Figure 7 ).

Selected Slot

Module

Refers to the type of the module that is currently selected in the power rail. For example, axis module (AM), integrated axis module (IAM), power interface module (IPIM), or empty slot.

Part Number

Slot Number

Axis Name

View Axis

Un- allocate

View Product

Guide

Catalog number of the selected drive module.

Power rail slot number occupied by the selected drive module.

Name you assigned to the axis associated with the selected drive module.

Click to launch the Axis view of the axis associated with the selected drive module.

Un-allocates the axis associated with the selected drive modules.

Click to open the Kinetix Motion Control Selection Guide. The page displayed from the selection guide corresponds to the selected drive module.


Figure 7 - Operations to Perform Example


Additionally, you can click, drag, and drop a module to reposition that module

on the power rail (refer to Figure 8

).

Figure 8 - Drag and Drop Modules to Reposition on Power Rail



1.2.2.1.2. Power Interface Module View

The integrated drive-motor power interface module (IPIM) mounts to the

Bulletin 2094 power rail and connects (daisy-chains) with up to sixteen integrated drive-motor (IDM) units.

Figure 9 - Power Rail View Example (Kinetix 6000M integrated drive-motor system)

20

Table 8 - Power Rail View Options (Kinetix 6000M integrated drive-motor system)

Options

IPIM Summary

(label 1 in

Image view

(label 2 in

Additional

Figure 9

Figure 9

Module Information

(inside red boxes)

)

)

Selected Slot Module

(label 3 in

Figure 9 )

Description

Slot Number

Number of

Associated Axis

Number of

Additional Axis

Allowed

Power rail slot number occupied by the selected IPIM module.

Displays the number of axes currently associated with the selected IPIM module.

Displays the additional number of axis that can be added in this IPIM module.

Graphical representation of the Kinetix 6000M integrated drive-motor system are displayed with the selected catalog numbers. Power rail configurations, like the order of IDM axes, can be configured using options available in this view.

Right-click an IDM unit and choose operations to perform from the menu (refer to Figure 10

).

Selected Slot

Module

Refers to the type of the module that is currently selected in the power rail. For example, integrated drive-motor unit (IDM) or power interface module (IPIM).

Part Number

IDM Position

Axis Name

View Axis

Catalog number of the selected unit or module.

The position of the selected unit or module, assuming the IDM unit closest to the IPIM module is identified as 1.

Name you assigned to the axis associated with the selected IDM unit.

Click to launch the Axis view of the axis associated with the selected IDM unit.

Un- allocate

View Product

Guide

Back to Rack

Un-allocates the axis associated with the selected IDM unit.

Click to open the Kinetix Motion Control Selection Guide. The page displayed from the selection guide corresponds to the selected IDM unit.

Click to switch back to the power rail view.


Figure 10 - Operations to Perform Example


Additionally, you can click, drag, and drop an IDM unit to reposition that unit in

the daisy-chain configuration (refer to Figure 11

).

Figure 11 - Drag and Drop to Reposition IDM Units



1.2.2.2. Group View

The Group view provides a summary of all the axes associated with the drive group. Additionally, the Group view gives a visual representation of the axis mapping in the power rail for multi-axes drive families. Group view varies

depending on the Application mode selected. Refer to Figure 12 and Figure 13

for examples of each.

Figure 12 - Group View Example (Select and Size mode)

Figure 13 - Group View Example (Just Quote mode)



There are two areas of interest in the Group view, as illustrated in Figure 14

.

Figure 14 - Group View Example

Table 9 - Power Rail View Options

Options

Power Rail Image

(label 1 in

Figure 14

)

Axis Summary Image

(label 2 in

Figure 14

)

Description

Power rail image based on the current system configuration. This graphic only applies to multi-axis drive families.

Displays a summary of the current axis configurations including drive module and motor/actuator catalog numbers.

Page

24

25



1.2.2.2.1. Power Rail Image

The power rail image only applies to multi-axis drive families. In this example, the current configuration of Kinetix 6000 servo drives is shown on an eight-axis

Bulletin 2094 power rail.

Figure 15 - Bulletin 2094 Power Rail Image

Table 10 - Power Rail Slot Example (refer to

Figure 15

)

Option

IAM Module (slots 1 and 2)

Description

Integrated axis module (IAM) is always the first drive module on the power rail. In this case, the IAM module is a double-wide module, so it occupies two slots.

AM Modules (slots 3…5) Axis modules (AM) are always right of the IAM module.

Empty Slots (slots 6…8)

Empty slots are always to the far right on the power rail and must be occupied by slotfiller modules.



1.2.2.2.2. Axis Summary Image

The axis summary images apply to all drive families. In this example, the current configuration of Kinetix 6000 servo drives includes the drive/motor combination featured below.

Figure 16 - Axis Summary Bar (servo drive)

Table 11 - Axis Summary Example

Option

Title Band

(label 1 in

Axis Bar

(label 2 in

Figure 16

Figure 16

)

)

Short-cuts to Axis view

(label 3 in

Figure 16

)

Description

Axis Solution

Status Icon

Axis Solution Status icon indicates the status of the selected

solution. Axis solution status is defined in Solution

on

page

208 .

Warning Icon

A warning triangle icon indicates a warning with this axis, which requires your attention.

Name of the Axis.

Axis Name

Displays information about the selected drive/motor axis or IPIM module.

Motor

(1)

Selected motor catalog number.

Drive

Gearbox

RBM

Selected drive module catalog number.

Selected gearbox catalog number.

Selected RBM module catalog number.

Icons are a graphical representation of the selected axis components. Click icons to switch to the corresponding data page in the Axis view.

(1) Configure Motor BOM is available for the selected motor. Click to launch the Configure Motor dialog box.

In this example, the current configuration includes a Kinetix 6000M power interface module (IPIM).

Figure 17 - Kinetix 6000M Power Interface Module

IPIM module icon along with the catalog number of the selected IPIM module is displayed in this bar. Click + to access the IPIM child nodes (IDM units).



1.2.2.3. Multiple Profile View

The Multiple Profile view permits viewing profiles of multiple axes simultaneously and defining axes synchronization and offsets among the axes.

Figure 18 - Multiple Profile View Example

Table 12 - Multiple Profile View Options

Options

Top Band

(label 1 in

Figure 18 )

Graph View

(label 2 in

Figure 18 )

Description

Lets you define the Time Span to which all graphs should be scaled.

Additionally, this view lets you select a subset of the available axes to view.

Profiles of all axes are displayed in this section with the shorter profiles being repeated to fit the length of the longest profile.

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Page

27



1.2.2.3.1. Top Band

This area lets you define the Time Span to which all graphs should be scaled.

Additionally, this view lets you select a subset of the available axes to view.

Figure 19 - Top Band of Multiple Profile View

Table 13 - Top Band Example

Option

Modify Time Span

(label 1 in

Figure 19

)

Show Axis

(label 2 in

Figure 19

)

Description

Time span is the length of x-axis on which all the profiles are plotted. Use this option to zoomin or zoom-out on the time scale. Enter the minimum and maximum value of the time scale of interest and click Apply to re-plot all graphs to this scale.

Select All to display all axes.

Select Selected (Change) to choose the axis of interest (refer to Figure 20

for typical dialog box).

Sort By

(label 3 in

Figure 19

)

This option lets you sort the axes in the graph area according to the Slot Number or Axis Name.

Figure 20 - Selected Axis Example



1.2.2.3.2. Graph View

The Graph view displays profiles of all axes with the shorter profiles being repeated to fit the length of the longest profile.

Figure 21 - Graph View Example

Table 14 - Graph View Options (refer to

Figure 21 )

Option

Synchronized with

Offset

Description

The phase relationship between the various axis profiles in a common DC bus system affects the peak bus current requirement. For example, if all axes accelerate simultaneously, the bus current demand is much greater than if each axis accelerates in turn.

From the Synchronized with pull-down menu, choose the random or synchronized operation for each axis.

Set at least one axis to Random as the reference axis. Set other axes to be synchronized with the reference axis or Random.

The safe setting for system sizing is all Random. In this case the worst case current demand for each axis is automatically lined up by adjusting the phase relationship of the axis profiles.

If the phase relationship is known and will not change, the Cycle Profiles should be set up in the correct relationship and Synchronized with set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected.

If all axis profiles are the same length and start at their correct respective positions, then the offsets will be zero. Otherwise, the offset may be used to align the profiles correctly.



1.2.2.4. Power Supply/Accessories View

In Axis view, you matched a drive with your motor. However, if there are power components needed for your application, you’ll select them in Power Supply/

Accessories view.

1.2.2.4.1. Power Supply/Accessories - Multi-axis Drive Systems

If your drive family is Kinetix 2000, Kinetix 6000, or Kinetix 6200/6500, you’ll also need to configure the IAM module and select the appropriate power rail.

Figure 22 - Power Supply/Accessories Dialog Box

Table 15 - Power Supply/Accessories Tabs (refer to Figure 22 )

Parameters

Power Data Tab

IAM and Shunt Tab

IAM Control Power Tab

Analysis Tab

Energy Tab

Configure Power Supply

BOM Tab

Description

View regeneration and motoring data for each axis.

Select drive modules and external shunt resistors for multi -axis systems.

Displays total auxiliary input power, input VA, input current, and power distribution across the axes. These are the installation ratings for the IAM module.

Analyze the drive module activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters.

View Input Current values, System Power values, Shunt Power, and Energy

Savings Estimates.

Configure the bill of materials (BOM) for the power supply after fully sizing the application.

Page

30

31

32

33

34

35



1.2.2.4.1.1. Power Data Tab

Use the Power Data tab to view regeneration and motoring data for each axis.

Table 16 - Power Data Tab Properties (refer to

Figure 22

)

Parameters

Axis Histograms

Random/Sync

Relationship

Offset

Description

The axis histograms show a multi-axis representation of axis currents including Peak

Motoring, Average Motoring, Peak Regenerating, and Average Regenerating.

The phase relationship between the various axis motion profiles in a common DC bus system affects the peak bus-current requirement. For example, if all axes accelerate simultaneously (for example, synchronous operation), the bus current demand is much greater than if each accelerates in turn. The pull-down menu lets you choose Random or

Synchronized mode for axes operation. At least one axis should be set to Random as the reference axis. Other axes may be set to Synchronized or Random relative to the reference axis. The safe setting for system sizing is all Random. In this case, the worst case current demand for each axis is automatically lined up by adjusting the phase relationship of the axis motion profiles. If the phase relationship is known and will not change, the Cycle

Profiles should be set up in the correct relationship and appropriate synchronized set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected.

If all axis motion profiles are the same length and start at their correct respective positions at the default time, then the offsets will be zero. Otherwise, a specified time offset may be used to align the motion profiles correctly.



1.2.2.4.1.2. IAM and Shunt Tab

Click Search to automatically configure the IAM and/or shunt module catalog number.

Figure 23 - IAM and Shunt Tab

Table 17 - IAM and Shunt Tab Properties

Parameters

IAM & Shunt Selection

(label 1 in

Figure 23

)

Description

Click Search to configure the IAM module (Kinetix 2000, Kinetix 6000, and Kinetix 6200/6500 drives) based on the selection made in Axis view, and/or an external shunt module, should an existing internal shunt for a given drive be outside its rating. Where multiple external shunts exist, these can be readily chosen by searching for a shunt.

Both the drive module and shunt module have automatic and manual selection options.

You can manually select a drive or IAM module and the compatible shunt. The manual selection of only one of the two components is also provided. This means that you can have manual drive and automatic shunt selection or vice versa.

Utilizations

(label 2 in

Figure 23

)

Component Listings of

Kinetix Shunts

(label 3 in

Figure 23

)

The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed. Use the forward or backward arrows to scroll through other drive and shunt options. Click the drive module or shunt module catalog number to view their product specifications.

This window is available only for the Kinetix multi-axis drive families after a valid IAM module and shunt solution is found. This window displays the shunt resistance, power, and capacitance values for all the components involved in the IAM and shunt module solution.

The components may include converter (IAM), all the inverters (AM), shunt module and shunt resistor. The Shunt Protect limit is also shown in order to reflect the shunt power utilization of the component.



1.2.2.4.1.3. IAM Control Power Tab

The IAM Control Power tab displays total auxiliary input power, input VA, input current, and power distribution across the axes. These are the installation ratings for the IAM module.

Figure 24 - IAM Control Power Tab

Table 18 - IAM Control Power Tab Properties

Parameters

Auxiliary AC Voltage

(label 1 in

Figure 24 )

Power Rail Summary

(label 2 in

Figure 24 )

Power Rail Details

(label 3 in

Figure 24 )

Description

Auxiliary AC Voltage is a user input value. The value can lie within the IAM Control Voltage

Range. Refer to the Kinetix Servo Drives Technical Data, publication GMC-TD003 , for servo drive power specifications.

This view shows the total auxiliary input power, input VA, and input current in a tabular format.

This view contains the slots occupied, slot number, drive module, and continuous output power distribution details in tabular format. The IPIM module is available as line item (axis level item) in this view.



1.2.2.4.1.4. Analysis Tab

Click Analysis to conduct detailed analysis of the drive module activity in terms of bus volts and system current, along with the capability of simulating changes to the system parameters.

Figure 25 - Analysis Tab Dialog Box

Table 19 - Analysis Tab Properties

Parameters

Simulation Parameters

(refer to

Figure 25

)

Description

Adjust these parameters to observe how changes to the parameters impact the bus voltage and current.

Time From/

Voltage From

Check these boxes to adjust the X- and Y-axis values for the plot.

Zoom Window

(refer to

Figure 25

)

Time Slice

The Time Slice variable sets the time interval for the Analysis display. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive.

The time is equal to the longest axis cycle. In the case of a very long length of time, it is suggested that a longer time slice be used for early checks, but a time slice of less 0.1 ms should be used for the final selection.

If the time is increased, this error message often appears.

This time slice message may also appear as soon as you click Solution on the main taskbar. In this case, clicking Yes or No still takes you to the Solution tab, but if you click No, some pre-calculations are not performed.

This time slice message often appears if one of the motion cycles is a cam, which often has very short time segments. In this case, click No to ignore the message.



1.2.2.4.1.5. Energy Tab

Click Energy to display the main power supply parameters including Input

Current, System Power, Shunt Power and Energy Savings Estimates.



1.2.2.4.1.6. Configure Power Supply BOM Tab

Click the Configure Power Supply BOM tab to complete the bill of materials

(BOM) for the Power Supply after fully sizing the application. In this tab, you select options for the power rail, shunt module, filters, circuit breakers, and fuses.



1.2.2.4.1.7. System Bill of Materials (BOM) View

Click BOM view to review the entire BOM (bill of materials) for the system and add any additional parts that may be needed.

Table 20 - BOM View Tabs

Parameters Description

Configuration Summary Tab

Shows all the axis components in axis order.

Software and Accessories Tab

Contains the Controllers, Software, and other Accessories to complete your system.

Additional Parts Tab

BOM Tab

Select any additional components.

Displays the full bill of materials (BOM).

39

40

Page

37

38



1.2.2.4.1.7.1. Configuration Summary Tab

Click Configuration Summary to display all the axis components and descriptions in axis order. Scroll down to see all the axes.



1.2.2.4.1.7.2. Software and Accessories Tab

Click Software and Accessories to complete your system.

To assist in selecting the Sercos cables, click Auto Select to automatically build a set of these cables with the required lengths to link the axes according to their slot configuration.

Break-out boards, cables, kits, and various connectors are available to complete cabling from drive to motor.

Other components such as connectors, safe-off headers, and line filters for example, are available.



1.2.2.4.1.7.3. Additional Parts Tab

Click Additional Parts to add any additional components you may need.

From the Product Family pull-down menu, choose the Family, Motor Series, and then by component category to reduce the time required to search for motion control components. If you know the catalog number, entering that is the quickest way to find your part.



1.2.2.4.1.7.4. BOM Tab

Click BOM to display the full bill of materials (BOM) in the same section headings as the other tabs.

This BOM can be exported to Microsoft Word or Microsoft Excel software by clicking the appropriate button.



1.2.2.4.2. Power Supply/Accessories - Integrated Drive-Motor (IDM) Systems

The integrated drive-motor (IDM) power interface module (IPIM) is effectively a power management module for the DC link to a group of individual IDM units, but to the 2094 power rail it looks like an axis module. Each IPIM module can handle up to 16 axes, with certain limitations.

Table 21 - IPIM Module Configuration

Options

Power Data Tab

Description

View regeneration and motoring data for each IDM unit.

IPIM Module Selection Tab

Lets you select the IPIM module.

Cable Length Tab

Cable selection for connecting IPIM module-to-IDM unit and

IDM unit-to-IDM unit.

Control Power Tab

Configure IPIM Module

BOM Tab

43

• Bar graph for control power

• Summary view

• Details view

44


45

Page

41

42


Click the Power Data tab to view regeneration and motoring data for each IDM unit.

Figure 26 - Power Data Tab



Table 22 - Power Data Tab Descriptions

Options

Label 1 in Figure 26

IDM Axis view

(label 2 in Figure 26 )

Back to Power Rail


Description

Name of the power rail and selected IPIM module slot is displayed here. Click the power rail name label switches the view from IPIM view to Power Rail - Power Supply view.

Summary of the all IDM units associated with the selected IPIM module along with the Axis

Motoring Bus Current and Axis Regenerating Bus Current values of each IDM unit.

Click to switch the view from IPIM view to Power Rail - Power Supply view.

1.2.2.4.2.2. IPIM Module Selection Tab

Click the IPIM Module Selection tab to select an IPIM module.

Figure 27 - IPIM Selection Tab

42

Table 23 - IPIM Selection Tab Descriptions

Options

Selection mode

(label 1 in Figure 27

Utilizations


Description

Automatic

Select Automatic for Motion Analyzer software to search for the best IPIM module solution for the selected slot.

Select Manual to manually select the IPIM module.

Manual

Current

Selection

Search

Displays the selected IPIM module catalog number.

IPIM

DC Bus Current

RMS Limit

DC Bus Current

Instantaneous

Limit

Search button is disabled because only one catalog number is available.

Arrows provide the means to scroll forward/backward to smaller/larger

IPIM module catalog numbers.

Graphical representation of DC bus current rms limit for the selected IPIM module.

Graphical representation of DC bus current instantaneous limit for the selected IPIM module.



1.2.2.4.2.3. Cable Length Tab

Click the Cable Length tab to select cables for connecting IPIM module-to-IDM unit and IDM unit-to-IDM unit.

Figure 28 - Cable Length Tab

Table 24 - Cable Length Tab Descriptions

Options

IDM Cables


IDM System Graphic


Description

From the Cable Length pull-down menus, choose the appropriate cable length for connecting

IPIM module-to-IDM unit and IDM unit-to-unit. The maximum cable lengths in an IDM system are specified as 25 m (82 ft) IDM unit-to-IDM unit and 100 m (328 ft) total cable length.

Cable For Specifies the modules the cables will join.

Cable Length Specifies the cable length.

Total Length Specifies the total length of the cables.

Graphical representation of IPIM module, associated IDM units and joining cables. Cable length is displayed over the cables.



1.2.2.4.2.4. Control Power Tab

Click the Control Power tab for utilization views and to select the number of sensor inputs and outputs.

Figure 29 - Control Power Tab

Table 25 - Control Power Tab Descriptions

Options

Utilizations

(label 1 in

Figure 29

Description

Control

Power

This bar graph displays the percentage of power utilized by all IDM units to the maximum power that can be supplied by IPIM module.

Total

IPIM

Displays the sum of power utilized by all the IDM units.

Displays the maximum power that can be supplied by the selected IPIM module.

Selection for Control

Power Usage

(label 2 in

Figure 29 )

Detailed View

(label 3 in

Figure 29 )

Summary view

From the pull-down menu, choose the quantity of each of I/O Sensor. Summary view displays the control power usage and control voltage for each IDM unit.

Click the Details arrow (refer to Figure 30 ) to display complete information for each IDM unit.

This table is hidden by default.

Figure 30 - Control Power Tab (details arrow)


Figure 31 - Control Power Tab (details revealed)


1.2.2.4.2.5. Configure IPIM Module BOM Tab

Click the Configure IPIM Module BOM tab to select hybrid and network cables, and other IDM system accessory items.

Figure 32 - Configure IPIM Module BOM Tab

Table 26 - Configure IPIM Module BOM Tab Descriptions

Options

Step 1 ( Figure 32 )





Description

IPIM module

Hybrid cables

Network cables

Hybrid coupler

Network bulkhead adapter

IPIM module selected on the IPIM Module tab is displayed here.

Hybrid cable lengths selected on the Cable Lengths tab are displayed here.

Network cables can be routed with the hybrid cables, so network cable lengths should be the same as the hybrid cable. The IPIM-to-IDM1 cable must have a straight connector to the IPIM module.

The hybrid coupler connects between two hybrid cables, to bypass an IDM unit.

Use the network bulkhead adapter for securing network cables as they pass through the cabinet.




1.2.2.4.3. Power Supply/Accessories - Single-axis Drive Systems

If your drive family is single axis, for example, Kinetix 300, Kinetix 350,

Kinetix 3, or Ultra™3000, Ultra5000, and Ultra1500, you must configure a shunt or specify no shunt required.

Figure 34 - Power Supply/Accessories Dialog Box

Table 27 - Power Supply/Accessories Tabs (refer to Figure 34 )

Parameters

Power Data Tab

Shunt Tab

Analysis Tab

Energy Tab

Configure Power Supply

BOM Tab

Description

View the regeneration and motoring data for each axis.

Select the external shunt resistors for single-axis systems.

Analyze the drive module activity in terms of bus voltage and system current.

With this tab, you can also simulate changes to the system parameters.

View input current values and energy savings estimates for each axis.

47

48

49


Page

47

50





Table 28 - Power Data Tab Properties (refer to Figure 34 )

Parameters

Axis Histograms

Description

The axis histograms show a multi-axis representation of axis currents including Peak

Motoring, Average Motoring, Peak Regenerating, and Average Regenerating.

1.2.2.4.3.2. Shunt Tab

Click Search to automatically configure the shunt module catalog number for each axis.

Figure 35 - Shunt Tab

Table 29 - Shunt Tab Properties

Parameters

Shunt selection

(refer to Figure 23

)

Continuous Current utilization bar

(refer to Figure 23

)

Description

Click Search to configure external shunts if an existing internal shunt for a given drive is outside its rating. If you need more than one external shunt, click search to select multiple shunt modules. You can also select a compatible shunt manually.

The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed in percentage form. Click the drive module or shunt catalog number to view its product specification.



1.2.2.4.3.3. Analysis Tab

Click Analysis to display plots of drive module activity in terms of the DC bus voltage and DC bus current:

•

The red line is the bus voltage trip point.

•

The green line is the DC bus voltage.

•

The grey line is the bus current.

Figure 36 - Analysis Tab Dialog Box

48

Table 30 - Analysis Tab Properties

Parameters


(1)

(refer to Figure 25 )

Description

Shunt On

Shunt Off

Trip

Resistance

Power

The voltage level where the shunt enables.

The voltage level where the shunt turns off.

The voltage level where the drive trips on an overvoltage fault by changing the trip volts.

The shunt resistance level in ohms.

Changing the power value modifies how much energy the shunt resistor can dissipate continuously.

Capacitance Changing the capacitance value changes the DC bus capacitance.

Zoom


Time From/

Voltage From

Check these boxes to adjust the X- and Y-axis values for the plot. Click Plot to implement these changes.

Time Slice

The Time Slice variable sets the time interval for the Analysis tab. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example).

However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is equal to the longest axis cycle.

(1) Click Apply to implement these changes.



If the time slice variable is increased, this error message often appears.



1.2.2.4.3.4. Energy Tab

Click the Energy tab to display the main power supply parameters including input current, cost of system energy, and cost of shunt energy.



1.2.2.4.3.5. Configure Power Supply BOM Tab


(BOM) for the Power Supply after fully sizing the application. In this tab, you select options for the shunt module, filters, circuit breakers, and fuses.



1.2.2.4.4. Power Supply/Accessories – AC/DC Power Sharing Systems (Kinetix 5500 drives)

If your drive family is Kinetix 5500, you must define a valid power sharing configuration and then configure a shunt and capacitor, or specify if no shunt or capacitor are required.

Figure 37 - Power Supply/Accessories

Parameters

Power Configuration options


Axes sharing – AC/DC


Table 31 - Power Configuration Options (refer to label 1 in Figure 37 )

Description

DC Sharing

AC Sharing Only

Use this option for shared AC/DC or common bus configuration. The following restrictions are imposed on the number of drives allowed in common bus, or shared AC/DC configuration, based on the converter capacity and/or connectors:

• Single phase operation is not allowed.

• The bus master drive or drives with an AC connection should have the same power rating (catalog number).

• The bus master drive or drives should always have a rating equal to, or greater than, the followers.

• The number of bus master drives cannot exceed the following rule: Frame 3 = two drives; Frame 2 = four drives;

Frame 1 = eight drives.

• The number of follower drives is driven by the frame of the master drive or drives, and cannot exceed this rule:

Frame 1 drive = only four more bus followers can be added; Frame 2 drive = only six more bus followers can be added.

• Converter power output should be reduced by 30% of the sum of the individual converter power capacities of drives configured for shared AC/DC.

• The maximum number of drives in a bus power sharing group is eight drives.

3-phase AC input power can be shared among drives with the same power rating. No DC bus connections are allowed in this configuration. AC power sharing allows you to minimize the system components, such as circuit breakers and fuses. The following limitations apply when drives are configured for sharing AC input power:

• Single-phase operation is not allowed.

• All drives must be configured for the same converter voltage rating.

• Drives with the same power rating (catalog number) can be used for this configuration.

• The maximum number of drives that can be configured for shared AC operation is limited by the amp capacity of the AC input connector. The following rules apply: Frame 1 drives can share AC with up to five drives of the same rating; Frame 2 drives can share AC with up to three drives of the same rating; Frame 3 drives can share AC with up to two drives of the same rating.

Select the AC and DC sharing option for each axis individually.



1.2.2.4.4.1. DC Sharing

Use the DC Sharing configuration to group axes to share a common DC bus and input AC supply (optional).

Table 32 - Power Supply/Accessories Tabs (refer to

Figure 37

)

Parameters

Power Data Tab

Converter and Shunt Tab

Analysis Tab

Energy Tab

Configure Power Supply BOM Tab

Description


Select the shunts and capacitor for your system.




1.2.2.4.4.1.1. Power Data Tab

Click the Power Data tab to view regeneration and motoring data for each axis.


Parameters

Axis histograms

Random/Sync relationship

Offset

Table 33 - Power Data Tab Properties (refer to

Figure 38

)

Description

The axis histograms show a multi-axis representation of axis currents including peak motoring, average motoring, peak regenerating, and average regenerating.

The phase relationship between the various axis motion profiles in a common DC bus system affects the peak bus-current requirement. For example, if all axes accelerate simultaneously (for example, synchronous operation), the bus current demand is much greater than if each accelerates in turn. The pull-down menu lets you choose Random or Synchronized mode for axes operation. At least one axis should be set to random as the reference axis. Other axes may be set to synchronized or random relative to the reference axis.

The safe setting for system sizing is all Random mode. In this case, the worst case current demand for each axis is automatically lined up by adjusting the phase relationship of the axis motion profiles. If the phase relationship is known and will not change, the cycle profiles should be set up in the correct relationship and appropriate synchronized set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected.

If all axis motion profiles are the same length and start at their correct respective positions at the default time, then the offsets will be zero. Otherwise, a specified time offset may be used to align the motion profiles correctly.



1.2.2.4.4.1.2. Converter and Shunt Tab

Select shunt and capacitor modules for your system.

Figure 39 - Converter and Shunt Tab

Table 34 - Converter and Shunt Tab Properties (refer to Figure 39 )

Description Parameters

Shunt Selection and Component

Listing

(label 1 in

Figure 39

)

In this section you select a shunt for each axis, and a capacitor module for the system.

Calculation Utilizations

Utilization

(label 2 in

Figure 39

)

Click Calculate Utilizations to analyze the behavior of the bus, and to calculate the drive and shunt utilizations.

The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed in this area. Click the drive module catalog number to view the drive specifications.



1.2.2.4.4.1.3. Analysis Tab

Click the Analysis tab to conduct detailed analysis of the drive module activity in terms of bus volts and system current, along with the capability of simulating changes to the system parameters. The analysis activities are described as follows:

•


•


•


Figure 40 - Analysis Tab

Parameters



Zoom window


Table 35 - Analysis Tab Properties (refer to

Figure 40

)

Description

Adjust these parameters to observe how changes to the parameters impact the bus voltage and current.

Time From/

Voltage From

Time Slice


The Time Slice variable sets the time interval for the analysis display. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive.

The time is equal to the longest axis cycle. In the case of a very long length of time, we suggest that a longer time slice be used for early checks, but a time slice of less than 0.1 ms should be used for the final selection.



If the time is increased, the time slice error message often appears.



1.2.2.4.4.1.4. Energy Tab

Click the Energy tab to display the main power supply parameters including

Input Current, System Power, Shunt Power, and Energy Savings Estimates.

Figure 41 - Energy Tab



1.2.2.4.4.1.5. Configure Power Supply BOM Tab


(BOM) for the power supply after fully sizing the application. In this tab, you select options for the power rail, shunt module, filters, circuit breakers, and fuses.

Figure 42 - Configure Power Supply BOM Tab

1.2.2.4.4.2. AC Sharing Only

Use the AC Sharing Only configuration to group axes to share input AC supply only, with no DC bus sharing.

Figure 43 - Power Configuration Tab for AC Sharing Only Mode



Table 36 - Power Supply/Accessories (refer to

Figure 43

)

Parameters

Power Data Tab

Converter and Shunt Tab

Analysis Tab

Energy Tab

Configure Power Supply BOM

Tab

Description


Select the shunt and capacitor for your system.




1.2.2.4.4.2.1. Power Data Tab



Table 37 - Power Data Tab Properties (refer to Figure 44 )

Parameters

Axis histograms

Description

The axis histograms show a multi-axis representation of axis currents including peak motoring, average motoring, peak regenerating, and average regenerating.



1.2.2.4.4.2.2. Shunt Tab

Select the shunt and capacitor module for your system.

Figure 45 - Shunt Tab

Table 38 - Shunt Tab Properties (refer to

Figure 45 )

Parameters

Shunt selection

(refer to

Figure 45

)

Continuous Current utilization bar

(refer to

Figure 45

)

Description

Click Search to configure external shunts if an existing internal shunt for a given drive is outside its rating. If you need more than one external shunt, click search to select multiple shunt modules. You can also select a compatible shunt manually.

The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed in percentage form. Click the drive module or shunt catalog number to view its product specification.



1.2.2.4.4.2.3. Analysis Tab

Click the Analysis tab to display plots of drive module activity in terms of the DC bus voltage and DC bus current. The analysis activities are described as follows:

•


•


•


Figure 46 - Analysis Tab

Table 39 - Analysis Tab Properties (refer to

Figure 46

)

Parameters

Simulation

Parameters

(1)


Zoom window


Description

Shunt On

Shunt Off

Trip

Resistance

Power

Capacitance

Time From/

Voltage From

Time Slice

The voltage level where the shunt enables.

The voltage level where the shunt turns off.

The voltage level where the drive trips on an overvoltage fault by changing the trip volts.

The shunt resistance level in ohms.

Changing the power value modifies how much energy the shunt resistor can dissipate continuously.

Changing the capacitance value changes the DC bus capacitance.


Click Plot to implement these changes.

The Time Slice variable sets the time interval for the Analysis tab.

Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example).

However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is equal to the longest axis cycle.

(1) Click Apply to implement these changes.



If the time is increased, the time slice error message often appears.



1.2.2.4.4.2.4. Energy Tab

Click the Energy tab to display the main power supply parameters including input current, cost of system energy, and cost of shunt energy.

Figure 47 - Energy Tab



1.2.2.4.4.2.5. Configure Power Supply BOM Tab


(BOM) for the power supply after fully sizing the application. In this tab, you select options for the power rail, shunt module, filters, circuit breakers, and fuses.

Figure 48 - Configure Power Supply BOM Tab



1.2.3. Preferences Tab

The Preferences tab contains three sections.

Figure 49 - Preferences Tab Options

Table 40 - Preferences Tab Descriptions

Options

Database

(label 1 in

Figure 49 )

Settings

(label 2 in

Figure 49 )

Options

(label 3 in

Figure 49 )

Description

My Preferred Database


User Defined Database


Check for Updates

The product databases may be modified to restrict selections to those items marked by you. This may be used, for example, by a distributor to select from a range of popular stock items. Drives, Motors, and

Gearboxes may all be marked.

Creates a database of custom motors with your own specifications that can be sized and analyzed.

Updates the Motion Analyzer database on your personal computer to the latest database available from the Motion Analyzer server.

User Information


Enter details about the end-user. Entries appear on printouts.

Key Status

Units of Measure

(refer to Figure 53

Operating Conditions

(refer to

Notes

Figure 54 )

)

Lets privileged users select the electronic keys to provide additional features and functions.

Lets you set default units for all data entry. Choice includes a user

Custom set.

Lets you set the operating conditions used to calculate Life calculations of Bearing Life, Ball Screw Life, Roller Screw Life, and Strip

Seal Life in Motion Analyzer software.

Launches system notes for the application.

Figure 50 - Preferred Data Dialog Box


Figure 51 - User Defined Motors Dialog Box


Figure 52 - Options - User Information Dialog Box



Figure 53 - Options - Units of Measure Dialog Box

Figure 54 - Options - Operating Conditions Dialog Box



1.2.4. Export – Import Tab

The Export - Import tab contains two sections.

Figure 55 - Export - Import Tab Options

Table 41 - Export - Import Tab Descriptions

Options

Export


Import


Description

Project Data to Word

Profile Data

BOM to Word

BOM to Excel

Export To RSLogix 5000

Axis Data

Profile Data

Exports the application data to a Microsoft Word document.

Launches the export wizard to let you export the profile data of the

selected axis. Refer to More Options Profile Editor Mode

on

page 142 .

Exports Bill of Material to Microsoft Word document.

Exports Bill of Material to Microsoft Excel file.

Exports motion system information to RSLogix™ 5000 software to use it in the next step of your design process.

Imports the axis data from another axis either of current application or from any other Motion Analyzer application.

Imports the Profile data for selected axis. Imported Profile Data must have been previously exported by Motion Analyzer software.

1.2.4.1. Export to RSLogix 5000 Wizard

Once you have selected a motor and drive in Motion Analyzer software, you can export motion system information to RSLogix 5000 software and use it in the next step of your design process. You can generate an RSLogix 5000 file (.L5X), version 18.00, 19.00, 20.00, or 21.00. Applications can be exported to

RSLogix 5000 software as new .L5X files or as updates to existing .L5X files.



1.2.4.1.1. Export Options - Create a New .L5X File

1.

From the Export-Import menu, click Export To RSLogix 5000.

The Output Format Selection dialog box opens.

2.

Select Create a New L5X and from the pull-down menu and choose the

RSLogix 5000 software version you intend to use.

3.

Click Next.

The Axis Mapping dialog box opens.



1.2.4.1.1.1. Axis Mapping

Information about .L5X file that Motion Analyzer generates is displayed at the top of the screen as read only information.

Table 42 - Axis Mapping Properties

Attribute

Controller Name

Controller Type

Chassis Type

Description

Motion Analyzer software assigns a default name for the controller. You can edit this once the file has been loaded.

Motion Analyzer software creates a file with a default controller type. You can edit this once the file has been loaded.

Motion Analyzer software creates a file with a default Logix chassis. You may change your chassis type once the file has been loaded.

The name you define for each axis in Motion Analyzer software is used to create a

RSLogix 5000 axis tag. Underscore characters replace spaces in the name defined in Motion Analyzer software. To change these names you must exit the Export to

RSLogix 5000 wizard and change the names by right-clicking each axis in the

Motion Analyzer explorer tree.

All axes in your Motion Analyzer (.mba) file appear in the table. If they will export without trouble, a green status check is displayed.



Table 43 - Axis Mapping Symbols

Attribute Description

Axes will export without errors.

Axes with warning icon only partially export to RSLogix 5000 software. A note at the bottom of the screen indicates what is wrong.

Not recommended icon. A note at the bottom of the screen indicates what is wrong.

If problems occur with selected catalog numbers, a warning icon and a note at the bottom of the dialog box appears.

Figure 56 - Axis with Warning Icon

If export isn’t possible, a note at the bottom of the dialog box indicates what the problem is. This axis is not exported to RSLogix 5000 software.

Figure 57 - Axis with Not Recommended Icon

68

If the number of axes a sercos module can support is exceeded, a new sercos module is added into the pull-down menu in the third column. This is selectable for the rest of the axes. This new module is also exported to the .L5X file.

4.

Click Next.



The Target Location dialog box opens.

1.2.4.1.1.2. Save and Import the L5X File

1.

Click Browse to select a target location and save the .L5X file.

IMPORTANT Do not use spaces or special characters in the name, or RSLogix 5000 software will not open the file.

2.

Click Finish.



3.

Open RSLogix 5000 software.

4.

Browse to your .L5X file and open it.



5.

Browse to the location where you would like to store your .acd file.

6.

Click Import.



Your motion system information imports from Motion Analyzer software.

Exceptions include warnings noted on the Axis Mapping dialog box.



1.2.4.1.2. Export Options - Update an Existing L5X File

1.

From the Export-Import menu, click Export To RSLogix 5000.

The Output Format Selection dialog box opens.

2.

Select Update an Existing L5X and click browse to find the file you wish to update.

3.

Click Next.



The Axis Mapping dialog box opens.

4.

Make changes as needed to the existing file.

5.

Click Next.


The Target Location dialog box opens.


Table 44 - Export Output Target Properties

Attribute

Save

Save As

Description

Select Save to replace the old L5X file with the updated file.

Select Save As to create an updated L5X file in a new location and/or with a new name.

6.

Open the file in RSLogix 5000 software as described earlier and notice that the motion system information from your Motion Analyzer software file has been included.

7.

Click Finish.



1.2.5. Bill of Materials (BOM) Tab

The Bill of Materials (BOM) tab contains two sections.

Figure 58 - Bill of Materials (BOM) Tab Options

76

Table 45 - Bill of Materials (BOM) Tab Descriptions

Options

Configure

(label 1 in

Figure 58 )

Export

(label 2 in

Figure 58 )

Description

Axis

System Module

This is a combo item and contains the axis names of all the axes in the

Drives Group that have a solution. It lets you navigate to the

Configure Axis BOM tab of Axis view where you can configure the

BOM for the axis chosen.

This is a combo item for single-axis drive family and a button item for multi-axis drive family. For single-axis drive family, it contains the axis names of all the axes in Drives Group that have a solution. It lets you navigate to Configure Power Supply BOM tab of the Power Supply

& Accessories view where you can configure the Power Supply BOM for the system.

Software and

Accessories Tab

Navigate to the Software & Accessories tab of System BOM view on

page 38 .

Additional Parts Tab

Navigate to the Additional Parts tab of System BOM view on

page 39 .

Configuration

Summary Tab

BOM to Word

BOM to Excel

Navigate to the BOM tab of System BOM view on

Exports Bill of Material to Microsoft Word document.

Exports Bill of Material to Microsoft Excel file.

page 37

.

1.2.6. Help Tab

The Help tab contains one section.

Figure 59 - Help Tab Options

Table 46 - Help Tab Descriptions (refer to Figure 59

)

Options Description

Motion Analyzer Help Launches Motion Analyzer help.

Activate Motion

Analyzer

Launches the Motion Analyzer Activation wizard. You can Purchase License or Activate their

Motion Analyzer installation (refer to Figure 60

).

Send Feedback

Release Notes

Provides contact information for Motion Analyzer software support.

Launches the Release Notes for the installed Motion Analyzer software revision.

About Motion Analyzer

Launches the About Motion Analyzer dialog box that displays details of the installed copy of

Motion Analyzer software (refer to

Figure 61 ).


Figure 60 - Motion Analyzer Activation Wizard


Figure 61 - About Motion Analyzer



1.3. Explorer View

The Explorer view provides a Windows Explorer style graphical user interface for accessing components in your Motion Analyzer software application.

For multi-axis drive systems, the axes are added under the Power Rail node in the

Explorer hierarchy view.

Figure 62 - Typical Multi-axis Drive Explorer View

For single-axis drive systems, the axes are added under the Project node in the

Explorer hierarchy view.

Figure 63 - Typical Single-axis Drive Explorer View

78

For drive families that allow stand alone as well as power sharing group (Kinetix

5500 drives), a mix of drive group and stand alone axes can be added under the

Project Node.



Figure 64 - Typical AC/DC Power Sharing System (Kinetix 5500) Explorer View

Options

Project Node

Table 47 - Explorer View Structure (refer to

Figure 62 )

Description

The project node contains two types of groups. The Power Rail/Drive Group (of the selected product family) and an unallocated group.

Power Rail Node

Applies to multi-axis drive families. Shown is the power rail icon, drive family name, and power rail catalog number. The default name for this node is Drives Group 1, however, it is renamed when a solution for any axis under this group is defined.

For single-axis family, the default name is Drives Group 1. For multi-axes family, the default name is Power

Rail 1. Also, for multi-axis family, after the drive family is defined, the power rail displays many empty slots until each slot is allocated a module.

Drives Group Node

Applies to drive families that allow AC and DC power sharing (Kinetix 5500). Shown is the drive group icon and drive name.

Axis Module Node

Axis Module Node

Axis node consists of two levels. First level displays the slot number of the power rail (available only for multi-axis families), axis name, drive catalog number, and the solution status of the axis. Second level displays the motor catalog number for the selected solution. Additionally, if there is a warning in the axis, then a warning triangle is also displayed beside the solution status.

When the solution is not yet selected, then only the axis node is displayed and instead of drive catalog number, Incomplete is displayed.

IPIM Module Node

This node displays the slot number that the IPIM module is assigned to on the power rail along with the name of the IPIM module, catalog number of the selected IPIM module, and the IPIM module status.

IDM Unit Node

IDM unit node is similar to axis module node except that the IDM unit node consists of only a single node representing the axis solution.

Empty Slot Node

Applies to multi-axis drive families. It is visible after a multi-axis drive family is selected.

Unallocated Axis Node The Unallocated Axes Node is where axes independent of other axes can be created. An unallocated axis can be allocated to a Drive Group using the allocate

button located in the Home Tab

on the menu bar or by dragging and dropping the axis.

Additionally, if the power supply solution is present, then the status of the selected power supply solution is also displayed, as described below.

Indicates that the selected power supply solution and all children support the application requirement.

Status Symbols

Indicates that the selected power supply solution or any one of the children marginally support the application requirement.

Indicates that the selected power supply solution or any one of the children is not recommended for the application. Additionally, this icon is also displayed when the IAM module for the power rail has not been sized.



Notes:


Sizing Your System

Topic

Identify Your Load

Linear Loads

Rotary Loads

Rotary Complex Loads

Application Template Loads

From SolidWorks

Define Your Profile

Less Options Profile Editor Mode

More Options Profile Editor Mode

Specify Your Linear Load Mechanism

Belt Drive

Lead Screw

Chain and Sprocket

Rack and Pinion

Linear Motor

Electric Cylinders

Linear Stages

Linear Thrusters

Specify Your Transmission

Compute Using Inertia and Ratio

Compute Using Pitch Circle Diameter

Compute Using Number of Teeth

Choose Your Motor Series

Choose Your Electric Cylinder Series

Choose Your Drive Family

181

182

183

184

140

142

178

180

87

96

120

139

83

86

Page

82

193

194

195

196

186

187

189

191

199

201

Chapter

2


Chapter 2 Sizing Your System

2.1. Identify Your Load

A load is a device that transfers the actuator output to the desired end effectors.

Loads do not affect the motion type.

Figure 65 - Load Type Tab

Table 48 - Load Type Options

Load Type

Linear Loads

Rotary Loads

Rotary Complex Loads

Application Template

Loads

From SolidWorks

Description

Load moves in a straight line.

Load rotates and the system has no translation to linear motion.

Rotary motion can be translated to linear motion, and vise versa. Inertia, friction, and/or torque values for the system change with time.

Simplify data entry dramatically where the application is appropriate. The

Application Templates include Press Roll Feed (Constant Time or Angle),

Carriage Cut Off, Cutter Knife Drive, Advanced Templates, and Power Speed.

87

96

Used to obtain load data to aid in sizing your application for the appropriate motors, drives, and accessories.

120

Page

83

86


2.1.1. Linear Loads

For a Linear application, the load moves in a straight line.

Figure 66 - Linear Load Type

Sizing Your System Chapter 2

Table 49 - Linear Load Parameters

Parameter

Load Mass

Applied Force

Coeff of Friction

Inclination

Description

Mass of the linear load.

Any external force (+/-) acting on the load. Positive force acts to oppose positive movement; down the inclination surface if inclination is non-zero. The arrow on the graphic indicates the force direction.

Coefficient of friction (μ). It is a unitless value, which is used to calculate the force of friction. It is largely dependent on the nature of the surfaces in contact with each other.

Typical values for the coefficient of friction can be found in engineering tables. This value, along with the load mass (for example, Load weight + Table/Slide/Carriage weight), determines the amount of motor force or torque necessary to move a slide or table, for example.

Angle of inclination from the horizontal. The limits for this value are 0 and 90°. In the horizontal case (0° inclination), the Table Mass, Belt/Chain Mass, and/or Slide Mass are not affected by gravity, whereas in the vertical case (90° inclination), only the table mass is affected by gravity. Values for Table Mass, Belt/Chain Mass, and/or Slide Mass may be entered on the Mechanism tab (a future step in the workflow) if a Belt Drive, Lead Screw,

Chain and Sprocket, or Rack and Pinion are selected.

If the Inclination angle is between 0 and -90°, you must enter the angle as a positive number and invert the motion profile. For example, enter a 45° angle value on the Load tab and a negative velocity in

More Options Profile Editor Mode on page 142 . Failure to do

this will result in an under-calculation of the regenerative energy.



2.1.1.1. Advanced Considerations - Counterbalances

In a counterbalanced system, unbalanced mass should be entered as Table Mass and balanced mass as Belt/Chain Mass. Values for Table Mass, Belt/Chain Mass, and/or Slide Mass may be entered on the Mechanism tab (a future step in the workflow) if a Belt Drive, Lead Screw, Chain and Sprocket, or Rack and Pinion are selected.

There are two main types of counterbalance.

Table 50 - Counterbalance Types

Type

Mass

Counterbalance

Force

Counterbalance

Description

A 100% counterbalance doubles the load mass entered on the Load tab. Friction is usually negligible and the net force is zero. Accelerations are normally limited to less than gravity

(9.81 m/s

2

) to maintain the suspension tension.

A 100% counterbalance means there is zero net force, but usually adds significant friction, especially hydraulic types. For example, pneumatic, hydraulic, or spring. The increase in load mass is usually negligible.

Figure 67 - Counterbalance Types

Mass Counterbalance Force Counterbalance

Drive Belt

Counterbalance Mass

Weight

Drive Belt

Load Mass

Weight

Motor

Motor

Load Mass

Weight

Force

Counterbalance

Cylinder

Air Pressure



2.1.1.1.1. Mass Counterbalance

•

Vertical load with a 100% mass counterbalance

Set the Inclination field to zero and enter a load mass two times greater than the load into the Load Mass field.

•

Vertical load with less than 100% mass counterbalance.

Set the Inclination field to zero and enter the load mass plus the counterbalance mass into the Load Mass field. Add an external positive force equal to the following into the Applied Force field:

F = (M load

- M counterbalance

) a where a = acceleration due to gravity = 9.81 m/s

2

2.1.1.1.2. Force Counterbalance

For a vertical load with a 100% force counterbalance, you have two choices:

•

Set the Inclination field to zero and enter the load mass into the Load Mass field.

•

Set the Inclination field to 90°, and enter the load mass into the Load Mass field. Add an external negative force equal to the load weight into the

Applied Force field.

For a vertical load with less than 100% force counterbalance, set the Inclination field to 90° and put the load mass into the Load Mass field. Add an external negative force equal to the counterbalance force into the Applied Force field.

Be sure to add some allowance for friction. Hydraulic type counterbalances are notorious for high friction, which is usually speed-dependent. Because a mass counterbalance cannot easily handle this directly, take the friction force at the maximum speed, convert the friction force to torque at the drive shaft and add this torque to the Losses field in the Actuator tab.



2.1.2. Rotary Loads

For a rotary application, the load rotates and the system has no translation to linear motion.

Figure 68 - Rotary Load Type

Table 51 - Rotary Load Parameters

Parameter

Primary Inertia

(1)

Description

This is the inertia of any balanced load about the axis of rotation. For example, if the main mass is a circular table which is driven about its own axis of symmetry, then primary inertia is equal to the table inertia.

This is the force resisting the relative motion of two surfaces against each other.

Friction

(1) Use the

Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily

available.



2.1.3. Rotary Complex Loads

A complex rotary load is non-linear, which means that the load position is not directly proportional to the input shaft position as it is with standard actuator types. A simple example is a crank, where the load velocity is sinusoidal with a constant shaft speed. The Crank and Four Bar Linkage templates are available for these applications.

The main challenge with non-linear mechanisms is that the inertia value varies with shaft angle. This means that even at constant shaft speed, a torque that varies with the rate of change of inertia is required to maintain that speed. The same is true of an unbalanced load in which external forces, such as gravity, induce torque values that depend only on shaft angle, not velocity or acceleration.

The Rotary Complex load separates the dynamic inertia values from the motion profile so that, having calculated inertia for a range of shaft positions, the motion profile can be varied without having to re-calculate inertia at each shaft position.

Figure 69 - Rotary Complex Load Type



Table 52 - Complex Load Data Options

Option

Complex Load Data

(label 1 in

Motion

(1)

(label 2 in

Graph tab

(label 3 in

Figure 69

Figure 69

Figure 69 )

)

)

Description

User Defined

Templates

Repeating

Limited Range

Import load data from an external file into the Complex Load Data table on

page 90

.

Use the Unbalanced Load and Crank templates to calculate load data and enter it in the Complex Load Data table on

page 90

.

With this option, the first and last points should be identical so that the motion profile can be repeated (for example, zero and 360 °). Motion

Analyzer software assumes that rotation may continue indefinitely in either direction.

With this option, the first and last points indicate the maximum and minimum positions permitted.

#

Position

Data point number; this number is arbitrary.

Driving shaft angle with reference to the starting angle.

Inertia Load inertia for the given shaft angle.

Applied Torque Torque applied at the given position.

Friction Torque Torque loss due to friction.

Description Available for you to enter optional notes.

The Graph tab of the display window shows the inertia, applied torque, and friction torque values as a function of shaft position based on the data entered in the table on the left (label 2 in

Figure 69

).

(1) The complex load data (position, inertia, and torque, for example) is entered manually, imported, or calculated in the available

Rotary Complex Templates.

It is important to start with the mechanism in the appropriate position. Click

Start Condition on the toolbar at the top of the

More Options Profile Editor

Mode dialog box to input the motion profile start condition.

Figure 70 - Graph Tab



In this Crank application, the green applied torque curve shows a sharp peak around 180° when a high force is encountered near the end of the linear stroke.

Figure 71 - Crank Application Example



2.1.3.1. User Defined

For the User Defined data entry option, calculations are typically made with a spreadsheet. Once the data is arranged in columns to match the Complex Load

Data table, you can copy the data to the clipboard and paste it into the table. The columns are tab delimited, which is the default format for Microsoft Excel software. Alternatively, you can create and import a text file.

IMPORTANT Before pasting data make sure that the column units match those of the data.

2.1.3.2. Templates

The Rotary Complex templates can be used to calculate Complex Load Data for

Unbalanced Load and Crank application types.

Figure 72 - Rotary Complex Loads

90

There are two Rotary Complex templates available to assist in calculating data for

the Complex Load Data table (label 2 in Figure 72

).

Table 53 - Template Options (label 1 in

Figure 72

)

Description Template

Unbalanced Load

Template

Crank Template

Lets you enter parameters for an Unbalanced Load application.

Lets you enter parameters for Crank applications.

Page

91

93



2.1.3.2.1. Unbalanced Load Template

This template lets you enter parameters for an unbalanced load application.

Figure 73 - Unbalanced Load Template

Motion Analyzer software assumes that the axis of rotation is parallel to the ground if no axis angle is entered and that unbalanced masses create a gravity related torque. Secondary Inertia, Secondary Mass and Axis Separation parameters are required to take into account gravity induced torque values.

Figure 74 - Axis of Rotation Parallel to Ground with No Axis Angle Defined



If the gravity torque (Secondary Mass * 9.81 m/s

2

* Axis separation

2

) is known to be small as compared to the acceleration torque or motor nominal torque, then it may not be necessary to include the unbalanced mass effects.

ATTENTION: If the angle of movement in any profile segment is such that the gravity torque changes significantly during that segment (a common occurrence) then break the segment into smaller portions.

Table 54 - Unbalanced Load Parameters (refer to

Figure 73

)

Parameter

Primary Inertia

Losses

(1)

Secondary Inertia

Secondary Mass

Axis Separation

Axis Angle

(1)

Description

The inertia of any balanced load about its own axis of rotation. For example, if the main mass is a circular table which is driven about its own axis of symmetry, then Primary

Inertia is equal to the table inertia.

The losses consist of the torque lost in the system due to friction.

The moment of inertia of the unbalanced mass about its own center of gravity.

The unbalanced mass.

The distance between the secondary mass’ center of gravity and the axis of rotation.

The starting angle of rotation. Zero indicates that at the start of the motion profile, the center of gravity lies vertically below the center of rotation. This is the position of the load if it is allowed to swing freely. Positive rotation is clockwise.

(1) Use the


available.



2.1.3.2.2. Crank Template

The Crank template is used to calculate the load profile for a given application, based on either input shaft velocity or linear load velocity.

IMPORTANT This template should only be used for constant inertia. Do not set secondary mass or secondary inertia when using this template.

Figure 75 - Crank Template

Figure 76 - Animated Display (for reference)

TIP Parameter entry descriptions are displayed when the cursor is held over an entry field for several seconds.



Table 55 - Crank Template Parameters

Parameter

Animated Display


Template Options

(inside red box in

Figure 75

)

Mechanical Data


)

)

Export to Complex Load


)

Description

For reference to make sure that entered data is accurate and particularly that the orientation of the crank is correct. The animation rotates the crank so that the system can be better visualized. The X/Y plane is horizontal.

Vertical Slider (Left)

Horizontal Slider (Top)

Sets the crankshaft inclination. Set this parameter before starting the animation. The 0y button sets the angle to 90°. The current angle is displayed in the Mechanical Data window.

Sets the linear slide inclination. The 0z button sets the angle to 0°. The current angle is displayed in the Mechanical Data window. The true angle to the horizontal is dependent on both slider positions since it is a compound angle.

Horizontal Slider (Scale)

Horizontal Slider (Speed)

Black Arrow

2D/3D

Thick Lines

Animate

Stop

Calculate

Sets the display scale.

Sets the animation speed.

Represents the external force and the arrow length is proportional to the applied force.

Toggles between two and three-dimensional representations of the crank.

Check this box if you would like the graphical displays to be shown with a thicker line.

Click to run the simulated crank image through the specified motion profile.

Click to stop the animation.

Click to calculate the external torque and reflected inertia values.

Crank Radius

Crank Inertia

(1)

Connecting Rod Length

(2)

The distance between crank shaft and crank pin.

The inertia of the crank alone, when the connecting rod is disconnected.

Connecting Rod Mass

The distance from the crank pin center to the gudgeon (wrist) pin center.

The total mass of the connecting rod.

Conrod C of G from Crankpin The distance between the crank pin and the connecting rod center of gravity.

Conrod Inertia about C of G

(1)

The inertia of the connecting rod about its own center of gravity.

Linear (Load) Mass

Linear (Load) Offset

Force Start Position

Force End Position

Force at End

(3)

The mass of the load attached to the connecting rod at the gudgeon pin.

The distance from the linear motion center line to the crankshaft axis.

The distance between gudgeon (wrist) pin and crank shaft center when force is applied.

The distance between the gudgeon (wrist) pin and crank shaft center when force stops.

Force v Angle Box

Draw

Logix Cam

Crankshaft Inclination

Crank Plane Inclination

The magnitude of the force at the ending point.

When this box is checked, the force varies according to shaft angle rather than linear position.

Click this button to show the geometry at the start angle/position.

Click this button to transfer the geometrical data to the clipboard for pasting into the RSLogix 5000 Cam Editor. The master axis is a virtual axis and the slave axis is the crank axis. A trapezoidal move of the virtual axis produces a trapezoidal load profile at the gudgeon pin. The master data must increase positively so only that part of the cam that satisfies this requirement is exported.

This displayed value is the angle of the crank shaft with respect to the XY (horizontal) plane. 90° indicates vertical and gravity has no effect.

This displayed value is the angle with respect to the horizontal plane along which the linear mass moves. Zero degrees indicates horizontal and gravity has no effect.

Start Angle

End Angle

Points

The starting angle for the Crank load profile.

The ending angle for the Crank load profile.

The number of points you would like to divide the load profile into.



Table 55 - Crank Template Parameters (continued)

Parameter

Results


Description

Peak Inertia

Peak Ext. + Grav. Torque

Apply

Cancel

The calculated maximum reflected inertia at the crankshaft.

The Peak External Force + Gravity Torque is the calculated peak torque, generated from the external linear force and gravity.

Click to apply the load profile data and close the window.

Click to close the window without

The Chart Display displays the crank velocity, the inertia that is reflected to the crankshaft, and the crank torque due to external influences such as gravity and applied force. These are the parameters which will be applied.

applying any data.

Chart Display


(1) Use the

Inertia Calculator Template

on

page 105 to calculate the inertia value for your application, if the value is not readily available.

(2) Setting this length to zero configures the mechanism as a Scotch Yoke, where the linear load follows a simple harmonic motion.

(3) If the Force at Start is different from the Force at End, the force varies between these two limits according to gudgeon pin position or crank angle. If the values are equal, a constant force is applied.



2.1.4. Application Template Loads

The application templates let you enter pre-configured mechanism application data.

Figure 77 - Application Template Load Type

96

Table 56 - Application Template Options

Template Type

Press Roll Feed (constant time/constant angle)

Carriage Cut Off

Cutter Knife Drive

Advanced Templates

Power/Speed Templates

Description

This application is typically cutting strip material into pre-set lengths with a

‘Press Shear’ (heavy-duty knife). The material must be stationary when the cut is made and the cut takes place over a fixed amount of time or a fixed angle of the driving crank whose speed is varied to match the cut rate.

Page

97


‘Flying Shear’ (heavy-duty knife on a moving carriage). The shear must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes a fixed time.

100


‘Rotary Knife’ (heavy-duty knife blades mounted on a pair of rotating drums). The blades must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes place over a fixed drum angle.

102

These templates let you enter data for complex mechanisms. Advanced

Templates include the Inertia Calculator, Crank, Winder/Unwinder, and Four

Bar Linkage.

These templates let you enter torque and speed values that are used to calculate the power requirement for the application.

104

118



2.1.4.1. Press Roll Feed (constant time/constant angle)

This application is typically cutting strip material such as steel into pre-set lengths by means of a press shear (heavy-duty knife). The material must be stationary when the cut is made and the cut takes place over a fixed amount of time or a fixed angle of the driving crank whose speed is varied to match the cut rate.

Strip material is unwound from a reel at constant surface speed and fed via separately driven leveler rolls into one end of a looping pit (a free-hanging loop of material providing storage). On the other side of the loop, a pair of feeder rolls grips the material and moves it forward the required cut length and then stops.

After the cut is complete, the material is moved again. The average velocity of the nip/feeder rolls must be equal to the constant velocity of the unwinder and leveler rolls.

Figure 78 - Press Roll Feed - Constant Time

Figure 79 - Press Roll Feed - Constant Angle



Table 57 - Press Roll Feed Parameters

Parameter

Load

(label 1 in

Figure 79

Figure 79

Figure 79

Figure 79

)

(label 2 in

)

(label 3 in

)

(label 4 in

)

Figure 78

Critical Preferences

Figure 78

System Properties

Figure 78

Figure 78

or

(1)

or

or

Motion Type Properties

or

Description

Moving Material Mass

Bias Force

Drive Roll Diameter

Total Roll Inertia

(2)

Cut (Waiting) Time

Cut (Waiting) Angle

Max Average Line Speed

Cuts/min

Settling Time

Cosine Compensation

Linear

S-Curve

Triangular Move

The mass of the material in the loop and on the flat before the Nip/Feed rolls.

(3)

The force required to overcome the force of gravity on the loop.

(3)

The diameter of the roll in direct contact with the strip, driven from the motor.

The total inertia of the strip material at the drive shaft.

The time during which the material must be stationary in an accurate position. This value is only required for Press Roll Feed -

Constant Time applications (refer to the red boxes in images above).

The crank angle during which the material must be stationary in an accurate position. This value is only required for Press Roll

Feed - Constant Angle applications (refer to the red boxes in images above).

Select this option for data entry when the maximum design speed of the constant-speed sections of the line is known. This speed does not refer to the peak velocity of the feeder section, which is determined by Motion Analyzer software.

Min. Cut length at

Max line speed

When you select the option to enter data based on Max Average Line Speed, this data is required. This is the critical condition on which the sizing process is performed. To cut shorter lengths than this critical length, the line speed must be reduced.

Select this option for data entry when the number of cuts made by the system per minute is known.

Max. Cut length at

Cuts/min

When you select the option to enter data based on Cuts/min, this data is required. This is the critical condition on which the sizing process is performed. To cut longer lengths than this critical length, the line speed must be reduced.

This is the time required for the system to achieve the required position accuracy before the cut commences. The finer the required accuracy, the longer the settling time value. This time is typically 20 to 75 ms for an A servo system.

This option is only required for Press Cutter Knife Drive applications. The Cosine Compensation is used to make sure that while the press cutter knife is in contact with the material being cut, the horizontal component of the knife’s velocity matches the material speed.

Select this option for standard linear acceleration and deceleration ramps.

Select this option for ‘S’ shaped acceleration and deceleration ramps that are used to produce smoother motion. You need to enter the percent jerk value for this option.

Select this option for a triangular load profile. This option is only required for Press Roll Feed - Constant Angle applications (see

red box in Figure 79

).

(1) At very long cut lengths, the limiting factor, determined by the design speed of the leveler rolls and unwinder, is the maximum line speed. As cut length is reduced, the servo has to index more and more rapidly until the peak or RMS (root mean squared) torque limit is reached. To cut shorter lengths than this critical length, the line speed must be reduced. Sizing is based on this critical length, maximum line speed and cut time, which are typically specified.

(2) Use the Inertia Calculator Template on page 105

to calculate the inertia value for your application, if the value is not readily available.

(3) You can enter this data manually or use the

Loop Calculator on page 99 , to determine the value.



Click or Figure 79 to determine the Moving Mass and Bias

Force parameters by using the Loop Calculator.

Figure 80 - Loop Calculator

Table 58 - Loop Calculator Parameters

Parameter

Material

(label 1 in

Loop

(label 2 in

Figure 80

Figure 80

)

)

Computed Parameters

(label 3 in

Figure 80

)

Description

Density

Thickness

Width

Choose strip material from the pull-down menu or enter the density value manually.

Strip material thickness.

Strip material width.

Flat Length Strip material flat length as defined in the Press Roll Feed Diagram.

Loop Length Strip material loop length as defined in the Press Roll Feed Diagram.

Loop Depth Strip material max loop depth as defined in the Press Roll Feed Diagram.

Moving Mass When you click Compute, the Loop Calculator displays the Moving Mass and Bias Force values based on the values you entered for the parameters

Bias Force above. These values are entered in the Application Template when you click

OK.



2.1.4.2. Carriage Cut Off

This application is typically cutting strip material such as steel into pre-set lengths by means of a Flying Shear (heavy-duty knife mounted on a moving carriage).

The shear must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes a fixed time.

Strip material is unwound from a reel at constant surface speed and fed via separately driven leveler rolls. After the cut is complete, the shear is stopped then moved back to its start position. It must accelerate to match the line speed at the correct position to cut the required length of material.

Figure 81 - Carriage Cut Off Template



Table 59 - Carriage Cut Off Parameters

Parameter

Load

(label 1 in


(label 2 in

(label 3 in

(label 4 in

Figure 81

Figure 81

System Properties

Figure 81

Figure 81

)

(1)

)

)


)

Description

Mass of Carriage

Drive Roll Diameter

Friction Coefficient

Cut Time


Cuts/min

Settling Time

Linear

S-Curve

Total mass of the linear moving parts.

Diameter of the roll, driven from the motor.

Coefficient of friction of the sliding bearing.

Time the carriage must be synchronized accurately with the material.


Min Cut length at

Max line speed



Max Cut length at

Cuts/min








2.1.4.3. Cutter Knife Drive

This application is typically cutting strip material such as steel into pre-set lengths by means of a rotary knife (heavy-duty knife blades mounted on a pair of rotating drums). The blades must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes place over a fixed drum angle.

Strip material is unwound from a reel at constant surface speed and fed via separately driven leveler rolls. After the cut is complete, the drum is adjusted forward or backward relative to the material in order to cut the required length. It must return to line speed at the position required to cut the required length of material.

When the cut-length is equal to the circumference of the locus of the knife blade tip, it is said to be the synchronous cut length. In this special case, the knife drums rotate at a steady speed.

Figure 82 - Cutter Knife Drive Template



Table 60 - Cutter Knife Drive Parameters

Parameter

Load



(label 2 in

System Properties

(label 3 in

Figure 82

Figure 82

(1)

)



)

)

Description

Total Knife Inertia

Effective Diameter

(2)

Inertia of the knife assembly at the drive shaft.

As illustrated in the Cutter Knife Drive (Rotary Knife) diagram, this is the diameter of the circle passing through the cutting edge.

Contact Angle (Before

BDC)

Time the material must be stationary in an accurate position.

Number of Blades/Knife Number of blades around the circumference of the knife.

Cutting Force

Maximum force required to cut through the material. Cutting force is essentially constant while maximum torque occurs at the first point of knife contact.


Cuts/min

Settling Time

Cosine Compensation

Linear

S-Curve


Min Cut length at

Max line speed



Max Cut length at

Cuts/min



This option is only required for Press Cutter Knife Drive applications. The Cosine Compensation is used to make sure that while the press cutter knife is in contact with the material being cut, the horizontal component of the knife’s velocity matches the material speed.




(2) Use the


on




2.1.4.4. Advanced Templates

The Advanced Templates tab let you enter data for complex mechanisms. The templates convert the complex mechanisms into Motion Analyzer mechanism data and load profiles with additional inertia and loads.

Figure 83 - Advanced Templates Dialog Box

Table 61 - Advanced Template Options

Template Type

Inertia Calculator

Crank Template

Winder/Unwinder

Four Bar Linkage

Description

Calculates the inertia for your application.

Lets you enter parameters for Crank applications.

Enter required inputs to calculate the load profile for Winder or Unwinder applications.

Enter required inputs to calculate the load profile for Four Bar Linkage applications.

114

Page

105

93

112



2.1.4.4.1. Inertia Calculator

The Inertia Calculator has several options for inputting parameters to calculate inertia for an application.

Figure 84 - Inertia Calculator Template

Table 62 - Inertia Calculator Template Options

Template Type

Less Options Inertia Mode

Description

This is the default mode when you open the Inertia Calculator. You can also enter this mode by clicking Less Options in the lower left corner of the calculator in More Options Inertia Mode. Use this mode to calculate inertia for a single cylindrical component. The center of mass/center of gravity of the cylinder must coincide with the axis of rotation.

Page

106

More Options Inertia Mode

Enter this mode by clicking More Options in the lower left corner of the calculator in Less Options Inertia mode. Use this mode to enter data for more complex shaped components. By assembling cylinders, cuboids, and prisms, any largely three dimensional shape can be constructed.

107

SolidWorks Import

Use this mode to directly import inertia data from SolidWorks. Enter

SolidWorks mode by choosing SolidWorks from the Type pull-down menu in the Element Properties window.

109



2.1.4.4.1.1. Less Options Inertia Mode

The Less Options Inertia mode is the default mode when you open the Inertia

Calculator. Use this mode to calculate inertia for a single cylindrical component.

The center of mass/center of gravity of the cylinder must coincide with the axis of rotation.

Figure 85 - Less Options Inertia Mode

106

Table 63 - Less Options Inertia Mode Properties

Parameter Description

Type

Name

Calculate Using

Diameter

Element Properties


Length

Mass

Material

Density

Element Properties


Results


Element Mass

Element Inertia

Total Inertia

Mass

Choose the type of cylinder (solid or hollow) you would like to calculate the inertia for.

Enter a meaningful name for the item you are calculating inertia for.

Select the type of data (mass or density) you would like to use to calculate inertia.

This is the diameter of the cylinder. When calculating inertia for a hollow cylinder, you also need to enter inner and outer diameter as defined in the Element Image window.

This is the length of the cylinder. This parameter is not required when calculating based on mass.

This is the cylinder mass. This parameter is not required when calculating based on density.

Choose the material of the cylinder from the pull-down menu. If Other is selected as the material type, the density value also needs to be entered. This parameter is not required when calculating based on mass.

When the cylinder material is not available in the Material pull-down menu, the density value must be entered here. This parameter is not required when calculating based on mass or when the material is selected from the pull-down menu.

Once the element properties are entered, the Element Mass and Element Inertia properties are displayed (see label 2) and in the Results window (see label 3).

The Element Mass and Element Inertia, and the Total Mass and Total Inertia are equivalent in Less Options Inertia mode, because data is only entered for a single cylindrical element.

Because the Less Options Inertia mode is used to calculate the inertia of a single cylindrical component, the options in the Add Element toolbar are not available.



2.1.4.4.1.2. More Options Inertia Mode

In More Options Inertia mode you can calculate the mass and inertia of complex shapes. By assembling cylinders, cuboids and prisms, you can construct any largely three dimensional shape.

Figure 86 - More Options Inertia Mode

Table 64 - More Options Inertia Mode Properties


Add Element

Add Element Toolbar

(label 1 in

Figure 86

)

Insert

Delete

Cut

Copy

Paste

Segment Selector

Pull-down menu that lets you add an inertia element at the bottom of the Element List. You have the option of adding a solid cylinder, hollow cylinder, cuboid, or prism.

Pull-down menu that lets you insert an inertia element above the selected inertia element in the Element List.

Deletes the selected inertia element in the Element List.

Removes the selected inertia element in order to place it in another location in the Element List.

Create a copy of the selected inertia element in order to replicate the element in another location in the Element List.

This button lets you replace the selected inertia element with a ‘cut’ or ‘copied’ inertia element.

Use the Inertia Element Selector arrows (red box in Figure 86 ) to navigate through the various inertia elements in the Element List. As

you navigate to an inertia element, the associated Element Properties window and Element Image tab are displayed.



Table 64 - More Options Inertia Mode Properties (continued)

Parameter

Element Properties

(label 2 in

Figure 86 )

Description

Once the Element Properties are entered, the Element Mass and Element Inertia values are displayed at the bottom of the Element Properties window (label 4

in Figure 86 ).

Type

Name

Calculate Using

X

Select the type of element (solid cylinder, hollow cylinder, cuboid, or prism) you would like to add to the Element List.

Enter a meaningful name for the element you are editing.

Select the type of data (mass or density) you would like to use to calculate inertia.

This is the position for the inertia element in the X (horizontal) direction. For a prism you will need to enter X1, X2 and X3 positions.

Y

Diameter

Inner Diameter

Length

Quantity

Mass

Material

Density

This is the position for the inertia element in the Y (vertical) direction. For a prism you will need to enter Y1, Y2 and Y3 positions.

This is the diameter of the inertia element if it is cylindrical. For a cuboid you will need to enter width and height.

This is the inner diameter of the inertia element if it is a hollow cylinder.

This is the length of the inertia element. This parameter is not required when calculating based on mass.

This is the number of identical elements.

This is the mass of the inertia element. This parameter is not required when calculating based on density.

Select the material of the cylinder from the pull-down menu. If Other is selected as the material type, the density value also needs to be entered. This parameter is not required when calculating based on mass.

When the inertia element material is not available in the Material pull-down menu, the density value must be entered here. This parameter is not required when calculating based on mass or when the material is selected from the pull-down menu.

Element List

(label 5 in

Figure 86 )

Results

(label 6 in

Figure 86 )

Error List

Summary list of the elements that make up the component with the current element highlighted in blue.

Motion Analyzer software takes gravity into account only if an unbalanced load is entered as secondary inertia. Gravity is taken to act from top to bottom of the

Component Plot window.

In the event of incorrect input data, a list of errors is displayed.

Figure 87 - Element Image Tab (label 3 in Figure 86 )

108

Use this tab to verify the correct placement of the various inertia elements.



2.1.4.4.1.3. SolidWorks Import

You can use the SolidWorks Inertia Calculator to import inertia data directly from SolidWorks software when the part geometry is complex and a SolidWorks model is readily available. The part must be balanced about the axis of rotation.

For unbalanced loads, a SolidWorks Motion Study must be completed and users must interface with SolidWorks, using the resulting torque data to appropriately size a motor. Refer to

From SolidWorks on page 120

for more information on the

SolidWorks Interface Wizard.

Figure 88 - SolidWorks Inertia Calculator

The density, volume, and surface area of the element (label 1 in

Figure 88 ) are displayed in the middle. The mass and inertia (label 2 in Figure 88

) are displayed at the bottom of the Element Properties window and in the Results window at the bottom right (label 3 in

Figure 88 ).

Receive inertia data from SolidWorks software by selecting SolidWorks from the

Type pull-down menu in the Element Properties window.



Click Import to open the SolidWorks - Data Import dialog box.

Figure 89 - Import SolidWorks Data

Table 65 - SolidWorks - Data Import (refer to

Figure 89 )

Parameter

Load/Change

Refresh

Select Axis

(1)

Description

Load or change the SolidWorks model.

Update the data returned to Motion Analyzer software if changes are made to the model while the part is open in SolidWorks software.

Click the radio button corresponding to the model’s axis of rotation in the Inertia Details section.

This step is critical to determining the inertia since the model needs to be balanced about the correct axis.

(1) The axis of rotation corresponds to the inertia value that is different from the other two values. Since the model is balanced about the axis of rotation, the inertia is the same about two axes, and different about one.

Click OK to import the data from SolidWorks into Motion Analyzer software.



The SolidWorks – Data Import window closes and returns to the Inertia

Calculator window and the imported element image.

Figure 90 - Imported Element Image



2.1.4.4.2. Winder/Unwinder

Use this template to enter required inputs to calculate the load profile for Winder or Unwinder applications.

Figure 91 - Winder/Unwinder Template

For a Winder or Unwinder application, two index moves are created:

•

Maximum diameter, minimum rotation speed

(= maximum torque for center driven)

•

Minimum diameter, maximum rotation speed

(= minimum torque for center driven)

The maximum torque condition is the worst case for winding temperature so the move time for this index is made large enough to dominate the temperature calculations.

The maximum speed case is included to check that the specified speed can be reached. If the application requires a different acceleration for the full roll compared to the core, this can be done in

Define Your Profile on page 139

after you click Apply.



Table 66 - Input Data (label 1 in Figure 91 )

Parameter

Center Driven

Description

The roll is driven directly via a shaft at its center of rotation. For a Center Driven application,

Rotary Load is selected and the roll is modeled as Inertia and Torque in a Multi-segment profile.

No further load information needs be added.

The roll is driven by the friction of rollers pressing onto the circumference of the web. For a

Surface Driven application, Linear Load and Belt Drive are selected and the roll is modeled as

Mass and Force in a Multi-segment profile.

Surface Driven

IMPORTANT The driving roll/rolls data should be added as Drive Roll and

Idler Roll.

You will be asked if you want to reset the Actuator parameters to zero. Click Yes, if this is the first time you applied this Winder. If you already applied it and added the drive roll data in the Belt

Actuator, the drive roll data will be deleted.

Empty Diameter Minimum reel diameter, when the roll is completely unwound.

Empty Inertia Inertia of the reel when it is completely unwound.

Full Diameter

Material Inertia

(1)

Maximum Web

Tension

Minimum Web

Tension

Maximum reel diameter, when the roll is completely wound.

Inertia of the reel when it is at full diameter or completely wound.

Maximum allowable web tension for the material. The value is used for sizing purposes.

Minimum web tension for the application. It is used to calculate the Tension Ratio.

Maximum Web

Speed

Design speed of the material running through the machine.

Acceleration Time Shortest required acceleration time from zero to maximum web speed.

Deceleration Time Shortest required deceleration time from maximum web speed to zero.

S-curve

Wind/Unwind

Profile Mirror

Check this box if the acceleration and deceleration follow a smooth S-curve. If this box is not checked, acceleration is considered trapezoidal.

Select either Wind or Unwind for your application. This setting determines the direction of pull from the web tension.

This option is used only when a Wind and Unwind axis share a DC power rail. The two axes are first sized as normal (for example, Profile Mirror is set to Off). The Winder is then set to Profile

Mirror. This matches the two axis motion profiles as if they were connected by the web. This is necessary only to check the system sizing. In this mode the motor winding temperature of the

Winder axis will be underestimated.

(1) Use the Inertia Calculator Template on page 105


Click Calculate to display the following values in the Results portion of the window (label 2 in Figure 91 ).

Table 67 - Calculated Parameters (label 2 in Figure 91 )

Parameter

Buildup Ratio

Inertia Range

Tension Ratio

Maximum Web

Power

Description

Ratio of the Maximum/ Minimum diameter of the roll.

Ratio of Maximum/Minimum inertia values. A large inertia range value is more difficult to control.

Ratio of the Maximum/Minimum tension values.

Maximum web tension multiplied by the maximum web speed. This power is regenerated continuously during unwind and should be catered for by suitably rated dump resistors or a regenerative power supply. Motion Analyzer software underestimates this rating by approximately 10%.



2.1.4.4.3. Four Bar Linkage

You can use this template to enter required inputs to calculate the load profile for

Four Bar Linkage applications.

Figure 92 - Four Bar Linkage Template

Figure 93 - Animated Diagram (for reference)

114

TIP Parameter entry descriptions are displayed when the cursor is held over an entry field for several seconds.



Table 68 - Four Bar Linkage Properties

Parameter

Animated Display

(1)


Mechanical Data


Description

Vertical Slider

(left)

Horizontal Slider

(top)

Horizontal Slider

(scale)

Horizontal Slider

(Speed)

Animate

Stop

Analyze

Calculate

Link 1 Length

Link 1 Inertia

(2)

This slider sets the crankshaft inclination and should be set before starting the animation. Click 0y to set the angle to 90°. The current angle is displayed in the Mechanical Data window.

This slider sets the linear slide inclination. Click 0z to set the angle to 0°. The current angle is displayed in the Mechanical Data window.

The true angle to the horizontal is dependent on both slider positions because it is a compound angle.

This slider sets the display scale.

This slider sets the animation speed. The black arrow in the plot represents the external force, and the arrow length is proportional to the applied force.

Click to run the simulated crank image through the specified motion profile.

Click to stop the animation.

Click to display the bar graphs that show the contribution of each mechanical component to the inertia and torque values.

Click to calculate the external torque and reflected inertia values that will be applied.

Distance between Pivot 1 and Pivot 2.

Inertia of Link 1.

Link 1 Start Angle Initial angle between Link 1 and X Axis. Angular load profile only.

Link 2 Length Distance between Pivot 2 and Pivot 3.

Link 2 Mass

Link 2 CG

Link 2 Inertia

Load Pivot X

Load Pivot Y

(1)

Mass of Link 2.

Link 2 Center of Gravity with respect to Pivot 2.

Inertia of Link 2 about its own center of gravity.

X distance between Pivot 1 and Pivot 4.

Y distance between Pivot 1 and Pivot 4.

Load Link Length Distance between Pivot 3 and Pivot 4.

Load Inertia

Load Mass

Inertia of the load (Link 3) about its own center of gravity.

Mass of the load (Link 3.)

Load G of G Radius Distance between Pivot 4 and center of gravity of the load (Link 3.)

Load G of G Angle Angle between the lines that make up the center of gravity of the load (Link 3), Pivot 4, and Pivot 3.

Link 1 Start Angle Link 1 angle when force is applied.

Force at Start Magnitude of the force at the starting point.

Force at End

Magnitude of the force at the ending point. If the Force at Start is different from the Force at End, the force varies between these two limits according to gudgeon pin position or crank angle. If the values are equal, a constant force is applied.

Force Orientation Force orientation from the X axis.

Draw Start

Position

Click to show the geometry at the start angle/position.

Export Logix Cam

Pivot 1 Axis

Inclination

Click to transfer the geometrical data to the clipboard for pasting into the RSLogix 5000 Cam Editor. The master axis is a virtual axis while the slave axis is the crank axis. A trapezoidal move of the virtual axis then produces a trapezoidal profile at the gudgeon pin. The master data must increase positive so only that part of the cam that satisfies this requirement is exported.

Displayed value is the angle of the crank shaft with respect to the XY (horizontal) plane. 90° indicates vertical, and gravity has no effect.



Table 68 - Four Bar Linkage Properties (continued)

Parameter

Profile Window


Results Window


)

Chart Display Window


Description

Coarse Data

Fine Data

Select this option if the size of the profile segments is sufficient to detect significant changes to force or inertia during each time slice.

Select this option if a finer resolution of the profile segments is needed to detect significant changes to force or inertia during each time slice.

You can copy spreadsheet data and paste into this grid. Click the Time column, Row zero, and then press Ctrl + v.

Delta T Column Profile segment duration (dT).

Profile Table

Insert

Delete

Clear All

Display

Maximum Fine

Segments

Peak Inertia

Peak Ext. + Grav.

Torque

Cycle Time

Velocity Column

Acc. Pk/Ave

Insert a new, blank row at the highlighted position.

Delete the row at the highlighted position.

Remove all profile data.

Final velocity at the end of the profile segment. Row zero is reserved for the start velocity only, hence the time and S-curve cells are grayed out.

Acceleration Peak/Average. The following values apply:

1 = Trapezoidal acceleration

2 = S-curve acceleration

>1 or <2 = partial S-curve

Click to show the load profile for checking purposes.

Specify the maximum number of profile segments that you would like the coarse segments divided into.

Calculated maximum reflected inertia at the crankshaft.

Peak External Force + Gravity Torque is the calculated peak torque, generated from the external linear force and gravity.

Calculated cycle time for the specified load profile.

Minimum Time

Slice

Apply

Cancel

Minimum time slice required for the simulation.

Click to apply the load profile and close the window.

Click to close the window without applying any data.

Shows the crank velocity, the inertia that is reflected to the crankshaft, and the crank torque due to external influences such as gravity and applied force.

These are the parameters that are applied. By checking Show Resultant Load Torque, the associated value can also be displayed.

(1) The Animated Display at the upper left corner of the template is provided for reference to make sure that entered data is accurate and particularly that the orientation of the crank is correct. The animation rotates the crank so that the system may be better visualized. In this example, the X/Y plane is horizontal.

(2) Use the

Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available.



Click to use the Quick Profile tool. A trapezoidal load profile is entered into the data grid after clicking Apply.

Figure 94 - Quick Profile Tool

Table 69 - Quick Profile Tool (refer to

Figure 94

)

Parameter

Move Angle

Move Time

Wait Time

Velocity Pk/Ave

Accel.Pk/Ave

Description

Angle through which the load profile takes place.

Time through which the load profile takes place.

Length of time to wait before the specified index move repeats.

Velocity Peak/Average. The following values apply:

2 = triangle; minimum peak torque

1.5 = equal trapezoid; minimum RMS (root mean squared) torque

1 = infinite acceleration; not useable

If the start velocity is non-zero, the peak velocity may be adjusted by the program to avoid crossing the zero line.

Acceleration Peak/Average. The following values apply:

1 = Trapezoidal acceleration

2 = S-curve acceleration

>1 or <2 = partial S-curve



2.1.4.5. Power/Speed Templates

You can use the Power/Speed templates to enter torque and speed values that are used to calculate the power requirements for the application.

Figure 95 - Power/Speed Templates

Table 70 - Power/Speed Template Options

Template Type

Power/Speed Template

(label 1 in

Figure 95 )

Constant Power Range

Template

(label 2 in

Figure 95 )

Description

Use this template when the torque and speed values are known at the load for the application.

Page

119

Use this template when three of the following values are known: maximum torque, minimum torque, maximum speed, or minimum speed.

120



2.1.4.5.1. Power/Speed Template

Use this template (label 1 in

Figure 95 ) when the torque and speed values are

known for the application.

Click to access the Power Calculator.

Figure 96 - Power Calculator

Table 71 - Input Properties (refer to

Figure 96 )

Parameter

Torque

Speed

Description

Torque value for your application.

Speed for your application.



2.1.4.5.2. Constant Power Range Template

Use this template (label 2 in

Figure 95 ) when three of the following four values

are known for the application.

Click to use the Power Calculator and enter the known torque and speed values.

Figure 97 - Power Calculator

120

Table 72 - Input Properties (refer to Figure 97 )

Parameter

Max Torque

Min Torque

Min Speed

Max Speed

Description

Maximum torque value for your application.

Minimum torque value for your application.

Minimum speed for your application.

Maximum speed for your application.

Click Apply to display the Power value and other missing value.

2.1.5. From SolidWorks

Integration with SolidWorks software can be used to obtain data to accurately size motors, drives, and accessories for mechanically complex applications.

SolidWorks Motion has built-in tools that let users obtain accurate inertia and force/torque data. Rather than manually recalculating or simply estimating these values for motor sizing, Motion Analyzer software integrates with SolidWorks software for consistency throughout the design process.

SolidWorks software calculates torque/force information for the following two load types.

Table 73 - Enter Motion Profile

Workflow Method Description

Independent Axis

Workflow

Inter-dependent Axes

Workflow

Select From SolidWorks as the load type.

Launch the SolidWorks Simulation tool from the System View page.

Page

122

131



Each load type requires a slightly different workflow in Motion Analyzer software to obtain the data from SolidWorks software. Both workflows support linear and rotational motion.

IMPORTANT A SolidWorks Assembly must be open in SolidWorks software when launching the SolidWorks Interface Wizard from Motion Analyzer software.

IMPORTANT A SolidWorks Motion Study must be set up before launching the SolidWorks

Interface Wizard. Gravity, SolidWorks motors, material properties, and any additional external forces must be defined in the SolidWorks Motion Study before integration. Velocity and force/torque Results Plots must be created in

SolidWorks software for the simulation to return results to Motion Analyzer software.

IMPORTANT Define reference geometry in SolidWorks software to define the axis of rotation for the component the SolidWorks motor is attached to. Using component faces to attach SolidWorks motors will work, but may inadvertently define motion about an incorrect location for some mechanisms.

TIP If you disable animation before SolidWorks software performs calculations the solver speed improves. This is because the software is not attempting to show the motion of the assembly while performing calculations.

Follow these steps to improve SolidWorks software solver speed.

1.

From the SolidWorks Motion Study explorer bar, click the Motion Study

Properties icon.

2.

Clear the Animate during simulation checkbox.



2.1.5.1. Independent Axis Workflow

With independent motors, each motor works alone to move the load in the single-axis, independent workflow, so the force/torque output stands isolated. An example is the single-axis lifter mechanism ( Figure 98 ) where one motor drives the load.

Figure 98 - Independent Motors

SolidWorks Motion software supports linear and rotary motors. For an independent motor workflow, there are two options for motion:

•

Translational (linear motion)

•

Rotational (rotary motion)



Follow these steps for an independent axis workflow.

1.

Click the Load tab.

Select Translational (Linear) if a linear load is defined or Rotational

(Rotary) if a rotary load is defined in the SolidWorks Motion Study.

2.

Click Next.



3.

Click Edit Profile to specify the motion profile that the mechanism will move through.

This motion profile is placed at the output of the motor or gearbox shaft, if

a gearbox is included in the motion system. Refer to Define Your Profile on page 139 for more information.

Once you specify the motion profile for the axis, the SolidWorks integration begins.

4.

Click Launch SolidWorks Simulator to obtain force/torque results from

SolidWorks software.



The Selected SolidWorks Assembly dialog box opens.

5.

Verify the following conditions:

•

The SolidWorks assembly must be open in SolidWorks software before the SolidWorks integration wizard is launched.

•

The SolidWorks file must be an assembly and not simply a part.

•

Only one instance of SolidWorks software can be running in order for integration to work.

6.

Click Refresh when changes are made to the associated SolidWorks model to make sure Motion Analyzer software is interfacing with the most recent version of the SolidWorks assembly.

7.

Verify this is the correct model and click Next.

If the model is not correct, open the correct assembly in SolidWorks software and click Refresh.



The Motion Study Setup dialog box opens.

8.

From the Motion Study Name pull-down menu, choose a SolidWorks

Motion Study for the data.

9.

Click Next.

If you need to create a new motion study, return to SolidWorks software. a. Return to the opening window and click Refresh to register the changes. b. Click Next.



The SolidWorks Motor Setup dialog box opens.

This dialog box lets you verify the SolidWorks Motor Setup. For interdependent motors, you assign Motion Analyzer motion profile data to each SolidWorks motor during this step. The Motor Setup dialog box is repeated for each axis of motion.

10.

From the Motion Analyzer Axis pull-down menu, choose the Motion

Analyzer axis.

IMPORTANT If all axes have the same name and this causes confusion, go to Options >Application Info to rename the axes.

11.

Check Reverse Direction if you find that the load moves in the wrong direction.

Play the animation in SolidWorks software after the motion profile has been sent across in a future step. Return to this step using the Back button and check this box to reverse the direction of the motion profile. If the motion is incorrect, select the Reverse Direction checkbox to switch the direction of motion.

12.

From the SolidWorks Motor Name pull-down menu, choose the name of the SolidWorks motor that runs in the motion profile with the chosen

Motion Analyzer axis.

The SolidWorks Moving Part pull-down menu, is for information only.

This states the component that the SolidWorks motor is attached to and the motion profile it will be applied to. If the component is not correct, return to SolidWorks to attach the motor to the correct component.

13.

Click Next.



The Summary dialog box opens.

14.

Enter a value in the Frames/Second field.

This value indicates the number of frames per second the motion profile is divided into. A large number yields fine resolution while a small number yields coarse resolution.

15.

Click Modify Selections.

Use this feature to edit a specific Motion Analyzer Axis. a. Select an axis in the table.

b. Click Modify Selections to jump back to the SolidWorks Motor Setup window for the selected axis.

16.

Click Next.



SolidWorks software calculates the force/torque required to move the load through the specified motion profile and the Results dialog box opens.

17.

From the Results pull-down menu, choose the axis of motion you wish to display.

18.

Click the View Graph tab.

This tab displays the data in graphical format.

19.

Click the View Data tab.

This tab displays the data in list format.

20.

Click Export Data.

The data exports into a spreadsheet.

21.

Click Apply to transfer force/torque data to Motion Analyzer software for use in sizing a motion system.

22.

Go to SolidWorks software and click Play from Start in the SolidWorks

Motion Study explorer.

View the motion profile as applied to your mechanism.

23.

Verify that the mechanism is moving in the right direction. If you find that the load moves in the wrong direction, return to

step 11

by clicking Back and check Reverse Direction.



The SolidWorks Load Data dialog box opens.

This dialog box lets you compare the actual Motion Analyzer velocity profile to the velocity profile returned from SolidWorks.

24.

Check Invert SolidWorks Output Data if the velocity profiles were reversed to resolve the discrepancy and correct your model. The discrepancy is due to different coordinate systems, which are arbitrarily defined.

25.

Click Proceed to Transmissions.

This step changes depending upon the application.

IMPORTANT With these versions of SolidWorks and Motion Analyzer, the inertia data is not brought out automatically. This means that Motion

Analyzer has no knowledge of the inertia ratio, and therefore cannot do the Motion Analyzer Simulation on the Solution tab.



2.1.5.2. Inter-dependent Axes Workflow

With inter-dependant motors, several motors work to move one load, so although the motors have separate force/torque outputs, they depend on each other to collectively move the load. An example is the two-axis linear pick and place mechanism ( Figure 99 ) where two motors drive the load.

Figure 99 - Inter-dependant Motors

Once the motion profile for each axis has been specified, the SolidWorks integration begins. Refer to

Define Your Profile on page 139 for more

information on defining a motion profile.

Follow these steps for an inter-dependent axis workflow.

1.

Click to access the Motion Analyzer/SolidWorks integration tool,

Motion Analyzer software launches a new window and displays the model that is open in SolidWorks software.

Use the integration tool to send motion profile data to more than one

SolidWorks motor simultaneously, thereby letting SolidWorks software accurately calculate the effect of multiple motors working together to drive one load.



The Selected SolidWorks Assembly dialog box opens.

2.

Verify the following conditions:

•

The SolidWorks assembly must be open in SolidWorks software before the SolidWorks integration wizard is launched.

•


•

Only one instance of SolidWorks software can be running in order for integration to work.

3.


4.

Verify this is the correct model and click Next.

If the model is not correct, open the correct assembly in SolidWorks software and click Refresh.


The Motion Study Setup dialog box opens.


5.

From the Motion Study Name pull-down menu, choose the SolidWorks motion study to be used for simulation.

If you need to create a new motion study, return to SolidWorks. Return to the opening dialog box and click Refresh to register the changes.

6.

Click Next.




7.

Enter the number of axes you would like to study.

Motion Analyzer detects the number of SolidWorks motors present in the chosen SolidWorks motion study.

IMPORTANT The number of Motion Analyzer axes to be studied must be less than or equal to the number of SolidWorks motors. Also, the number of motion profiles sent to SolidWorks software cannot exceed the number of

SolidWorks motors waiting to consume the motion profile data.

The number of SolidWorks motors defined in the SolidWorks motion study can be changed by returning to SolidWorks software to add or delete motors. After adding or deleting SolidWorks motors, return to the opening window and click Refresh to register the changes.

8.

Click Next.




This dialog box lets you verify the SolidWorks Motor Setup. For interdependent motors, you assign Motion Analyzer motion profile data to each SolidWorks motor during this step. The Motor Setup dialog box is repeated for each axis of motion.

9.

From the Motion Analyzer Axis pull-down menu, choose the Motion

Analyzer axis.

IMPORTANT If all axes have the same name and this causes confusion, go to Options >Application Info to rename the axes.

10.

Check Reverse Direction if you find that the load moves in the wrong direction.

Play the animation in SolidWorks software after the motion profile has been sent across in a future step. Return to this step using the Back button and check this box to reverse the direction of the motion profile. If the motion is incorrect, select the Reverse Direction checkbox to switch the direction of motion.

11.

From the SolidWorks Motor Name pull-down menu, choose the name of the SolidWorks motor that runs in the motion profile with the chosen

Motion Analyzer axis.

The SolidWorks Moving Part pull-down menu, information only, this states the component that the SolidWorks motor is attached to and the motion profile will be applied to. If the component is not correct, return to

SolidWorks to attach the motor to the correct component.

12.

Click Next.



The SolidWorks Summary dialog box opens.

13.

Enter a value in the Frames/Second field.

This value indicates the number of frames per second the motion profile is divided into. A large number yields fine resolution while a small number yields coarse resolution.

14.

Click Modify Selections.

Use this feature to edit a specific Motion Analyzer Axis. a. Select an axis in the table.

b. Click Modify Selections to jump back to the SolidWorks Motor Setup window for the selected axis.

15.

Click Next.



SolidWorks software calculates the force/torque required to move the load through the specified motion profile and the Results dialog box opens.

16.

From the Results pull-down menu, choose the axis of motion you wish to display.

17.

Click the View Graph tab.

This tab displays the data in graphical format.

18.

Click the View Data tab.

This tab displays the data in list format.

19.

Click Export Data.

The data exports into a spreadsheet.

20.

Click Apply to transfer force/torque data to Motion Analyzer software for use in sizing a motion system.

21.

Go to SolidWorks software and click Play from Start in the SolidWorks

Motion Study explorer.

View the motion profile as applied to your mechanism.

22.

Verify that the mechanism is moving in the right direction; if you find that the load moves in the wrong direction, return to

step 10

by clicking Back and check Reverse Direction.



The System View dialog box in Motion Analyzer software opens.

23.

Click the Motor and Drive icons to continue the sizing process.

With these versions of SolidWorks and Motion Analyzer software, the inertia data is not brought out automatically. This means that Motion

Analyzer has no knowledge of the inertia ratio and therefore cannot do the

Motion Analyzer Simulation on the Solution tab.


2.2. Define Your Profile


There are two ways to enter your Motion Profile into Motion Analyzer software.

Begin by clicking Edit Profile in the Cycle Profile Data dialog box.

Table 74 - Motion Profile Options

Template Type

Less Options Profile Editor

Mode

Description

This is the default mode. This mode is also accessed by clicking Less Options in the More Options Profile mode. This mode lets you enter a simple profile which consists of an acceleration, coast/dwell, and deceleration.

More Options Profile Editor

Mode

This mode is accessed by clicking More Options in the Less Options Profile mode. This mode lets you enter more complex motion profiles by providing you with the ability to enter data for individual profile segments, import or export profile data, and apply external loads to the individual profile segments.

Page

140

142



2.2.1. Less Options Profile Editor Mode

The Less Options Profile mode is the default mode. This mode is also accessed by clicking Less Options when in the More Options Profile mode.

Figure 100 - Simple Index Motion Parameters

When using this mode to enter motion profile data, a trapezoidal velocity index profile segment (see Automatic Index Type below) is the default motion profile.

This motion profile is optimized for minimal motor heating.

Table 75 - Less Options Profile Editor Properties


Move Distance

Move Time

Dwell Time

Simple Index Motion

Parameters


Index Type

Smoothness

IMPORTANT

Total distance for the motion profile.

Total time for the motion profile.

Total dwell time, if any, for the motion profile before the motion profile repeats.

From the pull-down menu, choose one of three available index types.

Automatic

This is a 1/3 acceleration, 1/3 coast, 1/3 deceleration trapezoidal motion profile. This is the default setting.

Triangular

Trapezoidal

This is a motion profile where ½ the time is spent accelerating and ½ is spent decelerating.

This index type lets you use sliders to adjust the velocity and time axes of the motion profile. As you mouse over a slider, the axis value is displayed.

This is used to decrease the discontinuity in the transition from a dwell to motion. From the pull-down menu, choose one of three available smoothness options.

Automatic

Standard

Maximum

0% Jerk time (Trapezoidal)

40% Jerk time (Partial S-curve)

100% Jerk time (Full S-curve)

Smoothness is used to reduce mechanical wear and tear. Due to display limitations, the

More

Options Profile Editor Mode does not show infinite jerk at points of velocity discontinuity.

Using 0% jerk time may lead to premature mechanical failure.



Table 75 - Less Options Profile Editor Properties

Parameter

Segment Plot

(refer to label 2 in Figure 100

and the example in

Figure 101

)

Description

Reset Zoom

(1)

Zoom

(1)

Grid

(1)

Color

(1)

Show Curve

(1)

Show Y Axis

(1)

Vertical Bar

Horizontal Bar

Resets the zoom to 1x.

Magnifies 1x, 2x, 6x, or 8x.

Select Normal, Fine or Remove Grid to change the display.

Adjust the background, curve and grid colors.

Select which curves you would like to display on the plot.

Toggle the Y-axis labels on and off when more than one curve is shown.

This adjusts the height/velocity component of the motion profile. As you increase the value of this slider, more time is spent accelerating and decelerating the load and less time is spent dwelling at a constant velocity.

This adjusts the ratio of the time spent accelerating to the time spent decelerating for the motion profile. A negative value on the slider indicates that more time is spent decelerating the load than accelerating it. A positive value on the slider indicates that more time is spent accelerating the load than decelerating it.

(1) In addition to the parameters in

Figure 100

, these options are also available when you right-click the Segment Plot window.

Figure 101 - Segment Plot Example



2.2.2. More Options Profile Editor Mode

The More Options Profile Editor mode helps you create a variety of industrystandard motion profiles. To access this mode, click More Options when in the

Less Options Profile mode.

Figure 102 - Profile Editor - More Options Mode

142

These windows are displayed by default when you open the

More Options Profile

Editor Mode

.

Table 76 - More Options Mode Features

Feature

Profile Toolbar

Segment Load Window

Segment Plot Window

Profile Plot

Description

This toolbar (label 1 in Figure 102

) contains buttons and pull-down menus for adding, moving, and removing profile segments or an entire motion profile.

Each profile segment type has an associated Segment Parameters window

(label 2 in

Figure 102 . As you highlight a particular profile segment in your

motion profile, that segment’s parameter window becomes available for entering data. The default profile segment type is an Index profile segment.

This window (label 3 in

Figure 102

) displays a plot for a single profile segment in the motion profile. The x-axis is time, and the y-axis can be adjusted to display various motion curves (for example, Distance, Velocity, or Acceleration.

Page

145

147

148

This window (label 5 in

Figure 102

) displays the entire motion Profile Plot that consists of a series of profile segments. The plot can be adjusted and analyzed with the two sub-windows that accompany the plot.

149



In addition to the windows that are opened by default, there are several tabs along the bottom (label 6 in

Figure 102 ) and left side (red arrow in Figure 102 ) of the


that open other windows.

Table 77 - Additional More Options Mode Features

Feature

Profile Grid

Derived Parameters

Comments Window

Error List Window

Segment Parameters

Window

Description

Lets you quickly input parameters into a table for each segment of your motion profile.

Displays various calculated values related to Time, Position, Speed,

Acceleration, and Jerk.

Page

152

153

Enter comments for the motion profile or for particular profile segments.

Contains a list of errors as they occur.

Enter load values for individual profile segments or for the entire motion profile.

154

155

167

In these windows, you can click the thumb-tack icon to toggle between Fixed mode and Auto-hide mode. In Fixed mode, the window is held in place and in

Auto-hide mode, the window is displayed when you hover over the window tab.

The window reverts back to a tab when the mouse pointer is moved off of the window.

When you have completed your motion profile and have entered the relevant parameters, you can export the data from the


t o external programs. Prior to exporting the data, make sure that the master and slave units are properly designated. From the Settings menu, choose Custom

Units to change these.

Table 78 - Export Options (refer to

Figure 102 )

Feature

Logix CAM Profile Editor

Logix Ladder Add-On

Instructions

SolidWorks Motion

Study Move Profile

User Defined

Description

With this option you can export the motion profile data to RSLogix 5000 software as a fixed cam profile. When using this export option, you must choose whether to export the data as a Motion Axis Time Cam (MATC) or a Motion Axis Position Cam (MAPC) profile.

With this option you can export the motion profile data as a rung of RSLogix 5000 code that dynamically builds the cam at run time. When using this export option, you choose whether to export the data as a Motion Axis Time Cam (MATC) or a Motion Axis Position

Cam (MAPC) profile. This type of instruction lets you adjust portions of the motion profile.

With this option you can export the motion profile data that SolidWorks uses for its animations.

With this option you can export the motion profile data to the clipboard or to a specified file type.



You also have the option to import motion profile data from external programs.

The following import options are available.

Table 79 - Import Options (refer to

Figure 102 )

Feature

Logix CAM Profile Editor

Logix Ladder Add-On

Instructions

User Defined

Feature Description

This option lets you import motion profiles created in the RSLogix 5000 Cam Editor. A Logix

Elements type profile segment is created and populated. You have four import options available for this type of import.

Before Selected Seg

After Selected Seg

Replace Selected Seg

The imported motion profile is placed before the profile segment

you selected in More Options Profile Editor Mode

.

The imported motion profile is placed after the profile segment

you selected in More Options Profile Editor Mode

.

The imported motion profile replaces the profile segment you

selected in More Options Profile Editor Mode

.

Replace Profile

The imported motion profile replaces the entire profile in

More

Options Profile Editor Mode .

This option lets you import motion profiles created as RSLogix 5000 Ladder Add-On

Instructions.

This option lets you import a motion profile directly from a program of your choice.



2.2.2.1. Profile Toolbar

The Profile toolbar contains buttons and pull-down menus for adding, moving, and removing profile segments or an entire motion profile.

Figure 103 - Profile Toolbar Features

Table 80 - Profile Toolbar Features (label 1 in

Figure 103 )

Feature

Segment Selector

Profile

Start Condition

Add

Description

Use the Segment Selector arrows (red box in Figure 103 ) to navigate through the various

segments in your motion profile. As you navigate to a profile segment, the associated

Segment Parameters Window

and Segment Plot Window are displayed. The Zero profile

segment is the start condition.

Lets you copy a motion profile from another axis in your Motion Analyzer project. It also lets you go to the


for another axis in your Motion Analyzer project.

Opens the Segment Parameters window and the Segment Plot window for the start condition.

Lets you add profile segments to the end of your motion profile. Also, refer to the Segment

Parameters section for information about the various profile segments that are available in

the More Options Profile Editor Mode

.



Figure 104 - Add Feature Pull-down Menu

Table 81 - Add Feature Properties (refer to Figure 104

)

Feature

Edit

Delete

Cut

Copy

Paste

Invert

Description

Lets you change the selected profile segment to another segment type.

Deletes the selected profile segment. You can also click the drop-down arrow and select the

Delete All option to delete all of the segments in your motion profile.

Lets you remove the selected profile segment in order to place it in another location in the motion profile.

Lets you create a copy of the selected profile segment in order to replicate the segment in another location in the motion profile.

Lets you replace the selected profile segment with a cut or copied profile segment.

Lets you invert an index profile segment about the x-axis.



2.2.2.2. Segment Load Window

Each profile segment type has an associated Segment Parameters window (label 2 in

Figure 102 . As you highlight a particular profile segment in your motion

profile, that segment’s parameter window becomes available for entering data.

The default profile segment type is an Index profile segment.

Figure 105 - Segment Load Properties

Table 82 - Segment Load Properties

Parameters

Apply All Segments

External Force

Payload Mass

Mass X, Y & Z - Offset

Payload Animation

Description

Lets you apply the current profile segment load parameters to all existing profile segments.

The load values are not applied to any profile segments that are added after you apply this feature. However, you can return to this window and click Apply All Segments again to apply the load values to new profile segments.

This is the external force that exists for the selected profile segment.

This is the payload mass that exists for the selected profile segment.

These Load Mass Offsets generate moments that are used in the calculation of Life for

Bulletin MPAS stages. Moments are generated when the Load Mass is off-line with the actuator. They arise as a consequence of forces generated by acceleration or deceleration of the load mass and gravity acting on the load mass being multiplied by the offset distance.

The offsets and moments are resolved into the three cartesian coordinates.

The load can be divided into either a fixed load or a load that changes by segment throughout the profile. Motion Analyzer software analyzes the sum of the fixed loads and moments (entered in

Mechanism Type on page 178

) and segment wise loads and moments generated by these offsets.

Starts a simple animation that demonstrates a pick-and-place machine where a heavy load is picked up and moved forward. The return stroke has no load. Refer to

Figure 106 .

Figure 106 - Payload Animation Example



2.2.2.3. Segment Plot Window

The Segment Plot window displays a plot for a single profile segment in the motion profile. The x-axis is time, and the y-axis can be adjusted to display various motion curves (for example, Distance, Velocity, or Acceleration).

Figure 107 - Profile Editor - Segment Plot Window

148

Right-click the Segment Plot window to display the properties.

Figure 108 - Segment Plot Properties (label 3 in Figure 107

)

Table 83 - Segment Plot Properties (refer to Figure 108

)

Parameters

Reset Zoom

Zoom

Grid

Color

Show Curve

Show Y Axis

Description


Lets you zoom in 1x, 2x, 6x or 8x.

Select Normal, Fine or Remove grid.

Adjust the background, curve, and grid colors.

Select which curves you would like to display on the plot.




2.2.2.4. Profile Plot

The Profile Plot window lets you view the entire motion profile and quickly navigate to specific segments within the profile.

Figure 109 - Profile Editor - Main Profile Plot

Right-click the Main Profile Plot window to display the properties.

Figure 110 - Main Profile Plot Properties (label 4 in Figure 109 )



Table 84 - Main Profile Plot Properties (refer to Figure 110 )

Parameters

Copy

Cut

Paste

Delete

Reset Zoom

Zoom

Show Segment

Selection

Grid

Color

Show Curve

Show Y Axis

Description

Create a copy of the selected profile segment to reuse in another location in the motion profile.

Remove the selected profile segment to use in another location in the motion profile.

Replace the selected profile segment with a cut or copied profile segment.

Deletes the selected profile segment. Also, from the pull-down menu, you can choose the

Delete All option to delete all of the profile segments in the Profile Plot window.

Resets the zoom to 1x magnification.

Zoom in 1x, 2x, 6x or 8x magnification.

Select whether or not you would like to highlight the selected profile segment within the

Profile Plot window.

Select Normal, Fine, or Remove grid.


Select which curves you would like to display on the plot (for example, Distance or Velocity).


The Plot Parameters sub-window appears to the left of the Main Profile Plot window. Click the arrows, left of the Main Profile Plot window, to open it. Click the arrows again to close the window.

Clicking the motion curves (for example, Distance or Velocity) toggles them on and off. From the motion curve pull-down menu, you can change the color for the curve in both the Main Profile Plot window and the Segment Plot window.

Figure 111 - Plot Parameters

150

In addition, as you hover over the Main Profile Plot window with the mouse pointer, the Plot Parameters sub-window provides a display of the numeric values of the time (x-axis), and active motion curves (y-axis) associated with the mouse pointer position.


Figure 112 - Main Profile Plot X and Y-axis Values


The Profile Zoom Plot sub-window appears below the Main Profile Plot window.

Click the arrows, below the Main Profile Plot window, to open it. Click the arrows again to close the window.

The Profile Zoom Plot window contains a slider (refer to the red box in

Figure 113 ) that you can move along the motion profile by clicking and dragging

it. As the slider moves, the Main Profile Plot window displays a magnified view of the portion of the plot that is selected by the slider. You can resize the slider by clicking and dragging from either edge.

Figure 113 - Profile Zoom Plot Window

Right-click the Profile Zoom Plot sub-window to display these options.

Figure 114 - Profile Zoom Plot Options

Table 85 - Profile Zoom Plot Options

Parameters

Grid

Color

Description





2.2.2.5. Profile Grid

Click Profile Grid (label 5 in

Figure 115 ) to use a table to input parameters for

each segment of your motion profile.

Figure 115 - Profile Grid Window

152

If you click a row in the Profile Grid window, the Segment Parameter window

and the plot for that profile segment are opened at the top of the More Options

Profile Editor Mode dialog box.

You have the option to enter the parameters in the Segment Parameters window

or the Profile Grid. Refer to Segment Parameters on page 167

for detailed descriptions of the parameters. The parameter values are automatically shared between the two windows.

As you enter the profile segment parameters, calculated Peak Acceleration and Peak

Deceleration values are displayed for reference in the Profile Grid window.

Click Table Setup in the

Profile Grid window to adjust column width preferences.



2.2.2.6. Derived Parameters

Click Derived Parameters (label 5 in Figure 116

) to display various calculated values related to Time, Position, Speed, Acceleration, and Jerk for the highlighted profile segment. Refer to the

Segment Parameters windows on page 167 to adjust

these values.

Figure 116 - Derived Parameters



2.2.2.7. Comments Window

Click Comments (label 5 in

Figure 117 ) to enter notes about the overall motion

profile in the Profile Comments window. For specific profile segments in the last comment of the table labeled Segment Comments. Highlight the row for a particular profile segment and the segment plot is displayed at the top of the

More Options Profile Editor Mode dialog box.

Figure 117 - Profile Editor - Comments Window



2.2.2.8. Error List Window

Click Error List (label 5 in

Figure 118

) to display errors in the Error List window.

Errors are listed as they occur.

Figure 118 - Error List Window

An example of a common error is a negative value for time in Absolute mode.

Figure 119 - Error List Example



2.2.2.9. Profile Export

When you have completed your motion profile and have entered the relevant

parameters, you can export the data from the More Options Profile Editor Mode

to external programs. Prior to exporting the data, make sure that the master and slave units are properly designated. From the menu bar go to Settings>Custom

Units to change these.

The Profile Export wizard is designed to help you successfully export your profile.

1.

From the Profile Editor dialog box, click Export.

The Profile Export Wizard dialog box opens.

2.

Click Next.

The Types of Exports dialog box opens.



Table 86 - Type of Export Options

Parameters

Logix CAM Profile

Editor

Logix Ladder Add-On

Instructions

SolidWorks Motion

Study Move Profile

User Defined

Description

With this option you can export the motion profile data to RSLogix 5000 software as a fixed cam profile. When using this export option, you choose whether to export the data as a Motion Axis Time Cam (MATC) or a Motion Axis

Position Cam (MAPC).

With this option you can export the motion profile data as a rung of RSLogix

5000 code that dynamically builds the cam at run time. When using this export option, you choose whether to export the data as a Motion Axis Time Cam

(MATC) or a Motion Axis Position Cam (MAPC). This type of instruction lets you adjust portions of the motion profile.

With this option you can export the motion profile data that SolidWorks software uses for its animations.

With this option you can export the motion profile data to the clipboard or to a specified file type.

Page

157

161

165

166

2.2.2.9.1. Logix CAM Profile Editor

1.

On the Types of Exports dialog box, select Logix CAM Profile Editor.

2.

Click Next.

The CAM Set-up dialog box opens.

3.

Select whether your CAM in RSLogix 5000 software is time or position based.

In this example, an MATC export was selected.

4.

Click Next.



The Export Options - Logix CAM dialog box opens and a preview of the data for export is displayed.

5.

Click Next.

The Target Location for Export dialog box opens.

158

6.

Select how you would like to store the data.

Table 87 - Target Location Options

Parameters

Clipboard

File

Description

The clipboard stores the data until you copy something else and it is useful if you are going to paste the data into RSLogix 5000 software immediately.

Save the data to a file location if you wish to email the file or save it for future use.

7.

Click Next.


The Profile Export Successful dialog box opens.


TIP If the Start and End Slope values are non-zero in your application, enter them into the Cam Editor manually.

8.

Click Finish.

9.

Open your RSLogix 5000 software application program to your MATC instruction.

10.

Click the Cam Profile ellipse



The Cam Editor dialog box opens.

11.

Right-click the first row entry arrow and from the window choose Paste.

Your move data appears in the Cam Editor dialog box.

160

TIP

12.

Click OK.

Click the magnifier icon to adjust the zoom.



2.2.2.9.2. Logix Ladder Add-On Instructions

To use this function it is necessary to have the following suite of cam-building

Add-On Instructions installed with your RSLogix 5000 project:

Table 88 - CAM-building Add-On Instructions

File Name

AOI_CG_00_Import_then_delete_this.L5X

AOI_CG_00_Controller_Tags.CSV

AOI_CG_00_Cam Generator Setup.doc

Cam_Generator_V2_1_Example.ACD

Description

Add-On Instructions files

Installation instructions

Generic (blank) project file

1.

On the Types of Exports dialog box, select Logix CAM Profile Editor.

2.

Click Next.

The CAM Set-up dialog box opens.

3.

Select whether your CAM in RSLogix 5000 software is time or position based.

In this example, an MATC export was selected.

4.

Click Next.



The Export Options - Logix Ladder dialog box opens.

5.

Click Next.

The Target Location for Export dialog box opens.

162

6.

Select how you would like to store the data.

Table 89 - Target Location Options

Parameters

Clipboard

File

Description

The clipboard stores the data until you copy something else and it is useful if you are going to paste the data into RSLogix 5000 software immediately.

Save the data to a file location if you wish to email the file or save it for future use.

7.

Click Next.


The Profile Export Successful dialog box opens.


TIP If the Start and End Slope values are non-zero in your application, enter them into the Cam Editor manually.

8.

Click Finish.

9.

Open your RSLogix 5000 software application program and paste the data into an empty rung.

IMPORTANT Make sure the entry type is In Neutral Text.



The Add-On Instruction appears on the rung. In this example, the

Add-On Instruction is a simple index move.



2.2.2.9.3. SolidWorks Motion Study Move Profile

1.

On the Types of Exports dialog box, select SolidWorks Motion Study

Move Profile.

This is not the preferred workflow. A direct link using API calls has been

developed and is described in From SolidWorks

on

page 120

.

2.

Click Next.

The Export Options - SolidWorks dialog box opens.

3.

Define the number of segments you would like to export the data in.

For example, a 2 second motion profile would be broken into 50 frames/ second if 100 segments are defined.

4.

Click Next.

A preview of the data and success dialog box is displayed, similar to the

workflow in Logix CAM Profile Editor

beginning on

page 157 .



2.2.2.9.4. User Defined

1.

On the Types of Exports dialog box, select User Defined.

2.

Click Next.

The Export Options - User Defined dialog box opens.

3.

Select the unit options.

You can export data in your application units or in SI units. In this example, application units are chosen.

4.

From the pull-down menu, choose the delimiter.

In this example, TAB was chosen. TAB delimited is a standard format for

Microsoft Excel software.

5.

Click Next.

A preview of the data and success dialog box is displayed, similar to the

workflow in Logix CAM Profile Editor

beginning on

page 157 .



2.2.2.10. Segment Parameters Window

Each profile segment type has a different associated Segment Parameters window.

The default profile segment type is an Index profile segment (label 2 in

Figure 120 ).

Figure 120 - Segment Parameters

The following basic profile segments are available in the More Options Profile

Editor Mode

dialog box.

Table 90 - Basic Profile Segment Options

Parameters

Start Condition

Accel/Decel

Cruise/Dwell

Index

Description

Sets the start conditions for your motion profile. The start condition is the initial time, position, and velocity of the motion profile.

Where you enter parameters for an Acceleration or Deceleration profile segment.

Page

168

168

Where you enter parameters for a Cruise or Dwell profile segment. The profile segment is considered a cruise if the velocity at the end of the previous profile segment is non-zero and is considered a dwell if that velocity is zero.

Where you enter parameters for an Index profile segment. An Index profile segment consists of an acceleration, a cruise, and a deceleration.

170

171

In addition to the basic profile segments, the following advanced profile segments are available in the


dialog box.

Table 91 - Advanced Profile Segment Options

Parameters

Index Advance

Description

Selects more advanced velocity, acceleration, and jerk profiles for an Index profile segment.

Page

173

Logix Element

Contains parameters that you can easily import or export into RSLogix 5000 software.

174

Motion Axis

Move (MAM)

Where you enter parameters for a Motion Axis Move command. The parameters are easily exported into a MAM instruction in RSLogix 5000 software.

176



2.2.2.10.1. Start Condition

Start Condition (refer to Figure 120 ) sets the start conditions for your motion

profile. The start condition is the initial time, position, and velocity of the motion profile.

Figure 121 - Start Condition Dialog Box

Enter the following parameters for the Start Condition, if relevant.

Table 92 - Start Condition Properties

Parameters

Time

Position

Velocity

Description

The initial time that the motion profile begins.

The initial position that the motion profile begins.

The initial velocity that the motion profile begins.

2.2.2.10.2. Accel/Decel

Where you enter parameters for an acceleration or deceleration profile segment

(refer to Figure 120 ).

Figure 122 - Acceleration/Deceleration Dialog Box



Enter the following parameters for Acceleration/Deceleration, if relevant.

Table 93 - Acceleration/Deceleration Properties

Parameters

Segment Name

Data Entry Permutation

Increment/Absolute

Parameter Entry

Jerk - Percentage

Jerk - Skew

Description

Enter a meaningful name for the profile segment.

Select an option for entering the profile segment parameters based on two data types

(for example, Time and Distance or Time and Velocity).

Select whether to input Incremental or Absolute parameter values. Incremental values represent the change in either the distance or time that occurs during the profile segment. Absolute values represent the total distance or time elapsed throughout the entire motion profile.

Enter the parameter values for the two data types selected from the Data Entry

Permutation pull-down menu, located below the Increment and Absolute buttons.

This value sets the amount of S-curve of the Acceleration/Deceleration profile segment.

Increasing the percent jerk increases the amount of S-curve. You can manually enter a value or adjust the value with the slider in the pull-down menu or the slider along the right side of the Segment Plot window (refer to

Figure 123

).

Changing the skew of jerk alters the time in the Acceleration/Deceleration profile segment at which the S-curve occurs. You can manually enter a value or adjust the value with the slider in the pull-down menu or the slider along the right side of the Segment

Plot window (refer to Figure 123

).

IMPORTANT Due to display limitations, the


dialog box does not show infinite jerk at points of velocity discontinuity. Using 0% jerk may lead to premature mechanical failure.

Figure 123 - Segment Plot Window



2.2.2.10.3. Cruise/Dwell

The profile segment is considered a cruise if the velocity at the end of the previous profile segment is non-zero and is considered a dwell if that velocity is zero.

Figure 124 - Cruise/Dwell Dialog Box

Enter the following parameters for a Cruise/Dwell profile segment, if relevant.

Table 94 - Cruise/Dwell Properties

Parameters

Segment Name

Velocity

Increment/Absolute

Distance/Time

Description


This is the velocity of the profile segment. This value is non-zero for cruise and zero for dwell.

Select whether to input Incremental or Absolute parameter values. Incremental values represent the change in either the distance or time that occurs during the profile segment.

Absolute values represent the total distance or time elapsed throughout the entire motion profile.

Select and enter either the Distance or Time parameter to define your Cruise/Dwell profile segment.



2.2.2.10.4. Index

An Index profile segment consists of an acceleration, a cruise, and a deceleration.

Figure 125 - Index Motion Parameters Dialog Box

Enter the following parameters for a Index profile segment, if relevant.

Table 95 - Index Properties

Parameters

Segment Name

Increment/Absolute

Distance/Time

Index Type

Description




Enter either the Distance or Time parameter to define your Cruise/Dwell profile segment.

From the pull-down menu, choose one of the three available index types.

Automatic

1/3 acceleration, 1/3 coast, and 1/3 deceleration trapezoidal motion profile. This is the default setting.

Triangular ½ acceleration and ½ deceleration motion profile.

Trapezoidal

This index type lets you use sliders to adjust the velocity and time axes of the motion profile.

Vertical Bar: Adjusts the height/velocity component of the motion profile. As you increase the value of this slider, more time is spent accelerating and decelerating the load and less time is spent dwelling at a constant velocity.

Horizontal Bar: Adjusts the ratio of the time spent accelerating to the time spent decelerating for the profile segment. A negative value on the slider indicates that more time is spent decelerating the load than accelerating it. A positive value on the slider indicates that more time is spent accelerating the load than decelerating it.



Figure 126 - Trapezoidal Profile

Parameters

Smoothness

Description

Used to decrease the discontinuity in the transition from a dwell to motion. Select the smoothness from the pull-down menu. Three smoothness options are available.

Automatic 0% Jerk (Trapezoidal)

Standard 40% Jerk (Partial S-curve)

Maximum 100% Jerk (Full S-curve)

The percent of time for Acceleration/Deceleration Jerk increases the peak acceleration (and therefore current) above that of a trapezoidal motion profile. The following values illustrate the effect of Acceleration/Deceleration Jerk on current. The acceleration of a trapezoidal motion profile is taken to be 100%.

Accel/Decel Jerk

0% Jerk 100% acceleration and current (Linear or Trapezoidal).

18% Jerk 110% acceleration and current.



100% Jerk 200% acceleration and current (S-curve).

When you enter the Positive or Negative Velocity Limit for the profile, Motion Analyzer adjusts the acceleration and deceleration times required to reach the desired velocity limits.

Apply +ve/-ve

Velocity Limit

IMPORTANT Smoothness is used to reduce mechanical wear and tear. Due to display limitations, the


dialog box does not show infinite jerk at points of velocity discontinuity. Using 0% Jerk time may lead to premature mechanical failure.



2.2.2.10.5. Index Advance

Index Advance selects more advanced velocity, acceleration, and jerk profiles for an Index profile segment.

Figure 127 - Index Advance Parameters Dialog Box

Enter the following parameters for a Index Advance profile segment, if relevant.

Table 96 - Index Advance Properties

Parameters

Advance Index Type

Segment Name

Increment/Absolute

Distance

Time

No. of Elements

Description

Index SHM

Index 3 4 5 Poly

Index Mod Sine

Index 2 3 Poly

Index 4 5 6 7 Poly

Index Adjusted Sine

Index Modified

Trapezoidal

Harmonic Motion.

Fifth order polynomial.

Modified Sine wave.

Third order polynomial.

Seventh order polynomial.

Industry standard cam profile.

Industry standard cam profile.




Distance for the Index profile segment.

Time for the Index profile segment.

Number of Elements for the profile segment.



2.2.2.10.6. Logix Element

Use this dialog box to import or export Logix elements into RSLogix 5000 software.

Figure 128 - Logix Element Dialog Box

The Logix Element Motion Parameter table is essentially the same as the

RSLogix 5000 cam editor. These profile segments can be mixed with any other types available in the

More Options Profile Editor Mode dialog box, thus a small

section of non-linear motion profile (for example, a cosine compensation profile segment) can be created in a spreadsheet and combined with a simple index profile segment.

It is important to distinguish between the terms segment and element.

Term

Element

Segment

Definition

Term used for each row of the RSLogix 5000 cam editor. These are indivisible or ‘raw’ elements.

Term used for all the profile ‘pieces’ available in More Options Profile Editor Mode

. Each of these typically create one or many elements when exported to RSLogix 5000 software.



Enter the following parameters for a Logix Element profile segment, if relevant.

Table 97 - Logix Element Properties

Parameters

Segment Name

Master

Slave

Slope

Type

Description


This is directly equivalent to the Master column in RSLogix 5000 software. These values can be entered only as Master and Slave Custom Units. From the Settings menu, choose Custom Units to change these.

This is directly equivalent to the Slave column in RSLogix 5000 software. These values can be entered only as Master and Slave Custom Units. From the Settings menu, choose Custom Units to change these.

Only the final row allows a value to be entered directly and then only if the corresponding element is cubic.

This is equivalent to the Type column in RSLogix 5000 software except that the Cubic/Linear format is applied to the element defined by the current line and the previous line. While in

RSLogix 5000 software it is applied to the element defined by the current line and the next line.

The first row (row zero in RSLogix 5000 software) displays the start conditions.

These cannot be entered directly, but are defined either by the end conditions of the previous profile segment or, if this is the first segment in the motion profile, by the

Start Condition on page 168 .

Each subsequent row completely defines the respective element.

Table 98 - Logix Element Properties

Parameters

Export to Logix Editor

Logix Element

Description

This button places the data onto the clipboard in order to be pasted into the

RSLogix 5000 cam editor. In the cam editor, click the ‘*’ to highlight the first row then right-click in the box and choose paste to paste the Logix Element. The start and end slopes must be entered manually in RSLogix 5000 software.

The start and end slopes must be entered manually in RSLogix 5000 software.

Import from Logix Editor

This button pastes data from the clipboard that was copied from the RSLogix 5000 cam editor. In the cam editor, click the ‘[]’ column and drag down to highlight all rows containing data. Then press Ctrl + c to copy the element. The Start and End

Slopes must be entered manually.



2.2.2.10.7. Motion Axis Move (MAM)

This window lets you enter data as if for a Motion Axis Move (MAM) instruction. For detailed information regarding a MAM, refer to the

RSLogix 5000 software help files.

Figure 129 - MAM Dialog Box

Enter the following parameters for a MAM profile segment, if relevant.

Table 99 - MAM Instruction Properties

Parameters

Position Units

Axis

Motion Control

Move Type

Position

Speed

Speed Units

Export MAM

Description

Select the required position units in the pull-down menu above the MAM profile segment.

From the Settings menu, choose Custom Units to change these.

This is the Axis name for the RSLogix 5000 MAM instruction.

This is the control tag for the instruction.

Select either 0 or 1 from the pull-down menu. The profile segment is inverted when this option is changed.

This is the final position after the Motion Axis Move profile segment.

This is the final velocity after the Motion Axis Move profile segment.

These units cannot be adjusted here. To change the units, choose an option from the Position

Units pull-down menu at the top of the MAM Segment Parameters window.

This places the information onto the clipboard. Clicking on a rung of an RSLogix 5000 project creates a MAM instruction with this data already filled in; only the Axis and a unique instruction tag need to be created.



Click More and enter the following parameters for a MAM profile segment, if relevant.

Table 100 - More MAM Instruction Properties

Parameters

Accel Rate

Accel Units

Decel Rate

Decel Units

Profile

Accel Jerk

Decel Jerk

Jerk Units

Merge

Merge Units

Description

This is the acceleration rate for the MAM profile segment.



This is the deceleration rate for the MAM profile segment.



From the pull-down menu, choose Trapezoidal or S-curve.

This is the jerk for the acceleration of the MAM profile segment.

This is the jerk for the deceleration of the MAM profile segment.



From the pull-down menu, choose Enabled or Disabled. Refer to the RSLogix 5000 help files for more information.

From the pull-down menu, choose Current or Programmed. Refer to the RSLogix 5000 help files for more information.



2.3. Specify Your Linear Load

Mechanism

A linear load mechanism is used to convert rotary motor torque to linear motion through a transmission (belt drive, lead screw, chain and sprocket, or rack and pinion), where thrust from a linear motor, electric cylinder, or linear stage produces linear motion directly.

Figure 130 - Mechanism Type

178

The following mechanisms are available in Motion Analyzer software.

Table 101 - Mechanism Types

Type

Belt Drive

Lead Screw

Chain and Sprocket

Rack and Pinion

Linear Motor

Description

A rotary motor coupled to a timing pulley that drives a flexible toothed belt, with its coupled load, back and forth between two idler pulley guides.

Page

180

A lead screw is coupled to a rotary motor and causes relative linear motion between a rotating screw and its non-rotating nut.

A chain and sprocket is a rotary motor coupled to a sprocket wheel that drives a linked chain, with its coupled load, back and forth between idler sprocket guides.

A rack and pinion is a rotary motor coupled to a toothed pinion wheel that engages a toothed rack to create relative motion between the two elements.

181

182

183

Linear motors are either iron-core and ironless motors that directly create linear thrust. Their separate sections (coil and magnet channel) produce relative motion between a carriage and its base along the user-supplied linear bearing guides.

184



In addition to the many linear mechanisms in Table 101 , a few fully-integrated linear mechanisms, listed in

Table 104

, are also included.

Figure 131 - Integrated Linear Mechanisms

Table 102 - Additional Mechanism Types

Linear Options

Electric Cylinders

Linear Stages

Linear Thrusters

Description

These electric cylinders provide flexible, digital servo control of a rod actuator

(linear control of force/clamping or position). They provide an electromechanical system for applying digital servo control with a familiar fluid power format. The cylinders are integrated into machines with the same fluid power application principals, mounting methods (trunnion mounts, rear clevis attachment kits, and front flanges, for example.) and rod-end attachments for connected loads (rod eye and rod clevis, for example).

A linear stage is used to restrict the load to a single axis of motion. It contains all the elements required to produce linear motion: base and carriage; drive

(linear motor or lead screw); linear bearings; and position feedback.

A linear thruster is used to provide a completely integrated linear motor-driven system.

Page

186

187

189



2.3.1. Belt Drive

A belt drive is a rotary motor coupled to a timing pulley that drives a flexible toothed belt, with its coupled load, back and forth between two idler pulley guides.

Figure 132 - Mechanism Type - Belt Drive

180

Enter the following parameters for belt drive mechanisms, if relevant.

Table 103 - Belt Drive Properties

Parameters

Mechanism Type

Mechanism Data

(label 1 in

Figure 132

)

Belt Drive and Application

(1)

(label 2 in

Figure 132

)

Description

From the pull-down menu, choose the mechanism type.

The load, stroke, speed, and acceleration values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference.

Diameter

Inertia

Friction

Torque

No. of

Rollers

(2)

The diameter of the drive shaft and idler shafts that make contact with the belt.

The inertia of the driver and idler groups.

Torque loss due to friction at the driver or idler shaft. You can obtain this value from the supplier or Engineering tables.

The number of rollers for each idler group.

Additional Loads

(label 3 in

Figure 132

)

Table

Mass

The mass of the linear load table. This mass is affected by gravity if the inclination in the

Load Type Tab on page 82

is non-zero.

Belt Mass The mass of the belt. This mass is not affected by gravity.

Losses

The total torque loss due to friction at the driver and the idler groups is calculated and displayed here.

(1) The Driver is the shaft that is driven by the motor through optional gearbox and transmission stages. The Idlers are the rotary elements driven by the belt. You may enter data for up to three Idler Groups. Check the corresponding box to add a second or third group of idlers. A graphic is displayed to help visualize the orientation of the additional idler groups and rollers.

(2) Use the




2.3.2. Lead Screw

A lead screw is coupled to a rotary motor and causes relative linear motion between a rotating screw and its non-rotating nut.

Figure 133 - Mechanism Type - Lead Screw

Enter the following parameters for lead screw mechanisms, if relevant.

Table 104 - Lead Screw Properties

Parameters

Mechanism Type

Mechanism Data


Lead Screw Parameters


Additional Load


)

Description


The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference.

Lead

The distance that the slide moves per one full rotation of the screw shaft. Pitch is sometimes used loosely to describe this parameter. Pitch is actually the distance between adjacent threads and is equal to lead only for single start threads.

Inertia

(1)

Pre Load

Efficiency

Slide Mass

The inertia of the lead screw in the event that the lead screw rotates and the nut is stationary. Enter the inertia of the nut when the lead screw is stationary and the nut rotates.

The friction torque produced by pre-loading the two nuts of a ball screw against each other. This is done to reduce backlash and increase stiffness in the system.

Seal friction should be included in this value. This value can be obtained from the manufacturer’s data and is normally quoted in data sheets.

The efficiency of the lead screw. This value is available from the manufacturer.

Plain Acme screw = typically 40…60%

Precision screw (with rolling elements) = typically 85… 90%

The mass of the slide that travels along the lead screw. This mass is affected by

gravity if the inclination in the Load Type Tab on page 82

is non-zero.

(1) Use the


on




2.3.3. Chain and Sprocket

A chain and sprocket is a rotary motor coupled to a sprocket wheel that drives a linked chain, with its coupled load, back and forth between idler sprocket guides.

Figure 134 - Chain and Sprocket Dialog Box

182

Enter the following parameters for chain and sprocket mechanisms, if relevant.

Table 105 - Chain and Sprocket Properties

Parameters

Mechanism Type

Mechanism Data

(label 1 in

Application

(label 2 in

Additional Loads

(label 3 in

Figure 134

Chain and Sprocket

Figure 134

Figure 134

)

)

)

Description



PCD

Inertia

Friction

Torque

(1)

No. of

Sprockets

Pitch Circle Diameter. This can be calculated by multiplying the link pitch by the number of teeth on the sprocket and dividing by pi.

The inertia of the driver and idler groups.

The torque loss due to friction at the driver or idler shaft. This value can be obtained from the supplier or Engineering tables.

The number of sprockets for each idler group.

Table Mass


Load Type Tab

on

page 82

is non-zero.

Chain Mass The mass of the chain. This mass is not affected by gravity.

Losses

The total torque loss due to friction at the driver and the idler groups is calculated and displayed here.

(1) Use the


available.



2.3.4. Rack and Pinion

A rack and pinion is a rotary motor coupled to a toothed pinion wheel that engages a toothed rack to create relative motion between the two elements.

Figure 135 - Rack and Pinion Dialog Box

Enter the following parameters for rack and pinion mechanisms, if relevant.

Table 106 - Rack and Pinion Properties

Parameters

Mechanism Type

Mechanism Data

(label 1 in

Figure 135

)

Pinion Application

(label 2 in

Figure 135

Additional Loads

(label 3 in

Figure 135

)

)

Description



Pinion PCD

Inertia

Friction

Torque

(1)

Table Mass

Pinion Pitch Circle Diameter. The pitch circle diameter value can be obtained from standard catalogue data. The value can also be calculated by multiplying the tooth pitch by the number of teeth on the sprocket and dividing by pi .

The inertia of the pinion.

The torque loss due to friction at the pinion shaft. This value can be obtained from the supplier or Engineering tables.


Load Type Tab on page 82

is non-zero.

(1) Use the

Inertia Calculator Template on page 105




2.3.5. Linear Motor

Linear motors are either iron-core and ironless motors that directly create linear thrust. Their separate sections (coil and magnet channel) produce relative motion between a carriage and its base along the user-supplied linear bearing guides.

Figure 136 - Linear Motor Dialog Box



Parameters

Mechanism Type

Mechanism Data


Enter the following parameters for linear motor mechanisms, if relevant.

Table 107 - Linear Motor Properties

Description


The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered in the previous Load and

Profile tabs and displayed here for reference.

Relative motion between the two motor elements is directed horizontally.

Horizontal

Relative motion between the two motor elements is directed vertically.

Orientation


Vertical

Relative motion between the two motor elements is directed at this angle relative to the horizontal plane.

Custom

Configuration


Load and Application


Ironless

Iron Core

Overtravel Length

Carriage Mass

Payload Mass

Due to its non-cogging and low magnetic attraction characteristics, direct-drive ironless linear motors are typically used for lighter duty bearings, smooth motion, and/or high precision applications.

At slightly lower cost relative to the Ironless configuration (one row of magnets versus two with ironless), these high magnetic attraction motors are typically used with heavy-duty bearings to produce high dynamic thrust performance.

The additional length of travel at each end of the motion profile to allow for user-defined machine movements outside of the motion profile (for example, setup of a mechanism or tool change spacing). It also provides room for the motor to stop if it accidentally exceeds the nominal travel envelope. Switches

(physical or software) detect this and the drive performs a controlled stop. Click the Axis Stop

tab to determine the minimum stopping distance required. The value is added to both ends of the calculated motion profile travel to make sure the proper length motor is specified and selected for the application.

User input that specifies the mass of the moving carriage, including its support bearing pucks. This mass should not include the mass of the moving motor elements.

The constant mass of the moving parts of the load. This value does not include profile loads that are

entered in the Load Type Tab on page 82 .

External Force

Heat Sink Type

This represents any linear force that the motor must overcome (both during motion and while at rest). It does not include frictional loads that are calculated elsewhere.

From the Heat Sink Type pull-down menu, choose a heat sink type. The heat sink affects the motor thermal continuous operation ratings.

Bearing Friction

Coefficient

The friction coefficient between the linear moving parts and the fixed parts of the system. You can edit

this value in the Load Type Tab on page 82

.

Counter Balance

Type

From the Counter Balance Type pull-down menu, choose a

Counter Balance The mass of the

Counterbalance

(refer to

page 85 ).

Counterbalance Type

(refer to

page 84 ).



2.3.6. Electric Cylinders

The MP-Series™ and TL-Series™ electric cylinders provide flexible, digital, servo control of a rod actuator (linear control of force/clamping or position). They provide an electromechanical system for applying digital servo control with a familiar fluid power format. The cylinders are integrated into machines with the same fluid power application principals, mounting methods (for example, trunnion mounts, rear clevis attachment kits, front flanges) and rod end attachments for connected loads (for example, rod eye and clevis).

Figure 137 - Electric Cylinders Dialog Box

186

Enter the following parameters for electric cylinder mechanisms, if relevant.

Table 108 - Electric Cylinder Properties

Parameters

Mechanism Type

Mechanism Data

(label 1 in

Figure 137

)

Electric Cylinder

(label 2 in

Figure 137

)

Description


The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters

entered previously in the Load Type Tab and

Profile Tab , and displayed here for reference.

Rod Guide

This accessory is used when the cylinder shaft is exposed to moment (Mx,

My, Mz) and/or lateral side loading (Fy, Fz).

Overtravel

Length

This is the additional length of travel at each end of the motion profile to allow for user-defined machine movements outside of the motion profile

(for example, setup of a mechanism or tool change spacing). It also allows room for the motor to stop if it accidentally exceeds the nominal travel. Switches (physical or software) detect this and the drive performs a controlled stop. Once you have entered your motor and drive requirements, and have searched for possible solutions for your system, click the

Axis Stop

tab to determine the minimum stopping distance required. This is added to both ends of the calculated motion profile travel to make sure the proper length electric cylinder is specified and selected for the application.



2.3.7. Linear Stages

The MP-Series integrated linear stage actuators are used to restrict the load to a single axis of motion. They contain all of the elements required to produce linear motion: base and carriage; drive (linear motor or lead screw); linear bearings; and position feedback.

Figure 138 - Linear Stage Dialog Box



Parameters

Mechanism Type

Mechanism Data

(label 1 in

Figure 138

)

Orientation

(1)

(label 2 in

Figure 138

)

Enter the following parameters for linear motor mechanisms, if relevant.

Table 109 - Linear Motor Properties

Description



The actuator lies flat on a table.

Horizontal Table

Mount

The actuator moves up and down on a vertical wall.

Vertical Wall

Mount

Horizontal Wall

Mount

The actuator moves horizontally on a vertical wall.

Configuration

(label 3 in

Figure 138

Constant Load

(label 4 in

Figure 138

)

)

Direct Drive

Ball Screw

Cover

Overtravel Length

Actuator Stroke

Constant Mass

External Force

X, Y, and Z - Offset

Profile Based

Loads

Edit Payload

Payload

Animation

Linear brushless motor.

Conventional rotary brushless motor driving a screw.

An actuator cover provides protection from dust and dirt.

The addition length of travel at each end of the motion profile to allow for user-defined machine movements outside of the motion profile (for example, setup of a mechanism or tool change spacing). It also allows room for the stage to stop if it accidentally exceeds the nominal travel. Switches (physical or software) detect this

and the drive performs a controlled stop. Click the Axis Stop tab to determine the minimum stopping

distance required.

From the Select Actuator Stroke pull-down menu, choose the required stroke length. If the option Automatic is selected, the next largest value above Required Stroke + (2 x Overtravel) is selected. Larger sizes may be selected at will if additional stroke is required for a function not considered in the motion profile.

Any unchanging mass attached to the actuator. The actuator mass itself is automatically taken into account.

This value is editable in the

Load Type Tab on page 82 .

Any unchanging force, other than gravity, acting on the load. It is also known as static force. This value is

editable in the Load Type Tab on page 82

.

These offsets allow for a load that has a center of gravity that is not close to the mounting plate of the actuator. This value is significant for linear stage life calculations.

Any mass or force that changes during the cycle. The values must be entered for each segment of the motion

profile. These are entered in More Options Profile Editor Mode

, under the Profile toolbar.

Lets you quickly access More Options Profile Editor Mode

.

Displays a simple example of an application with a varying load.

(1) Only horizontal and vertical mounts are permitted corresponding to 0 and 90° inclination in the

Load Type Tab on page 82 . Any other inclination in the Load tab is converted to

horizontal mount.



2.3.8. Linear Thrusters

The Bulletin LDAT linear thruster is a new type of Allen-Bradley linear actuator product being developed by Rockwell Automation. Its purpose is to provide a completely integrated linear motor driven system. The Bulletin LDAT product is integrated with linear motor, mechanical bearings, high-resolution linear encoder, and standard circular DIN connectors for easy integration with Bulletin

2090 extension cables.

Figure 139 - Linear Thrusters Dialog Box



Table 110 - Linear Thruster Properties

Parameters

Mechanism Data


Orientation


Configuration


Description

The Constant/Peak Load Mass, Constant/Peak Applied Force, and Stroke values are calculated based on the parameters entered in the previous Load and Profile tabs and displayed here for reference.

Only horizontal and vertical mounts are allowed, corresponding to 0 and 90° inclination in the

Load tab. Any other inclination in the Load tab is converted to horizontal mount.

Select the appropriate thruster orientation image for your application:

• Horizontal table base mounting

• Horizontal table side mounting

• Horizontal wall base mounting

• Horizontal wall side mounting

• Vertical wall base mounting

• Vertical wall side mounting

Overtravel

Length

This is the additional length of travel at each end of the motion profile to allow for user-defined machine movements outside of the motion profile For example, setup of a mechanism or tool change spacing. It also allows room for the motor to stop if it accidentally exceeds the nominal travel envelope.

Switches (physical or software) detect this and the drive performs a controlled stop. Click the Axis Stop tab to determine the minimum stopping distance required. The value is added to both ends of the calculated motion profile travel to make sure the proper length motor is specified and selected for the application.

Actuator

Stroke

Length

Mounting

Surface

From the Actuator Stroke pull-down menu, choose the required actuator stroke length. If Automatic is chosen, the next largest value above Required Stroke +

(2 x Overtravel) is selected. Larger sizes may be selected if additional stroke length is required for a function not considered in the motion profile.

From the Mounting Surface pull-down menu, choose the type of surface the thruster is mounted to.


2.4. Specify Your

Transmission


A transmission helps to provide a speed-torque conversion, such as a gear reduction or speed reduction, from a higher speed to a slower, more forceful output.

Figure 140 - Transmissions Tab

Enter the following parameters for transmissions, if relevant.

Table 111 - Transmission Properties

Parameters

Required Components

(label 1 in

Figure 140

)

Type

(label 2 in

Figure 140

)

Description

Select the transmission components for your application. You may add up to two transmission components and one gearbox by checking the boxes above the appropriate component.

Belt Drive

A belt drive consists of a loop of flexible material that is used to mechanically link two or more rotating shafts with pulleys.

Chain and

Sprocket

A sprocket is a profiled wheel with teeth that mesh with a chain.

Spur Gear

Coupling

A spur gear consists of a rod or disk with the teeth extruding radially.

These gears can be meshed together correctly only if they are fitted to parallel shafts.

A coupling is a device used to connect two shafts together at their ends for the purpose of transmitting power. The inertia, stiffness, and backlash of couplings can be found in Manufacturers Data Sheets.

Define Parameters

(label 3 in

Figure 140

)

Click Edit for each transmission selected to enter data.



Figure 141 - Transmission Data Dialog Box

There are three options for entering transmission component parameters to calculate the transmission component Ratio, Efficiency, Inertia and Friction

Torque values. The applicability of these options change depending upon the type of transmission component.

Table 112 - Calculate the Transmission Component Ratio

Parameters

Compute Using Inertia and Ratio

Compute Using Pitch Circle Diameter

Compute Using Number of Teeth

Description

Directly enter the transmission component ratio and effective inertia. This option is available for all transmission components.

Compute the desired data (ratio and inertia values) by using the pitch circle diameter. This option is not available for a coupling transmission.

Compute the desired data (ratio and inertia values) by using the number of teeth. This option is not available for a coupling transmission.

Page

193

194

195



2.4.1. Compute Using Inertia and Ratio

Use this mode to directly enter the transmission component ratio and effective inertia. This option is available for all transmission components.

Figure 142 - Compute Using Inertia and Ratio Dialog Box

Enter the following parameters for inertia and ratio, if relevant.

Table 113 - Compute Using Inertia and Ratio Properties

Parameters

Inertia and Ratio

(label 1 in

Figure 142

)

Efficiency and Losses

(label 2 in

Figure 142

)

Description

Ratio

Inertia

Efficiency

Friction

Torque

Transmission component ratio. If a straight-through coupling is being modeled, set Ratio = 1.

Inertia on the motor side (the rotor inertia and if a gearbox is present, the inertia of the pinion attached to the rotor).

Efficiency is widely misused. It refers to the ratio of output power to input power for a single operating condition, but a servo system typically operates over a wide range of operating conditions. A gearbox supplier normally specifies the efficiency at an optimum point such as full load and full speed.

For example, a gearbox that has an output rating of 100 N•m (885 lb•in) and an efficiency of 98%. This means that the losses at full load are 2 N•m (18 lb•in).

But because most of the losses in a gearbox are due to shaft seal friction and churning of the lubricant, this would not reduce significantly at a lower load torque.

In using this gearbox, a well-matched servo motor only has a continuous rating around one third of the peak torque, and it is quite likely that the average torque over the motion cycle would be even lower, for example about 20 N•m

(177 lb•in) at the gearbox output. The losses of 2 N•m (18 lb•in) amount to 10% of the load on the motor, which can have a significant effect on the temperature rise of the motor.

Motion Analyzer software overcomes this problem by dynamically computing the real losses throughout the motion cycle, and thereby avoids underestimating the effect of losses on the motor.

This is the torque caused by friction on the motor side between the rotor and the transmission component. This value can be obtained from the supplier or

Engineering tables.



2.4.2. Compute Using Pitch Circle Diameter

Use this mode to compute the desired data (Ratio and Inertia values) by using the pitch circle diameter. This option is not available for a coupling transmission.

Figure 143 - Compute Using Pitch Circle Diameter Dialog Box

194

Enter the following parameters for pitch circle diameter, if relevant.

Table 114 - Compute Using Pitch Circle Diameter Properties

Parameters

Inertia and Ratio




)

Description

Belt/Chain

Motor Side Pulley/

(1)

Sprocket/Gear

Load Side Pulley/

(1)

Sprocket/Gear

Efficiency

Friction Torque

Transmission component ratio. If a straight-through coupling is being modeled, set Ratio = 1.

These values are the Pitch Circle Diameter (PCD) and Inertia for the transmission component on the motor side.

These values are the Pitch Circle Diameter (PCD) and Inertia for the transmission component on the load side.


For example, a gearbox that has an output rating of 100 N•m (885 lb•in)and an efficiency of

98%. This means that the losses at full load are 2 N•m (18 lb•in). But because most of the losses in a gearbox are due to shaft seal friction and churning of the lubricant, this would not reduce significantly at a lower load torque.

In using this gearbox, a well-matched servo motor only has a continuous rating around one third of the peak torque, and it is quite likely that the average torque over the motion cycle would be even lower, for example about 20 N•m (177 lb•in) at the gearbox output. The losses of

2 N•m (18 lb•in) amount to 10% of the load on the motor, which can have a significant effect on the temperature rise of the motor.


This is the torque caused by friction on the motor side between the rotor and the transmission component. This value can be obtained from the supplier or Engineering tables.

(1) Use the




2.4.3. Compute Using Number of Teeth

Use this mode to compute the desired data (ratio and inertia values) by using the number of teeth. This option is not available for a coupling transmission.

Figure 144 - Compute Using Number of Teeth Dialog Box

Enter the following parameters for number of teeth, if relevant.

Table 115 - Compute Using Number of Teeth Properties

Parameters

Inertia and Ratio

(label 1 in

Figure 144


(label 2 in

Figure 144

)

)

Description

Belt/Chain

Motor Side Pulley/

(1)

Sprocket/Gear

Load Side Pulley/

(1)

Sprocket/Gear

This is the mass and tooth pitch for the belt/chain. This value is required for belt drive and chain and sprocket transmission components only.

These values are the Number of Teeth and Inertia for the transmission component on the motor side.

These values are the Number of Teeth and Inertia for the transmission component on the load side.

Efficiency

Friction Torque


For example, a gearbox that has an output rating of 100 N•m (885 lb•in)and an efficiency of

98%. This means that the losses at full load are 2 N•m (18 lb•in). But because most of the losses in a gearbox are due to shaft seal friction and churning of the lubricant, this would not reduce significantly at a lower load torque.

In using this gearbox, a well-matched servo motor only has a continuous rating around one third of the peak torque, and it is quite likely that the average torque over the motion cycle would be even lower, for example about 20 N•m (177 lb•in) at the gearbox output. The losses of

2 N•m (18 lb•in) amount to 10% of the load on the motor, which can have a significant effect on the temperature rise of the motor.


This is the torque caused by friction on the motor side between the rotor and the transmission component. This value can be obtained from the supplier or Engineering tables.

(1) Use the




Figure 145 - Gearbox Data Dialog Box

2.5. Choose Your Motor

Series

Enter the Manufacturer, Configuration, Series, and Frames gearbox data.

Use the Motor Series Selection tab to enter application requirements and then select a compatible motor series.

Figure 146 - Motor Series Selection Dialog Box



Enter the following parameters to further narrow the motor options and help you decide which motor is best for your application.

Parameters

Applications

Requirements

(label 1 in

Figure 146

)

Display Window

(label 2 in

Figure 146

)

Table 116 - Motor Series Selection Properties

Description

Maximum Speed

Continuous Torque

Peak Torque

Ambient

Temperature

Values are based on the information you entered in the previous tabs. These values cannot changed in this tab.

Ambient temperature for the application environment.

be

Altitude

Brake

Altitude for the application environment.

From the Brake pull-down menu, choose YES or NO depending on your application.

Displays the available motor series. As application requirements are entered or motor series are selected, incompatible motors are dimmed and crossed-out (boxed in red in

Figure 147

).

Figure 147 - Compatible Motor Series

Table 117 - Motor Series Legend (refer to Figure 147 )

Symbol Description

By hovering over this symbol, the particular motor series’ voltage ratings are displayed.

Indicates that the motor series supports the application.

Indicates that the motor series support for the application is marginal.

Indicates that the motor series is not recommended for the application.

Indicates that the motor series is incompatible with the application.



Select the List View option to view details regarding Key Features and

Applications, Voltage/Travel & Speed, Feedback Options, and Continuous Stall

Torque/Force.

Click Compatibility List to view a comprehensive table containing Motor Series

Voltage Compatibility and Motor Series-Drive Family Compatibility.


2.6. Choose Your Electric

Cylinder Series


Use the Electric Cylinder Selection tab to enter application requirements and select a viable electric cylinder series.

Figure 148 - Electric Cylinder Selection Dialog Box

Enter the following parameters to further narrow the electric cylinder options and help you decide which actuator is best for your application.

Parameters

Applications

Requirements

(label 1 in

Figure 148

)

Table 118 - Electric Cylinder Selection Properties

Description

Maximum Speed

Continuous Force

Peak Force

Ambient

Temperature

Altitude

Brake

Values are based on the information you entered in the previous tabs. These values cannot be changed in this tab.

Ambient temperature for the application environment.

Altitude for the application environment.

From the Brake pull-down menu, choose YES or NO depending on your application.

Display Window

(label 2 in

Figure 148

)

Displays the available electric cylinder options.



Table 119 - Electric Cylinders Legend (refer to

Figure 148

)


By hovering over this symbol, the particular electric cylinder voltage ratings are displayed.

Indicates that the electric cylinder supports the application.

Indicates that electric cylinder support for the application is marginal.

Indicates that the electric cylinder is not recommended for the application.

Indicates that the electric cylinder is incompatible with the application.



Torque/Force.

Click Compatibility List to view a comprehensive table containing Actuator

Series Voltage Compatibility and Actuator Series-Drive Family Compatibility.


2.7. Choose Your Drive

Family


Use the Drive Family Selection tab to enter application requirements and select a viable drive family.

Figure 149 - Drive Family Selection Assistant Dialog Box

Enter the following parameters to further narrow the drive family options and help you decide which drive is best for your application.

Table 120 - Servo Drive Family Selection Properties

Parameters

Applications

Requirements

(label 1 in

Figure 149

)

Description

Supply Type

Nominal Voltage

Average Motoring

Power

Voltage Type

Select Single phase AC (AC1ph), 3-phase AC (AC3ph), or DC supply type.

From the Nominal Voltage pull-down menu, choose the nominal voltage value.

This value is displayed for reference. Click Details to view more information.

(

More Options

Figure 150

)

(1)

Lower Nominal

Upper Nominal

Tolerance

Select an option to enter a single value for voltage or a range of voltages.

This parameter is required when you select the option to enter a range for the voltage type.

Enter the lower value for the voltage range.

This parameter is required when you select the option to enter a range for the voltage type.

Enter the upper value for the voltage range.

This is the high and low tolerance for the voltage range.

Display Window

(label 2 in

Figure 149

)

Displays the available electric cylinder options.

(1) Click More Options to further narrow the drive parameters and help you decide which motor is best for your application.



Figure 150 - Additional Servo Drive Selection Properties

Figure 151 - Compatible Drive Families

Table 121 - Drive Family Legend (refer to Figure 149

)


By hovering over this symbol, the particular drive family’s voltage ratings are displayed.

Indicates that the motor series supports the application.

Indicates that the motor series support for the application is marginal.

Indicates that the motor series is not recommended for the application.

Indicates that the motor series is incompatible with the application.





Torque/Force.

Click Details to view a comprehensive table containing Motor Series and Drive

Family Compatibility.



Notes:


Understanding Your System Solution

Topic

Selection

Automatic

Manual

Solution

Solution List

View Solution

Axis Stop

Controlled Stop

Resistive Brake Module

Load Data

RBM Selection

Apply RBM Selection

Life Estimate

Configure Axis BOM

Super Review

Summary View

Details View

255

256

258

260

250

252

252

253

260

265

208

209

211

250

Page

206

207

208

Chapter

3


Chapter 3 Understanding Your System Solution

3.1. Selection

In the Selection tab, you perform a search for the drive/motor solution for your application, based on the drive and motor families you selected previously. The search also includes a gearbox, if gearbox was selected in the Transmission tab.

Figure 152 - Sizing and Selection Dialog Box

206

The search for possible drives and motors is performed based on these two options:

•

Select Full if you want the search performed on the entire database of motors, drives, and gearboxes.

• Select My Preferred if you want the search performed on motors, drives,

and gearboxes that you have selected within My Preferred Database

on

page 62 .

Searching methods include these two options:

•

Select Automatic

if you want Motion Analyzer software to perform the

search based on the selected database option (refer to page 207

).

•

Select Manual if you want to select the components (motor, drive, and/or gearbox) from a list (refer to page 208

).


Understanding Your System Solution Chapter 3

3.1.1. Automatic

Follow these steps to have Motion Analyzer software to make the motor, drive, and/or gearbox selections for you.

1.

In the Automatic field, select Motor, Drive, and Gearbox (if present).

2.

Click Search.

The Search in Progress dialog box opens.

When the search is complete, the

Solution List

opens with a list of motor/ drive combinations and a selection based on the application requirements that you entered previously.

3.

Click View Solution.

The Component Details and Axis System Performance windows open.

If the automatic selection process does not find a solution, it means that no motor or drive in the specified family is capable of performing the task. When this happens, the result is No Solution Found, which means you should try one or more of the following:

•

Select a Motor Mounted Gearbox in the Transmissions Tab on page 191 .

•

Try a bigger family of motors and drives.

•

Reduce application requirements until a solution is found.

•

Use Torque Analysis, within the

Efficiency Analysis

tool on

page 227 , to

determine which parameters are dominant. This may indicate which factor to investigate.

•

Use

Tolerance/Design Analysis on page 222

to explore how much a parameter should change to obtain a passing solution.



3.1.2. Manual

Follow these steps to select the components yourself (motor, drive, and/or gearbox) from a list.

1.

In the Manual field, select Motor, Drive, and Gearbox (if present).

2.

Click Select.

The Manual Selection dialog box opens.

3.2. Solution

208

3.

Select the motor/actuator required for your application from the

MotorID column.

For each motor/actuator selected, the compatible drives appear below in the Drive column.

4.

Select a drive.

5.

Click View Solution.

The Component Details and Axis System Performance windows open.

When using the automatic method of selecting components, the Solution tab opens providing a solution list of motor/drive combinations and a selection, based on the application requirements that you entered previously.

If you are using the manual method of selecting components go directly to View

Solution on page 211

.



3.2.1. Solution List

You can organize the solutions by using the List Categories pull-down menu, or by clicking one of the headings in the table. The column data is sorted in descending order the first time the heading is clicked and ascending order when you click the heading a second time. You can also rearrange the columns by clicking and dragging them.

Figure 153 - Solution List Dialog Box

Table 122 - Solution Tab Properties

Parameters

View Utilizations as

Description

Text Data in columns appear only as text (for example, 17%).

Graphically Data in columns appears as text and graphic ally to enhance the view (this is the default setting).

Solution View Setup Click to adjust display options for the solution list.

View Solution Click to open the View Solution dialog box.

System Notes Enter system notes for the application (optional).

Table 123 - Solution List Legend

Symbol Status Definition

Supports All parameters passed.

Marginal

One or more parameters exceeded the recommended limit, but the solution is viable provided all customer data is accurate.

Not

Recommended

One or more parameters exceeds 100%. The solution is not viable as entered, but may respond to optimization. For more information, refer to

Automatic on page 207 .



3.2.1.1. Preferred Product

A preferred product is a top selling product of Rockwell Automation that is guaranteed to ship from the factory within five days. The preferred status is displayed in the Preferred Product column in the solution list.

Figure 154 - Preferred Product Solution List Dialog Box

Table 124 - Preferred Product Status (refer to

Figure 154

)

-

Preferred Product Status Definition

Motor & Drive

Drive

The drive is a preferred product and has a shorter lead time/quicker delivery. The motor may be a preferred product depending on options (for example, encoder option, brake, key, and others). Please view the complete catalogue number in the ProposalWorks™ application for preferred product status.

The drive is a preferred product and has a shorter lead time/quicker delivery.

Motor

The motor may be a preferred product depending on options (for example, encoder option, brake, key, and others). View the complete catalogue number in the

ProposalWorks application for preferred product status.

Neither the motor nor the drive is a preferred product. Contact your local Rockwell

Automation distributor for the lead time/delivery schedule of these products.



3.2.2. View Solution

The View Solution dialog box contains information and tools that you can use to to evaluate system performance and efficiency.

Figure 155 - View Solution Dialog Box

View the following parameters for your solution. The Component Details portion of the detailed solution view provides an overall summary of the performance characteristics for the various components of the system.

Table 125 - Component Details (label 1 in

Figure 155 )

Parameters

Motor Cat. No.

Forward/Backward

Arrows

Description

Click to access the product specifications for that catalog number.

Navigate to the View Solution information for the next component in the solution list.

When a solution includes a gearbox, the inertia ratio is not simply the Reported

Application Inertia divided by the Reported Motor Inertia (rotor inertia), as with systems that do not include a gearbox.

When a system includes a gearbox, the Input Pinion of the gearbox is rigidly attached to the rotor, while the rest of the gears in the gearbox remain connected to the application. Most of the backlash in the system occurs between the input pinion and the rest of the system.



To correctly calculate the inertia ratio, the Input Pinion Inertia must be removed from the Reported Application Inertia and added to the Reported Motor Inertia.

Reported Application Inertia - Input Pinion Inertia

= Inertia Ratio

Reported Motor Inertia + Input Pinion Inertia

For example, the system in Figure 156

with an MPL-B680F motor and a

VDT100-MF1 gearbox has a 6.50:1 inertia ratio.

Figure 156 - Inertia Ratio Calculation

Click the Motor tab to view the Reported Application Inertia and the Reported

Motor Inertia.

Figure 157 - Motor Tab



The Motion Analyzer database contains the Input Pinion Inertia for every available gearbox. In this example, the Input Pinion Inertia is 0.00298 kg-m

2

. To obtain a correct inertia ratio, Motion Analyzer software adds the Input Pinion

Inertia to the Reported Motor Inertia, which decreases the application inertia and increases the motor inertia. Division produces the correct inertia ratio of

6.50:1.

0.07274 - 0.00298

0.00775 + 0.00298

=

6.50

1.0

The individual component tabs (for example, Motor, Drive, Gearbox and

Transmission) provide detailed performance information.

Figure 158 - Motor Tab

In the Motor tab, the brake rating compares the maximum static torque that can be applied to the brake with the quoted holding torque of the brake. This normally occurs when the drive is disabled with the motor/load stationary. This static torque arises from any applied load torques or forces, including gravitational effects. It does not take into account friction. If a high proportion of the brake torque (or force) is used for static loads, then little may be left in case the brake is required to stop motion suddenly. Brakes reduce performance if operated during motion. The motor brake is intended as a holding brake applied when motion is stopped and cannot be relied upon to stop a moving load when the drive fails or loses power. An independent method of stopping is recommended for all emergency situations where there is a gravitational load or applied force/torque. A resistive brake module provides some braking but will never stop a mechanism with a gravitational load or applied force/torque.

If available, Get Engineering Data opens a webpage with the Product Description and Supplementary Documents for the selected product.



The Axis System Performance portion of the detailed Solution view provides graphical representations of the performance characteristics for the system. If you click the graph, the graph expands to fill your screen. In addition, as you mouse over the graph, the X- and Y-values are displayed below the graph.

The Torque-Speed tab contains the torque/speed graph for the selected motor/ drive combination. This graph is created dynamically, which means that if the supply voltage changes in the Motor or Drive tab, the graph will change accordingly.

Figure 159 - Torque-Speed Graph

214

Parameters

Quadrant

Graph Detail

X-/Y- Axis Button

Table 126 - Axis System Performance (label 2 in Figure 155 )

Description

Single

Four

Displays single quadrant graph.

Displays four quadrant graph.

Opens the Torque Speed Details dialog box.

Summary

All Segments

Displays only the critical profile segment data on the graph.

Displays the data for all profile segments on the graph.

Segmentwise

Displays the data for one profile segment at a time. Use the Forward and Backward arrows to navigate between profile segments.

Show RMS Torque Check to display the RMS (root mean squared) torque value on the graph.

Auto Cycle Check to highlight each data point, in order, at the specified update rate.

Flips the X- and Y-axes on the graph.



The Power-Speed tab (label 2 in

Figure 155 ) contains the power/speed graph for

the selected motor and drive combination. This graph is typically used for

Variable Frequency Drive (VFD) applications where power is more appropriate than torque as a measure of performance.

Figure 160 - Power-Speed Graph



The Load tab displays the characteristics of the load alone without the influence of the motor or drive. It may be viewed before selecting motor or drive. For rotary loads, the influence of transmission/gear component ratio may be investigated by moving the ratio slider. This is a preliminary test—no transmission losses are included at this stage. For example, efficiency as defined on the Transmission tab is not factored into transmissions.

Figure 161 - Load Graph

Table 127 - Axis System Performance (label 2 in Figure 155 )

Parameters

Summary

Description

Displays the data only for the critical profile segment.

All Segments Displays the data for all profile segments on the graph.

Segmentwise

Displays the data for one profile segment at a time. Use the Forward and Backward arrows to navigate between profile segments.

Show RMS Torque Select to display the RMS (root mean squared) torque value on the graph.

Gearbox Ratio Use the slider to adjust the Gearbox Ratio and observe the effect on the Torque-Speed graph.

Quadrant Select the option to view either the Single or Four quadrant graph.



The Thermal tab displays the output of drive and motor thermal models that reside in the drive firmware.

Figure 162 - Thermal Graph

Table 128 - Axis System Performance (label 2 in Figure 155

)

Parameters

Motor/Drive Capacity

Description

Select the thermal curves you would like displayed on the graph.

Steady State/Single Cycle Select whether to view thermal data for Steady State or for a Single Cycle.

Full/Auto Scale

Select whether to view the data on the Full Scale graph (y-axis values from zero to the maximum value) or Auto Scale graph (y-axis values from the minimum value to the maximum value).

RBM tab

Power-Supply

This graph is available after a Resistive Brake Module (RBM) has been added to the System

BOM (bill of materials) in the Axis Stop tab. The graph displays the Velocity versus Time

data for the RBM module.

This graph is available after a Power Supply Analysis has been performed on the system in

the Power Supply/Accessories View

. This graph displays the Voltage and Current

Simulation data.



The Data Analysis Toolbar provides tools that can be used to analyze and optimize the system. Use these tools to quickly evaluate the effect of changing the application parameters, without having to build physical prototypes. When an optimized system is realized, return to the appropriate parameter to manually update it.

Figure 163 - Data Analysis Toolbar

218

Table 129 - Data Analysis Toolbar (label 3 in Figure 155

)

Parameters

Ratio/Design Analysis

Tolerance/Design

Analysis

Efficiency Analysis

Dynamic Simulation

Segment Data

Description

Provides information that you can use to optimize the mechanical advantage and/or transmission stages for the system.

Page

219

Provides information that you can use to determine the sensitivity of the design to changes.

Provides information that you can use to determine the efficiency of the system.

222

227

Provides information that you can use to determine the dynamic performance of the system.

Provides detailed performance data for each profile segment.

230

249

These parameters can be used to view data for other solutions.

Table 130 - Additional Tools (label 3 in Figure 155 )

Parameters

Solution List

Description

Click to return to the Solution List. This feature is dimmed if there is only one solution for the system configuration.

Page

209



3.2.2.1. Ratio/Design Analysis

You can use the Ratio/Design Analysis tool to analyze the effect of the transmission or gear component ratios on the system performance and quickly optimize the ratio values. This tool is not applicable for linear actuators.

When you click Ratio/Design Analysis, the following dialog box opens.

Depending on your system configuration, the following Ratio Analysis options may be available to you:

•

Gearbox

•

Transmission 1

•

Transmission 2

•

Lead

•

Sprocket PCD (sprocket pitch circle diameter)

•

Pinion PCD (pinion pitch circle diameter)

•

Drive Diameter

For more information, refer to Ratio Analysis on page 220 .

The Cut Length Analysis option is available when you use the Press Roll Feed

(constant time/constant angle)

, Carriage Cut Off

, or

Cutter Knife Drive

application templates.

For more information, refer to Cut Length Analysis on page 221 .



3.2.2.1.1. Ratio Analysis

When you select a Ratio Analysis option, the following dialog box opens.

Motor Speed an

Ratio Value

220

Motor Speed and ratio values are displayed above the graph for reference. The slider below the chart is available to adjust the ratio you are optimizing. As you mouse over the slider, the ratio value is displayed.

The buttons below the Ratio Analysis chart select which curves are displayed.

When you click Selected Curves, the motor and drive parameters to the right of the chart are displayed. If you select another button below the chart, only that parameter is shown.

Table 131 - Ratio Analysis Options

Parameters

Motor/Drive

Parameters

Graph Scale

Description

Check which motor and drive parameters are displayed when you click Selected Curves. The value for each parameter is listed for the particular gearbox or transmission component ratio indicated by the slider.

From the Graph Scale pull-down menu, choose the X-axis scale for the chart. You can set the

Graph Scale to 1, 2 or 3 decades or the scale can be defined. When the User Defined option is selected, the lower and upper limits for the X-axis of the graph must be entered. Once the axis limit values are entered, click Recompute to refresh the chart.

Available

Solutions

Return

Click the forward or backward arrow to scroll through the various available solutions.

Click Return to exit.



3.2.2.1.2. Cut Length Analysis

When you select a Cut Length Analysis option, the following dialog box opens.

Table 132 - Cut Length Analysis Options

Parameters

Range Parameters

Description

Enter the Minimum Cut Length, Maximum Cut Length, and Increment values and click Compute.

The calculated parameters are displayed in the table and Line Speed versus Cut Length chart.

Critical

Parameters

Print

The Minimum Cut Length at Max. Line Speed and Max Line Speed values are displayed here for reference. To adjust these values, return to the

Application Template Loads

tab on

page 96 .

Print the Cut Length Analysis in a project report.



3.2.2.2. Tolerance/Design Analysis

When you click Tolerance/Design Analysis, the following dialog box opens.

The buttons below the Tolerance Analysis chart are available to select which curves are displayed. When you click Selected Curves, the parameters selected on the Graph tab (right of the chart) are displayed. If you select another button below the chart, only that parameter appears.

The slider below the chart is available to adjust the selected Profile, Load, or

Actuator parameter. As you mouse over the slider, the parameter value is displayed.



3.2.2.2.1. Profile Tab

Follow these steps to adjust the profile parameters.

1.

From the Segment No. pull-down menu, choose the profile segment number you would like to analyze.

2.

Select the motion profile parameter.

This becomes the parameter corresponding to the X-axis on the graph. The value next to each parameter indicates the parameter value based on the current system configuration.

3.

Adjust the selected profile parameter range and number of steps in the Low, High, and

Steps text boxes, as needed.

4.

Click Plot Graph to refresh the chart when you have finished entering the values.

5.

Click Setup to designate a parameter to vary by checking the adjacent box and/or clicking the radio button.

Designate an upper and lower limit for the parameter and the number of steps to observe on the graph within the specified range.

6.

Click Plot to see the graph of the selected parameter versus time.

7.

Click OK.



3.2.2.2.2. Load Tab

Follow these steps to adjust the load parameters.

1.

Select the Load parameter you would like to analyze.

This becomes the parameter corresponding to the X-axis on the graph. The number next to each parameter indicates the parameter value based on the current system configuration.

2.

Adjust the selected load parameter range and number of steps in the Low, High, and


3.


4.

Click Setup to enter all of the ranges and numbers of steps for the Load parameters in the Tolerance Analysis - Setup dialog box.

224

5.

Select whether to enter data ranges as Percentages of nominal values or as actual Values.

6.

Enter the Low, High, and Steps values in the text boxes.

7.

Click OK.



3.2.2.2.3. Actuator Tab

Follow these steps to adjust the actuator parameters.

1.

Select the Actuator parameter you would like to analyze.

This becomes the parameter corresponding to the X-axis on the graph. The number next to each parameter indicates the parameter value based on the current system configuration.

2.

Adjust the selected actuator parameter range and number of steps in the Low, High, and


3.


This tab is not available for the Rack and

Pinion and Sprocket loads.

4.

Click Setup to enter all of the ranges and numbers of steps for the Actuator

Tolerance Parameters in the Tolerance Analysis - Setup dialog box.

5.

Select whether to enter data ranges as Percentages of nominal values or as actual Values.

6.

Enter the Low, High, and Steps values in the text boxes.

7.

Click OK.



3.2.2.2.4. Graph Tab

This tab is not available for the Rack and Pinion and Sprocket loads.

Follow these steps to decide which parameters are displayed.

1.

Check the Motor Parameter curves to display.

2.

Check the Drive Parameter curves to display.

3.

Click Setup to enter all the ranges and numbers of steps for the Profile, Load, and

Actuator tolerance parameters.

4.




3.2.2.3. Efficiency Analysis

Click Efficiency Analysis to analyze the contribution of various system parameters to the overall efficiency of the system.

You can use this information to optimize the system configuration and reduce the torque, power consumption, or energy loss in the system. For example, if more torque is applied toward overcoming the preload on a ball screw than towards moving the load, this may indicate a good place for further analysis.

3.2.2.3.1. Torque Tab

Click the Torque tab to identify the torque contributions of the various system components.

Figure 164 - Torque Tab

Click either the Peak Torque Analysis or RMS Torque Analysis option to display the data. The torque analysis for the critical profile segment is displayed by default when you open the Efficiency Analysis dialog box. To change the

Segment Number, click the Forward or Backward arrows.

The torque contributions of each system parameter are listed in descending order.

To view the torque contribution of a particular system parameter for all profile segments, click the arrow next to the system parameter.



3.2.2.3.2. Power Tab

Click the Power tab to display aids in identifying how the system’s power is distributed.

Figure 165 - Efficiency Analysis Dialog Box

Click Segment Average to display the various power contributions for each profile segment or Cycle Average to display the power contributions for the entire motion profile.

The Power Consumption analysis for the critical profile segment is displayed by default when you open the Efficiency Analysis dialog box. To change the

Segment Number, click the Forward or Backward arrow.

The power consumption contributions of each system parameter are listed in descending order. To view the power consumption contribution of a particular system parameter for all profile segments, click the arrow next to the system parameter.



3.2.2.3.3. Energy Tab

Click the Energy tab to identify how the system’s energy consumption is distributed.

Figure 166 - Efficiency Analysis Dialog Box




3.2.2.4. Dynamic Simulation

Motion Analyzer dynamic simulation lets you predict the dynamic performance of an axis at the sizing stage. The Dynamic Simulator contains similar functionality in gains and behavior as RSLogix 5000 software.

Figure 167 - Dynamic Simulation Dialog Box

230

Table 133 - Dynamic Simulation Options

Options

Simulation Inputs

(label 1 in

Figure 167

)

Simulation Analysis

(label 2 in

Figure 167

)

Control Loop Gains and other Parameters

(label 3 in

Figure 167

)

Description

Consists of Controller, Drive, Motor, Load, and Test Disturbances specifications and lets you define the parameters for each.

Page

231

Consists of Simulation Plots, Simulation Data, and Control Loop Diagram tabs and lets you run simulation and analyze output simulation plots and data.

239

Lets you manually enter control loop gains or perform auto-tuning.

246


Collapsed View


3.2.2.4.1. Simulation Inputs

Click to toggle between the expanded and collapsed view of the simulation inputs.

Figure 168 - Simulation Inputs

Expanded View



Parameters

Table 134 - Simulation Input Parameters

Controller


Drive


Motor


Load


Test Disturbances


Description

Coarse Update Rate Coarse update rate of the Logix controller.

Sercos update rate of the Logix controller.

Sercos Update Rate

Counts Per Motor

Revolution

Drive feedback counts per motor revolution.

Counts Per User Unit

Drive feedback counts per user unit. The combination may be chosen arbitrarily to make sure that the user units are exact. The user unit is the unit selected for Angular

Distance from Preferences->Units of Measure in the main Motion Analyzer window.

Displays drive catalog number as selected in sizing. Parameters cannot be edited.

Continuous Current Current that may be drawn indefinitely.

Peak Current Maximum current that may be drawn briefly.

Displays motor catalog number as selected in sizing. Parameters cannot be edited.

Motor Inertia

Continuous Torque

Motor rotor inertia.

Nominal or continuous torque (100%).

Peak Torque Limit

Feedback

Feedback Counts/

Revolution

Peak available torque from the motor in %. Dynamic simulation assumes that this peak torque is available at all speeds required by the specified profile. It does not model bus voltage limit behavior.

You can select the feedback device available to the base motor (for example, selected in sizing). Selecting the feedback device changes the motor catalog number to reflect the feedback device. This motor catalog number also reflects in the BOM area.

Feedback resolution in counts per motor revolution. This field is updated by selecting a feedback device.

Motion Analyzer Load

Select to use the load defined in the Motion Analyzer software. This is the default selection when you open Dynamic Simulation.

SolidWorks Load

Select SolidWorks software to model a more complex load and use SolidWorks integration to perform simulation. Dynamic Simulation uses SolidWorks results to predict the dynamic behavior of the load.

If SolidWorks is not installed on your personal computer, the SolidWorks Load option is dimmed.

Test disturbances test the stability of the system. The defined step torque value is added to the system for the specified duration.

Step Torque

Step Start Time

Step Duration

Simulates a step torque occurring part way through the cycle.

Defines the point in the cycle that the step occurs.

Defines the length of time that the torque is applied.



3.2.2.4.1.1. Motion Analyzer Load

Selecting the Motion Analyzer load provides simulation using the Motion

Analyzer software load sizing definitions.

Figure 169 - Motion Analyzer Software Load

Inertia B

Inertia A

The load is modelled as two inertias coupled by compliance (the spring in this example diagram). Inertia A is rigidly coupled to the motor and so effectively becomes part of the motor. If backlash is selected, it replaces the spring in this diagram. The two friction components are not yet supported.

From the Coupling pull-down menu, choose the Coupling type.

Figure 170 - Coupling Type

Table 135 - Coupling Type Options

Options

Rigid Coupling

Backlash

Compliance

Description

The load is rigidly coupled to the motor.

Simulates backlash such as gearbox.

A spring is connected between motor and load.

Page

234

234

235



3.2.2.4.1.1.1. Rigid Coupling

Rigid coupling occurs when the load is rigidly coupled to the motor.

Figure 171 - Rigid Coupling

Table 136 - Rigid Coupling Options

Options

Total Inertia

Rigid Inertia

(Inertia A in Figure 169 )

Decoupling Factor

Description

Maximum load inertia reflected to the motor shaft.

Any part of the load inertia that is rigidly attached to the motor shaft. This becomes significant only when resonance or backlash is present because it becomes effectively part of the motor. Any inertia entered here is subtracted from the Load inertia leaving the total

(system) inertia unchanged.

For example, a gearbox always has backlash, but its input shaft/pinion is normally coupled rigidly to the motor shaft. This effectively becomes part of the motor, creating a higher inertia motor. This can significantly alter the performance of an axis.

This factor is much more indicative of potential dynamic performance than the conventional Inertia Ratio. Velocity Bandwidth is increased by this factor when the load is decoupled. Instability typically results beyond 2 unless gains are reduced. Anything greater than 1 starts to impact performance.

DF = Jdc / (Jm + Jrc) + 1

Where, DF = Decoupling Factor, Jdc = decoupled load inertia,

Jm = motor inertia, Jrc = rigidly coupled load inertia

3.2.2.4.1.1.2. Backlash

Backlash occurs (for example) when a gearbox is added to the motor. Choosing

Backlash enables an additional field, in addition to the Rigid coupling fields, where you can enter a backlash value.

Figure 172 - Backlash Coupling



3.2.2.4.1.1.3. Compliance

Choosing Compliance enables the following additional fields, in addition to the

Rigid coupling fields.

Figure 173 - Compliance Coupling

Table 137 - Compliance Coupling Options (refer to

Figure 173

)

Options

Damping Ratio

Stiffness

Stiffness Calculator

Natural Frequency

Description

Enter a system damping ratio. The damping ratio provides a means of expressing the level of damping in a system relative to critical damping.

The Stiffness entry is useful when Natural Frequency is not known, but stiffness is.

Click Stiffness to launch the stiffness calculator and calculate stiffness from Shear Modulus, diameter and length.

Simulates a resonance between load and motor (0 = infinitely stiff).

Figure 174 - Stiffness Calculator



3.2.2.4.1.2. SolidWorks Load

Selecting SolidWorks Load provides simulation of complex loads modeled in

SolidWorks software. Using the SolidWorks interface, the Dynamic Simulator sends the torque value to the load in SolidWorks software and brings back the position of the load for each time slice. The time slice is the smallest update rate.

For example, Kinetix 6000 drives have the smallest update rate of 0.125 ms. This position feedback is used to compute the position error and to plot the various feedbacks such as load position, load velocity, position errors, for example.

Figure 175 - SolidWorks Integration

Use these tips before clicking SolidWorks Integration:

• A SolidWorks Assembly must be open in SolidWorks software before the

SolidWorks Load Definition dialog box opens.

•

A SolidWorks Motion Study must be set up before opening SolidWorks

Load Definition dialog box. SolidWorks Force element must be defined in the SolidWorks Motion Study before integration.

•

Define reference geometry in SolidWorks software to define the axis of rotation for the component the SolidWorks force is attached to. Using component faces to attach SolidWorks force will work, but may inadvertently define motion about an incorrect location for some mechanisms.

Follow these steps to improve solver speed.

1.

Click Motion Study Properties on the SolidWorks Motion Study explorer bar.



2.

Clear the Animate during simulation check box.

This increases the speed of the solver (and in turn the speed of Dynamic

Simulation) since SolidWorks software is not attempting to show the motion of the assembly while performing calculations. Animation is not necessary because it can be played after the study has been calculated.

3.

Set Frames per second to 8000.

This should match the smallest update rate of the Kinetix 6000 drive

(0.125 ms).

4.

Click SolidWorks Integration (

Figure 175

) to open the SolidWorks Load

Definition dialog box.

The Dynamic Simulation launches the SolidWorks Load Definition dialog box and displays the model that is open in SolidWorks software:

• The SolidWorks assembly must be open in SolidWorks software before the SolidWorks Load Definition dialog box will open.

•


•

Only one instance of SolidWorks software may be running in order for integration to work.



5.


6.

After verifying that this is the correct model, select the desired motion study and force element.

Table 138 - SolidWorks Load Definitions

Description Options

Selected SolidWorks

Assembly

Selected SolidWorks

Study

SolidWorks Force

Element

Displays the location of the selected SolidWorks model.

From the pull-down menu, select the desired SolidWorks motion study from the existing motion studies in the currently selected assembly.

From the pull-down menu, select the SolidWorks force element.

7.

Click OK to confirm the desired selections and go back to Dynamic

Simulation.

8.

Click Run Simulation to invoke SolidWorks based simulation.

9.

Click Stop Simulation to stop the analysis.



3.2.2.4.2. Simulation Analysis

Simulation Analysis lets you invoke simulation and analyze various reports displayed as plots and data. It also lets you enter control loop gains in the Control

Loop Diagram tab.

Figure 176 - Simulation Analysis Dialog Box

Table 139 - Simulation Analysis Tab Definitions (refer to Figure 176 )

Options

Simulation Plots

Simulation Data

Control Loop Diagram

Description

Graphical representation of the simulation output data.

Displays the simulation output data in a tabular format and provides data export.

Displays control loop diagram of motion control system. You can enter loop gain and other parameters here.

Page

240

243

245



3.2.2.4.2.1. Simulation Plots

Simulation plots can be drawn and displayed for position, velocity, and torque.

Figure 177 - Simulation Plots Tab



Table 140 - Simulation Plots Tab Definitions


Motor Position (Default ON) Position of the motor, measured by the feedback device.

Target Position

(Default ON) Position target from motion planner in the controller to the drive.

Load Position Simulated position of the load.

Position

(label 1 in

Figure 177

)

Position (Δ):

Target-Motor

Position (Δ):

Target-Load

(Default ON) Difference between Command Position and Actual Position

(when simulation Position Feedback is the same as Actual Position).

Difference between Command Position and Load Position.

Position (Δ):

Motor-Load

Difference between Actual Position and Load Position.

Motor Velocity (Default ON) Velocity of the motor.

Target Velocity

Velocity command in the drive (output of position loop plus velocity feed forward).

Load Velocity Simulated velocity of the load.

Velocity

(label 2 in

Figure 177

)

Velocity

Reference

Velocity (Δ):

Target-Motor

Velocity (Δ):

Target-Load

Velocity (Δ):

Motor-Load

Velocity command in the drive (magnitude & rate limited)

Difference between Command Velocity and Velocity Feedback (velocity feedback is a filtered derivative approximate of position feedback).

(Default ON) Difference between Command Velocity and Load Velocity.

Difference between Actual Velocity and Load Velocity.

Torque

(label 3 in

Figure 177

)

Target Torque (Default ON) Torque target in the drive.

Motor Torque (Default ON) Actual Motor Torque.

Figure 178 - Position Plots

Figure 179 - Velocity Plots



Figure 180 - Torque Plots

Use check boxes to show or hide the simulation curves. From the color pull-down menu, choose a color for each plot.

Figure 181 - Simulation Plot Pens

The software displays up to four plots at a time. If there are more than four curves, then use pull-down menus to select desired plot. The selected plots are dimmed in the pull-down menus.

Figure 182 - Choose Curves to Plot



3.2.2.4.2.2. Simulation Data

The Simulation Data tab displays the simulation output data in a tabular format and provides data export.

Figure 183 - Simulation Data Tab

Table 141 - Simulation Data Options

Options

Simulation Data Filters

(label 1 in

Figure 183

)

Description

As there are numerous records of simulation output data, the following data filters can be used to view more records.

Time Step

Use to increase or decrease the time step to view records in larger or small time spans.

Time Span

Apply

Define start and end time of the records being displayed in the grid.

Click to see your changes in the data grid.

Data Grid

(label 2 in

Figure 183

)

Export Data

(label 3 in

Figure 183

)

Displays the simulation data records. Up to 10,000 records are shown.

Click to launch the Export Data dialog box (refer to

Figure 184 )

.



You can select the export settings (such as data elements, time step, time span, units, delimiter, and target location for the file export) before exporting the simulation data.

Figure 184 - Simulation Data - Export Data



3.2.2.4.2.3. Control Loop Diagram

The Control Loop Diagram tab is a graphical representation of the control loops.

You can enter loop gains and other parameters, just as in the Control Loop Gains and other Parameters window (refer to page 246 ).

Figure 185 - Control Loop Diagram Tab

If you enter any gains parameters here, it also updates in the

Control Loop Gains and other Parameters

window.

Figure 186 - Updating Loop Gains



3.2.2.4.3. Control Loop Gains and other Parameters

Control loop gains and other parameter windows let you manually enter control loop gains or perform auto-tuning.

Figure 187 - AutoTune Options (expanded)

AutoTune Options simulate the Logix function by setting the Load Inertia Ratio and the appropriate gains based on measured system inertia. As per the Logix convention, there are five different application types for AutoTune. Selecting an application type selects the gain parameters.

Table 142 - AutoTune Options (refer to Figure 187

)

Options

Basic

Constant Speed

Point to Point

Tracking

Custom

Damping Ratio

Position Bandwidth

Description

When selected, position proportional and velocity proportional gains and load inertia ratio are calculated.

When selected, velocity integral and velocity feedforward are calculated apart from the position proportional, velocity proportional, and load inertia ratio.

When selected, position integral is calculated apart from the position proportional, velocity proportional, and load inertia ratio.

When selected, velocity integral, velocity feedforward, and acceleration feedforward are calculated apart from the position proportional, velocity proportional, and load inertia ratio.

Use for custom/manual selection of the gain parameters to be calculated.

The default damping ratio value is 0.8. This is the classic single-overshoot setting. Higher values cause the system to be softer. This may help if the standard value results in an axis that is too hot or even unstable.

This sets to the default for the drive/motor combination selected. It may be overridden downwards to soften the response or get to a stable condition.



You can perform AutoTune in the collapsed state also. This state shows the selected application types and parameters to be autotuned.

Figure 188 - AutoTune Options (collapsed)

Figure 189 - Output Parameters

Table 143 - Output Parameter Options (refer to

Figure 189

)


Load Inertia Ratio Ratio of load inertia over motor inertia.

Torque Offset

Low Pass Filter

Notch Filter

Used to inject a constant torque command into the torque loop, typically used to offset gravity.

Used to limit the torque command frequency response.

Used for eliminating a spot frequency.

When you change parameters in any section, Reset appears in the title bar of that section. For example, the Test Disturbances section is shown in Figure 190 . Click

Reset to reset all parameters to default values.

Figure 190 - Reset Feature



Figure 191 - Position and Velocity Gains

248

Table 144 - Position and Velocity Parameter Options (refer to Figure 191 )


Position Gain

Proportional Gain

Integral Gain

Position proportional gain creates a velocity reference proportional to position error. In Logix this is actually Position Loop Bandwidth (regardless of system inertia). The unit of proportional gain is radians/s.

Position integral gain creates an increasing velocity reference when any position error exists.

Velocity Gain

Integral Hold

Proportional Gain

Velocity proportional gain creates a torque reference proportional to velocity error. In Logix this is actually Position Loop Bandwidth.

Integral Gain

Integral Hold

Velocity integral gain creates an increasing torque reference when any velocity error exists.

When checked, the integral terms are ignored if command velocity is zero.

Figure 192 - FeedForward Options

Table 145 - FeedForward Parameter Options (refer to

Figure 192

)

Options

Velocity Feedforward

Acceleration Feedforward

Description

Velocity feedforward creates a velocity reference equal to the theoretical value required.

It reduces position error to zero at constant velocity.

Acceleration feedforward creates a torque reference equal to the theoretical value required. It reduces position error to zero at constant acceleration.

Figure 193 - Limits

Table 146 - Limits Parameter Options (refer to

Figure 193

)

Options

Position Error Tolerance

Position Lock Tolerance

Description

Two red lines are displayed if the magnification is appropriate.

Two green lines are displayed if the magnification is appropriate. If this value is exceeded, the axis decelerates to zero speed at peak torque. When Position Lock Tolerance is exceeded, a warning icon appears next to it. When you mouse over the icon, a message also appears (Limit for Lock tolerance).



3.2.2.5. Segment Data

Click Segment Data to view various system parameters for each individual profile segment.

Figure 194 - Segment Data Dialog Box

The Initial and Final Velocity, Acceleration, Position, Time, Thrust, and Load values are listed by profile segment in the Segment Data table. Various system parameters are listed for the selected profile segment in the Segment Analysis window. The overall motion profile is displayed in the Segment Profile window.




3.3. Axis Stop

The Axis Stop tab is used to determine the time and distance that the system takes to come to a stop.

Figure 195 - Axis Stop Dialog Box

250

For each profile segment, Motion Analyzer software finds the highest velocity and evaluates the time and distance the axis takes to stop from that speed using the maximum available axis current (for example, at maximum permissible current limit for the axis). Motion Analyzer software displays the worst possible scenario.

3.3.1. Controlled Stop

The critical time and distance for the motion profile for each axis are captured and displayed in the Controlled Stop section of the tab. This gives the machine designer a guide when determining over-travel limits. These figures are a guide and do not necessarily show the worst possible case. In a runaway situation or if the motion programming is faulty, the axis may hit an over travel limit at a higher speed than those used in this calculation. Similarly, if the real load is greater than that used in this calculation, the stopping time and distance will be greater. The machine designer must perform a risk analysis of such situations. The Drive

Capacity (Temp) bar changes color depending on the capacity percentage; for

80%, the bar is yellow, and for 100% the bar is red.

Click Details to view the Controlled Stop Details dialog box. The Deceleration

Distance on both the motor and load sides, Deceleration Time, Amplifier

Utilization, and Energy Absorbed starting and ending values are displayed for each profile segment.


Figure 196 - Controlled Stop Details Dialog Box


Table 147 - Controlled Stop Details Properties (refer to Figure 196

)

Parameters

Decel Distance

Decel Time

Amplifier Utilization

Energy Absorbed

Description

This is the critical deceleration distance. It is common to find that the mechanical design does not allow enough distance to stop, if a fault occurs at the end of normal travel. This display helps to predict the required distances on both the motor side and the load side.

The time required to come to a complete stop.

This mimics the internal drive protection algorithm. In the event that 100% is exceeded, the drive faults and the motor coasts to a stop.

This is an indication of the energy that must be handled during a controlled stop and may help to size dump resistors.

IMPORTANT Amplifier utilization is critical because it may indicate that a bigger drive is necessary to achieve the required stopping time and/or distance.



3.3.2. Resistive Brake Module

Check Resistive Brake Module to enable selection and analysis of resistive brake modules (RBM).

RBM modules provide controlled motor braking by connecting resistors across the windings. An RBM module does not stop the motor if the axis has a thrust, an external force, or a gravity force as a result of being inclined. The RBM module only produces motor torque if the motor is moving and may act as a speed limiter. When this happens, it is essential to use a fail-safe brake. The motor brake may not be sufficient to stop the system and should not be applied when it is in motion.

The stopping behavior depends on the initial velocity, inertia, contactor delay, and the value of resistance in the RBM module. This tab enables you to select the optimum resistive brake module.

Table 148 - Resistive Brake Module Properties (refer to

Figure 195

)


Resistive Brake

Modules

Start Speed

Plot Time

Select the Max. Appl. Speed option if you are sure this value cannot be exceeded.

Select the Max. Motor Speed option for a high level of security. This is generally the worst case scenario.

This sets the time scale for the distance calculation and graphical display. To zoom in on the left-hand end of the graph, decrease the Plot Time. Increase the

Plot Time if the system has not stopped, to evaluate longer stopping times, and to view the ultimate speed when not stopping.

3.3.3. Load Data

Table 149 - Load Data Properties (refer to Figure 195 )


Load Data

Mechanism Data

User Defined

Select this option to use the External Torque and Load Inertia values from the system data that has been entered in previous tabs. This is the torque on the motor produced by any external torque or force.

Select this option to manually enter External Torque and Load Inertia values. In some cases, the maximum inertia/thrust may not coincide with the maximum speed. When this happens, the default (maximum speed and inertia/thrust) may produce an over-cautious solution. Advanced users may want to enter their own value for the inertia and thrust torque (with reference to the motor) for the maximum speed condition.



3.3.4. RBM Selection

Figure 197 - Available Resistive Brake Module Dialog Box

Table 150 - RBM Selection Properties (refer to

Figure 195 )


RBM Selection

Select RBM

Details

Click to produce a list of compatible resistive brake modules, with their associated distances travelled in the Plot Time. You may adjust the Plot Time by entering a new value and clicking Re-Plot. Click each resistive brake module to view the associated Speed versus Time graph. Click Apply when you determine the optimum unit (refer to

Figure 197

).

Click to open the Resistive Brake Module Data dialog box (refer to

Figure 198 ).



Click the Speed-Time, Torque-Time, and Distance-Time tabs to view graphs for the selected resistive brake module. You may also view parameters for a custom resistive brake module.

Figure 198 - Resistive Brake Module Data

Click Product Catalog to view product specifications.

Figure 199 - RBM Module Product Specifications



3.3.5. Apply RBM Selection

The initial period (70 ms) allows for the contactor change-over. The speed may stay the same or increase if there an external load during this time and torque will be zero. The peak torque depends upon the speed and may peak at a medium speed, being less at higher and lower speeds. Check for distance continuing to increase over a long period of time, which indicates a non-stopping condition.

Figure 200 - Axis May Not Stop Message

This error message indicates that the axis speed has not fallen close to zero in the allotted time. This may apply to all resistive brake modules or only some of them.

Increase the allotted time to analyze further. There are several possible outcomes:

•

Axis may stop with a longer time.

•

Axis speed may reduce but not stop. Be careful to note if the axis speed has really become zero and not a low speed—make sure that the position graph is not increasing.

•

Axis speed may increase to a sustained higher level.

•

Axis may run-away; the speed may continue to increase.



3.4. Life Estimate

The Life Estimate tab provides information on the life and bearing load utilizations for electric cylinders.

Figure 201 - Life Estimate Dialog Box

256

Table 151 - Life Estimate Properties

Parameters

Operating Conditions

(label 1 in

Figure 201

)

Normal Forces and Moments

(label 2 in

Figure 201

)

Description

The Hours per Day, Days per Week, and Weeks per Year assumptions are listed here. You can adjust these values by clicking Change Operating Conditions.

To calculate the cylinder bearing load utilization, it is necessary to specify the mechanical forces and moments applied to the moving part of the cylinder. All loads must be separately guided and supported.

Loads should align along the line of thrust throughout the complete stroke of the cylinders. If residual radial or torsional loading cannot always be eliminated, enter these expected values here to help determine if the loading exceeds the recommended limits of the cylinder. If so, counter measures such as a rod-guide accessory and/or an adjustment to loading and mechanical connections may be necessary.

These values are not entered if a rod guide is used.

Normal Forces

These forces are applied at right angles both horizontally and vertically to the end of the cylinder as shown in the diagram.

Normal Distances These distances are from the end of the cylinder where each normal force is applied.

Moments

These moments are applied to the cylinder in the three planes. They are in addition to any normal forces.

Life Estimate

(label 3 in

Figure 201

)

Bearing Load Utilization

(label 4 in

Figure 201

)

Lubrication Schedule

(refer to

Figure 202

)

Strip Seal Life Estimate

(refer to

Figure 203

)

The roller screw or ball screw life estimate (depending on the linear actuator type) is listed here.

This information is available for Bulletin MPAI and MPAR linear actuators. The normal force and moment utilization (Fz, Fy, Mz, My) and moment utilization (Mx) are displayed here as percentages.

Applies to Bulletin MPAI electric cylinders.

Applies to Bulletin MPAS linear stages. The Slide Bearing Life Estimate and Strip Seal and Cable Track life estimate is also listed.



Figure 202 - Lubrication Schedule (Bulletin MPAI actuators only)

Figure 203 - Strip Seal Life Estimate (Bulletin MPAS linear actuators only)



3.5. Configure Axis BOM

You can complete the Bill of Materials (BOM) for each axis after fully sizing the application by clicking on the Configure Axis BOM tab. You can configure the motor encoder, and choose connectors, cables, and drive accessories here.

Many options are already configured in Motion Analyzer software, as these are required for sizing and cannot be changed in the BOM. These options include, for example, brake, cover, rod guide, or blower.

Throughout the steps, use More Info or the Product Details links for more information or refer to the Kinetix Motion Control Selection Guide, publication

GMC-SG001 , to access the relevant product specifications.

Figure 204 - Configure Axis BOM Dialog Box



Table 152 - Configure Axis BOM

Parameters

Step 1 Motor/Actuator


Description

Select the options required. Options that are not available are dimmed. Standard options are shown by default.

Encoder Options

Brake and Key

From the Encoder Options pull-down menu, choose the encoder type for your motor.

The brake is chosen during sizing on the Motor tab. The shaft key will be selected if it is available.

Mounting

Flange

Some motors have different mounting options.

Miscellaneous

Options

Different motors and actuators have various options that can be selected. Some options such as blowers and covers, for example, affect sizing and have been selected in the sizing process.

Select motor and actuator accessories. The rod guide for electric cylinders was selected during sizing.

Step 2

Accessories

Step 3

Axis Module/Drive/IAM

Check for connector kit.

Step 4

Motor/actuator power cable

Step 5

Motor/actuator feedback cable

Step 6

Motor/actuator brake cable

Step 7

Resistive brake module

Step 8

Resistive brake module cables

Check non-flex or continuous-flex cable and cable length options. The length selected for the power cable is used for the other cables, unless the lengths are individually changed.

Check non-flex or continuous-flex cable, cable length, and flying-lead or connector at drive-end options.

Check non-flex or continuous-flex cable and cable length options. For most motors, separate brake cable is not required because brake wires are included in the power cable.

Resistive Brake Module for the application is selected in the Axis Stop tab on page

250

and cannot be changed here.

Specify cable AWG size and cable length options.



3.6. Super Review

Click the Super Review tab to review the overall application parameters that were entered or calculated in the previous tabs.

There are two options for viewing the Super Review dialog box.

Table 153 - Super Review Tab Options

Parameters

Summary View

Details View

Description

Provides summary data and plot profile for the application.

Provides segment data in table form from all review locations.

Page

260

265

3.6.1. Summary View

The summary view displays data and the plot profile of your choice.

Figure 205 - Summary View Dialog Box

260

Table 154 - Summary View Properties

Parameters

Review Location

Summary Data

Plot

Description

From the Review Location pull-down menu, choose the point in the system where you would like to review the data.

These parameters are listed for the chosen Review Location:

• Maximum Velocity

• Total Time

• Maximum Inertia

• Maximum Acceleration

• Total Distance

• RMS (root mean squared) Torque

Select the graph type to display:

•

Profile/Load-Time Graph on page 261 .

•

Show Force-Speed Graph

on

page 263

.

•

Show Power-Speed Graph

on

page 263

.



3.6.1.1. Profile/Load-Time Graph

The Profile/Load-Time graph is divided into two sub-windows. In the explanation that follows, the Show Profile/Load-Time graph is used in the example.

The Plot Parameters sub-window appears to the left of the Main Profile Plot window. Click the arrows, left of the Main Profile Plot window, to open it. Click the arrows again to close the window.

Clicking the motion curves (for example, Distance or Velocity) toggles them on and off. From the motion curve pull-down menu, you can change the color for the curve in both the Main Profile Plot window and the Segment Plot window.

Figure 206 - Plot Parameters

In addition, as you hover over the Main Profile Plot window with the mouse pointer, the Plot Parameters sub-window provides a display of the numeric values of the time (x-axis), and active motion curves (y-axis) associated with the mouse pointer position.

Figure 207 - Main Profile Plot X and Y-axis Values



The Profile Zoom Plot sub-window appears below the Main Profile Plot window.

Click the arrows, below the Main Profile Plot window, to open it. Click the arrows again to close the window.

The Profile Zoom Plot window contains a slider that you can move along the motion profile by clicking and dragging it. As the slider moves, the Main Profile

Plot window displays a magnified view of the portion of the plot that is selected by the slider. You can resize the slider by clicking and dragging from either edge.

Figure 208 - Profile Zoom Plot Window

Right-click the Profile Zoom Plot sub-window to display these options.

Figure 209 - Profile Zoom Plot Options

Table 155 - Profile Zoom Plot Options

Parameters

Grid

Color

Description





3.6.1.2. Show Force-Speed Graph

The force versus speed curve is displayed below.

Table 156 - Show Force-Speed Graph Options

Parameters

Force-Speed Options

RMS Force

Plot Force Curve

Description

Select how to view the data: Summary, All Segments, or Elementwise.

Check to include the RMS (root mean squared) force on the plot.

Check to display the Force Curve.

3.6.1.3. Show Power-Speed Graph

The power versus speed curve is displayed below.

Table 157 - Show Power-Speed Graph Options


Power-Speed Options Select how to view the data: Summary, All Segments, or Elementwise.

Plot Power Speed Curve Check to display the Power Speed Curve.

Right-click one of the plots to choose any of the following options.



Figure 210 - Segment Plot Dialog Box

Table 158 - Graph Options

Parameters

Reset Zoom

Zoom

Grid

Color

Show Curve

Show Y Axis

Description


Lets you zoom in 1x, 2x, 6x or 8x.


Adjust the background, curve and grid colors.

Select which curves you would like to display on the plot (for example, Distance or Velocity).

Toggle the Y-axis labels on and off when more than one curve is shown. This option is only available on the Profile Plot.



3.6.2. Details View

The Details view of the Super Review tab provides a table that contains position, time, velocity, acceleration, inertia, and various torque values for each Review

Location (Load, Motor, and Drive, for example) and for individual profile segments.

Figure 211 - Details View Dialog Box

Table 159 - Details View Options

Parameters

Select Segment

Export Data

Description

From the pull-down menu, choose All Segments or a specific profile segment to view in the table. You can view the segment data for each Review Location by clicking + to expand the

Review Location.

Click the Export Data link to save the Super Review data as a CSV (Comma Separated

Variable) file.



Notes:


Just Quote

Topic

Axis View

IPIM Power Supply/ Accessories View

Power Supply and Accessories

Page

268

272

273

Chapter

4


Chapter 4 Just Quote

4.1. Axis View

For each axis, enter the required drive family, motion type, and motor/actuator series and associated optional components by clicking BOM Configuration.

Figure 212 - Axis View Dialog Box

Table 160 - Drive and Motor/Actuator a Families

Description Parameter

Product Family

(step 1 in

Figure 212 )

Motion Type

(step 2 in

Figure 212 )

From the pull-down menu, choose the drive family for your motion application.

• Rotary Motion includes, for example, low-inertia servo motors and direct-drive motors

• Linear Motion includes, for example, linear motors, linear stages, and electric cylinders

Motor/Actuator

Series

(step 3 in

Figure 212 )

MP-Series includes:

• Bulletin MPL, MPM, MPF, MPS rotary motors

• Bulletin MPAS and MPMA linear stages

• Bulletin MPAR and MPAI electric cylinders

TL-Series includes:

• Bulletin TL and TLY rotary motors

• Bulletin TLAR electric cylinders

Integrated Drive-Motor include Bulletin MDF rotary drive-motor units


Figure 213 - Axis View (continued)

Just Quote Chapter 4

Table 161 - Motor/Actuator Options

Parameter

Options

Cat. No.

Description

From the pull-down menus choose the options available for your rotary or linear motion product.

Scroll to select from the valid catalog numbers for your rotary or linear motion product.


Table 162 - Axis Module Options

Parameter

Cat. No.

Connector Kits

Description

Scroll to select from the valid servo drive catalog numbers.

Check to indicate the connector kit for your IAM (converter and inverter) or AM (inverter only) modules.




Table 163 - Motor Power Cable Options

Parameter

Motor Power Cable

(standard)

Motor Power Cable

(continuous-flex)

Description

Check and from the pull-down menu, choose the length for your drive and motor/actuator

(standard) power cable.


(continuous-flex) power cable.


Table 164 - Motor Feedback Cable Options

Parameter

Motor Feedback Cable

(standard)

Description


(standard) feedback cable with premolded connector on the drive end.


(standard)


(standard) feedback cable with flying-leads on the drive end.


(continuous-flex)


(continuous-flex) feedback cable.




Table 165 - Motor Brake Cable Options



(standard)


(standard) brake cable.


(continuous-flex)


(continuous-flex) brake cable.


Table 166 - Resistive Brake Module (RBM) Cable Options

Description Parameter

Resistive Brake

Module

Resistive Brake

Module Cable

Select none, or the catalog number for your motion application.


(standard) RBM cable.

When finished click System View, or use the Axis View pull-down menu to configure the next axis.



4.2. IPIM Power Supply/

Accessories View

Power Supply Accessories view of an IPIM module helps you select options for hybrid and network lengths, hybrid coupler cables, and bulkhead adapters.

Figure 219 - IPIM Module Selection

Table 167 - Configure IPIM Module BOM Tab Descriptions

Options

Step 1 (

Step 2 (

Step 3 (

Figure 219

Figure 219

Figure 219

)

)

)

Description

IPIM module

Hybrid cables

Network cables


Hybrid coupler


Network bulkhead adapter

IPIM module selected on the IPIM Module tab is displayed here.

Hybrid cable lengths selected on the Cable Lengths tab are displayed here.

Network cables can be routed with the hybrid cables, so network cable lengths should be the same as the hybrid cable. The IPIM-to-IDM1 cable must have a straight connector to the IPIM module.

The hybrid coupler connects between two hybrid cables, to bypass an IDM unit.

Use the network bulkhead adapter for securing network cables as they pass through the cabinet.



4.3. Power Supply and

Accessories


Click Power Supply/Accessories to select all the power supply components. This includes any back plane, fuse, contactor, LIM module, or Shunt module. Some filtering of suitable units is arranged according to the other components selected.

The power rail field populates based on the number of slots required.



Notes:


Index

A

AC sharing configuration

56

acceleration

168

actuator tab

225

additional parts tab

39

additional resources

5

advanced templates

104

allocate

16

analysis tab

33

application template

96

advanced four bar linkage

114

inertia calculator

105

winder/unwinder

112

applied force

83

automatic profile

171

selection

207

autotune

246

axis histograms

30

,

47

of rotation

91

options

269

stop

250

controlled stop

250

load data

252

resistive brake module

252

,

253

summary image

25

B backlash

234

ball screw life

62

bearing life

62

belt drive

180

BOM tab

40 ,

76

C carriage cut off

100

center driven

113

chain and sprocket

182

coefficient of friction

83

comments window

154

complex rotary load template

90

crank

93

unbalanced load

91

user defined

90

compliance

235

compute transmission data using inertia and ratio

193

number of teeth

195

pitch circle diameter

194

configuration summary tab

37

configure axis BOM

258

IPIM BOM tab

45

power supply BOM tab

35

control loop diagram

245

gains

246

controlled stop

250

conventions

5

counterbalance

84

force

85

mass

85

coupling type backlash

234

compliance

235

rigid coupling

234

crank

93

cruise/dwell

170

cut length analysis

221

cutter knife drive

102

D damping ratio

235

data analysis toolbar

218

cut length analysis

221

dynamic simulation

230

efficiency analysis

227

energy tab

229

power tab

228

ratio analysis

220

ratio/design analysis

219

segment data

249

tolerance/design analysis

222

torque tab

227

DC sharing configuration

52

deceleration

168

define your profile

139

less options profile editor

140

more options profile editor mode

142

derived parameters

153

details view

265

download Motion Analyzer

5

dwell time

140

dynamic simulation

230

control loop gains

246

simulation analysis

239

simulation inputs

231

E efficiency analysis

227

electric cylinders

186

selection

199

empty diameter

113

inertia

113

end effector

82

energy tab

34 ,

229


Index

276 error list window

155

explorer view

78

export/import tab

65

axis mapping

67

export mapping

67

export options

66

RSLogix 5000

65

external force

147

F feedforward

248

file tab

15

force counterbalance

85

four bar linkage

114

from SolidWorks

120

G gearbox data

196

graph tab

226

view

28

graphical view

17

group view

22

H help tab

76

home tab

16

axis summary image

25

graph view

28

graphical view

17

power interface module (IPIM) view

20

power rail view

18

group view

22

multiple profile view

26

top band fields

27

power rail image

24

power supply/accessories view analysis tab

33

configure IPIM BOM tab

45

configure power supply BOM tab

35

energy tab

34

IAM control power tab

32

IAM/shunt tab

31

IDM cable length tab

43

IDM control power tab

44

IDM power data tab

41

IPIM selection tab

42

multi-axis drives

29

power data tab

30

single-axis analysis tab

48

single-axis config PS BOM tab

50

single-axis drive systems

46

single-axis energy tab

49

single-axis power tab

47

single-axis shunt tab

47

system BOM view

36

system bill of materials view additional parts tab

39

BOM tab

40

configuration summary tab

37

software and accessories tab

38

I

IAM control power tab

32

IAM/shunt tab

31

IDM cable length tab

43

control power tab

44

power data tab

41

inclination

83

independent axis workflow

122

index advance

173

profile

171

type

140

inertia calculator

105

less options inertia mode

106

more options inertia mode

107

SolidWorks import

109

inter-dependent axis workflow

131

IPIM selection

272

selection tab

42

J jerk

169

,

177

just quote

13

accessories view

IPIM selection

272

axis view axis options

269

motor brake cable options

271

motor feedback cable options

270

motor power cable options

270

motor/actuator options

269

product family

268

RBM cable options

271

power supply accessories view

273

just quote mode

22

L lead screw

181

less options inertia mode

106

less options profile editor

140

life estimate

256

operating conditions

62

limits

248

linear load

83

counterbalance

84

motors

184

stages

187

thrusters

189

load data

252

Motion Analyzer

233


Index load type tab

82

,

224

application template

96

advanced

104

carriage cut off

100

cutter knife drive

102

power/speed

118

press roll feed

97

from SolidWorks

120

linear load

83

rotary complex load

87

rotary load

86

Logix elements

174

motor brake cable options

271

feedback cable options

270

power cable options

270

selection

196

motor/actuator options

269

motoring

30

,

47

move distance

140

move time

140

multiple profile view

26

M

MAM profile

176

manual selection

208

mass counterbalance

85

mechanism type

178

belt drive

180

chain and sprocket

182

electric cylinders

186

lead screw

181

linear motors

184

stages

187

thrusters

189

rack and pinion

183

menu bar

14

mode

BOM tab

76

explorer view

78

export/import tab

65

file tab

15

help tab

76

home tab

16

preferences tab

62

just quote

22

less options inertia

106

less options profile editor

140

more options inertia

107

more options profile editor

142

select and size

22

more options profile editor

142

comments window

154

derived parameters

153

error list window

155

profile grid

152

profile plot

149

profile toolbar

145

segment load window

147

segment parameters window

167

segment plot window

148

Motion Analyzer download

5

existing

13

just quote

13

new

13

motion axis move (MAM)

176

N natural frequency

235

Q quick access toolbar

14

R rack and pinion

183

ratio analysis

220

ratio/design analysis

219

RBM cable options

271


P payload power animation

147

mass

147

data tab

30

tab

228

power interface module (IPIM) view view

20

power rail image

24

view

18

power sharing configuration

51

power supply accessories view

273

power/speed template

118

preface additional resources

5

conventions

5

preferences tab

62

preferred product

210

preferred product status

210

press roll feed

97

profile automatic

171

grid

152

MAM

176

mirror

113

plot

149

tab

223

toolbar

145

trapezoidal

171

triangular

171

ProposalWorks application

210

277

Index

278 regenerating

30

,

47

reported application inertia

212

reported motor inertia

212

resistive brake module

252

selection

253

rigid coupling

234

roller screw life

62

rotary complex load

87

rotary load

86

S-curve

113

S segment data

249

load window

147

parameters window acceleration/deceleration

168

cruise/dwell

170

index advance

173

index profile

171

Logix elements

174

motion axis move (MAM)

176

start condition

168

plot window

148

select and size mode

22

selection

206

automatic

207

manual

208

servo drive selection

201

simulation analysis

239

control loop diagram

245

simulation data

243

simulation plots

240

data

243

inputs

231

Motion Analyzer load

233

SolidWorks load

236

plots

240

single-axis analysis tab

48

config PS BOM tab

50

drive systems

46

energy tab

49

power tab

47

shunt tab

47

sizing and selection

206

sizing your system axis stop

250

configure axis BOM

258

define your profile

139

electric cylinders selection

199

life estimate

256

load type tab

82

mechanism type

178

motor selection

196

selection

206

servo drive selection

201

solution

208

torque/speed curve

211

super review

260

transmission

191

smoothness

140

software and accessories tab

38

software requirements

5

SolidWorks software import

109

independent axis workflow

122

inter-dependent axis workflow

131

load

236

solution

208

data analysis toolbar

218

start condition

168

stiffness

235

strip seal life

62

summary view

260

super review

260

details view

265

summary view

260

surface driven

113

system BOM view

36

T templates

90

tolerance/design analysis

222

actuator tab

225

graph tab

226

load type tab

224

profile tab

223

torque tab

227

torque/speed curve

211

transmission

191

compute using inertia and ratio

193

number of teeth

195

pitch circle diameter

194

trapezoidal profile

171

triangular profile

171

U unallocate

16

unbalanced load

91

unwind

113

user defined

90

W web speed

113

tension

113

wind

113

winder/unwinder

112

zoom

140

Z


Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products.

At http://www.rockwellautomation.com/support , you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://www.rockwellautomation.com/knowledgebase for FAQs, technical information, support chat and forums, software updates, and to sign up for product notification updates.

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer

TechConnect SM support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://www.rockwellautomation.com/support/ .

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html

, or contact your local Rockwell

Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

United States

Outside United States

Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process.

Please contact your local Rockwell Automation representative for the return procedure.

Documentation Feedback

Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002 , available at http://www.rockwellautomation.com/literature/ .

Publication MOTION-UM004B-EN-P - October 2012

Supersedes MOTION-UM004A-EN-P - May 2012 Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

Motion Analyzer Software

User Manual

Motion Analyzer Software

Important User Information

New and Updated

Information

Summary of Changes

Notes:

Preface

About This Publication

Who Should Use This Manual

Conventions Used in This

Manual

System Requirements

Additional Resources

Notes:

Welcome to Motion Analyzer Software

Chapter

1.1. Before You Begin Sizing

1.2. Menu Bar and Quick

Access Toolbar

1.3. Explorer View

Notes:

Sizing Your System

Chapter

2.1. Identify Your Load

2.2. Define Your Profile

2.3. Specify Your Linear Load

Mechanism

2.4. Specify Your

Transmission

2.5. Choose Your Motor

Series

2.6. Choose Your Electric

Cylinder Series

2.7. Choose Your Drive

Family

Notes:

Understanding Your System Solution

Chapter

3.1. Selection

3.2. Solution

3.3. Axis Stop

3.4. Life Estimate

3.5. Configure Axis BOM

3.6. Super Review

Notes:

Just Quote

Chapter

4.1. Axis View

4.2. IPIM Power Supply/

Accessories View

4.3. Power Supply and

Accessories

Notes:

Index

Rockwell Automation Support

Documentation Feedback

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