Emerson PCM-22 Manual

Rotary knife controller

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Page 1 PCM-22 Rotary Knife Controller Information furnished by EMERSON Motion Control is believed to be accurate and reliable. However, no responsibility is assumed by EMERSON Motion Control for its use. EMERSON Motion Control reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice.
Page 2 © 1998 EMERSON Motion Control. All Rights Reserved. Document Number: 400274-01 No part of this manual may be reproduced by any means without the written permission of EMERSON Motion Control. EMERSON Motion Control is a registered trademark of EMERSON ELECTRIC.
Page 3 Customer Services EMERSON Motion Control offers a wide range of services to support our customers’ needs. Listed below are some of these services. Application Engineering (612) 474-1116 E-Mail: [email protected] An experienced staff of factory application engineers provide complete customer support for tough or complex applications. Our engineers offer you a broad base of experience and knowledge of electronic motion control applications.
Page 4 PCM-22 Rotary Knife Controller Service Support Check List To ensure the most timely and efficient support possible, please have the following items ready before calling for Service Support. 1. The model and serial number(s) of your FX Amplifier(s) and manual(s).
Page 5: Table Of Contents
Maximum Master Velocity..................19 Sensors ........................20 Selection ......................20 Sensors: When, Where and Why ................21 Installation Guidelines Attaching the PCM-22 Module ................... 23 I/O Wiring ........................23 Input Wiring ......................23 Output Wiring...................... 23 P/N 400274-01 Revision A7...
Page 6 PCM-22 Rotary Knife Controller PCM-22 Software Setup Programming the PCM-22 ...................25 Master Axis .........................29 Description ......................29 Master Axis Setup....................31 Master Cycles ......................37 Master Cycle Number....................37 Master Cycle Length .....................37 Master Phase Distance ..................40 Master Cycle Defined By Sensor ................40 Follower Cycles ......................42 Cycle Number .......................43...
Page 7 TC5 - Working Ratio Change Increment ..............95 Appendix B - PCX Cycle Screens to FX Command Cross Reference PCM-22 Master Cycles Screen ..................96 PCM-22 Follower Cycles Screen ................. 97 Appendix C - Master Signal Components Encoder Operation ...................... 98 Encoder to Drive Cables....................
Page 9: Introduction
The PCM-22 Rotary Knife Controller is an application module that attaches to any EMERSON Motion Control FX positioning servo drive. The PCM-22 enables a FX drive to automatically calculate and create motion profiles using sensor information and/or user-defined parameters. The PCM-22 is designed to maintain a phased relationship between the motor axis (referred to as the Follower axis) and the motion of an independent axis (referred to as the Master axis).
Page 10 PCX. The PCM-22 will automatically make adjustments to compensate for the difference in length. These capabilities allow the PCM-22 to produce one or more cycles of motion for every individual cycle of motion produced by the Master axis. The PCM-22 will position the Follower axis to a corresponding position and velocity relative to the Master axis while it is executing a cycle.
Page 11: Features
• Interactive cycle diagnostic capabilities. • Always uses linear ramps for Homes, Indexes, Jogs and Follower cycles for increased accuracy. Note: Not all of the features available with the PCM-22 will be used in every application. For example: There are 15 programming functions available with the PCM-22 however, a typical rotary knife program will use only a few of them.
Page 12: Terminology
Follower Cycle Length The Follower Cycle Length (also called the Follower Length) is the distance, in user units, that the Follower axis (PCM-22/FX drive) moves during each Follower cycle. It is the distance between two Follower cycle zero positions. See Figures 2 and 3.
Page 13: Working Segment
Introduction FOLLOWER LENGTH CYCLE MASTER LENGTH ONE TO ONE RELATIONSHIP (IGNORING SCALE) BETWEEN MASTER LENGTH AND FOLLOWER LENGTH. Figure 3 Relationship Between the Master Cycle Length and the Follower Cycle Length If the Follower Cycle Defined By Sensor is “ No” ; when the Follower cycle starts, it is at the Follower zero position.
Page 14: Variable Segment
Working Segment. This is where all cycle adjustments occur. See Figures 4, 5, 6 and Cycle Inter-Relationships. WARNING! When designing a PCM-22 system, the peak acceleration and the peak velocity required during the Variable Segment must be calculated at the maximum process speed with the shortest Master Length spacing.
Page 15: Cycle Drop Out Position
Introduction Cycle Drop Out Position The Cycle Drop Out Position is the position exactly opposite the Cycle Point. While Cycle Drop Out input function is active, the Follower will complete its current cycle and decelerate to this position and hold there. See Figure 5, the Cycle Drop Out input function, Cycle Inter-Relationships, Homes and the Follower Zero Position.
Page 16: Phase
Figures 3, 4 and 6 show a phase relationship of zero. Average Length The PCM-22 uses continuous averaging when an axis is defined by sensor. Continuous averaging provides increased stability by incorporating every length into the average, starting from the initial Follower Cycle Length or Initial Master Length.
Page 17 Introduction For example: If eight is entered here the new average Follower Length calculated by the PCM would be: Current *7) + New Average Length Averaging It takes at least three times the averaging number of cycles on an axis to “...
Page 19: Theory Of Operation
PCM-22 monitors the Zero Master Cycle and Zero Follower Cycle sensors of both the Master and the Follower axes. If the Follower axis does not use a sensor then the PCM-22 will use the Follower Cycle Length parameter entered and only correct for Following Error.
Page 20: Master Cycle Defined By Sensor Mode
Master Cycle Not Defined By Sensor Mode If the Master is Not Defined By Sensor, the user entered Master Cycle Length will be used by the PCM-22. No corrections to the Follower axis’ motion profile will be made for product or encoder slippage in this mode.
Page 21: Resetting The Master Cycle Processing
Automatically Resetting the Master Processing • If the PCM-22 has been powered-up but has not yet executed a Follower cycle, it is executing the Master Cycle 0 data definition. The first time after power-up the Y Execute Follower Cycle program step is executed in a PCX program, the Master processing will be reset.
Page 22: Manually Resetting The Master Processing
Manually Resetting the Master Processing Manually Resetting the Master Cycle Processing is particularly useful for troubleshooting product handling (slippage or registration) issues. The PCM-22 provides two ways for resetting the Master processing manually by: • Writing the MF serial command.
Page 23: Starting A Follower Cycle
Working Segment. If this is not possible (i.e., the start-up distance is longer than the first product position), the PCM-22 will check the second product position. If it can not make the second product position, it will check the third and so on, until the PCM-22 finds a product position that will allow the Follower axis to reach the product’...
Page 24: Homes And The Follower Zero Position
Follower cycle will start. If this is not the actual Follower zero position and the Follower cycle is defined by sensor, the PCM-22 will perceive this as an error and correct for it. Indexes and the Follower Zero Position An index may be used instead of a home to move the Follower axis to the Follower zero reference position.
Page 25: Cycle Inter-Relationships
Cycle Inter-Relationships Every cycle has certain relationships pertaining to the Working Segment. These relationships must be maintained for the PCM-22 to execute the motion profile required by the Follower axis for each product on the Master axis. Please refer to the Terminology section for clarification of terms.
Page 26: Operational Timing
In both cases, all motion profile changes (user requested changes, learned length and/or phase variations) occurring before the Cycle Point will be applied when the PCM-22 calculates the next Working Segment location. When the Follower reaches the end of the current Working Segment, the new motion profile is used to move to the next Working Segment.
Page 27: Maximum Master Velocity
Theory of Operation Maximum Master Velocity For every set of Master and Follower cycle parameters, the user must limit the maximum velocity of the Master so that the maximum velocity of the Follower is not exceeded. This is critical for product lengths shorter than the Follower Cycle Length.
Page 28: Sensors
1 and 2. Selection The PCM-22 reacts to learned sensor information by adjusting the motion of the Follower to match the Master axis. If the sensor information is inaccurate or not consistent, it will be reflected in the accuracy of the Follower positioning.
Page 29: Sensors: When, Where And Why
The Master sensor, ideally, should be positioned between one and two Average Master Lengths away from the Cycle Point to minimize the effects of product slippage and to allow the PCM-22 to correct for any phase variation on that product. See Operational Timing.
Page 30 PCM-22 Rotary Knife Controller For example: The Follower axis is moving at a specific acceleration and its sensor has a response time (R.T.) of 1000 Hz (0.001 seconds). The acceleration and response time effects on sensor accuracy are shown in the following table.
Page 31: Installation Guidelines
Installation Guidelines Installation Guidelines Attaching the PCM-22 Module PCM modules attach to the front of any FX amplifier with two locking arms. All electrical connections (except I/O) are made using the 48 pin connector. All PCM modules are equipped with eight input lines and four output lines, doubling the I/O capability of the standard FX drive.
Page 32 PCM-22 Rotary Knife Controller PCM MODULE 48 PIN CONNECTOR INPUTS/OUTPUTS EXAMPLE A: SOURCING INPUT EXTERNAL SUPPLY(10.5 to POWER 30)VDC INPUT SWITCH EXAMPLE B: SINKING INPUT EXTERNAL INPUTS SUPPLY(10.5 to POWER 30)VDC INPUT SWITCH EXAMPLE A: SOURCING OUTPUT EXTERNAL SUPPLY(10.5 to...
Page 33: Software Setup
PCM-22/FX amplifier combination using PCX 7.x software. Programming the PCM-22 The first step in programming your FX drive with a PCM-22 is to configure the drive using the 5 (7 for 525 PMC) menu options in the Drive Configuration screen. The Drive Parameters, Limits, Inputs and Outputs screens are explained in the Software Setup and Operation section of the 230V FX Drives Setup and Programming Operator’...
Page 34 PCM-22 Rotary Knife Controller Drive Setup Define Drive Programming Motion Configuration Drive Parameters Master Homes Axis Limits Indexes Master Input Cycles Functions Output Follower Cycles Functions Suspend Figure 14 PCX Hierarchy Diagram #1 Initialize Memory Operations Entire Memory Program Data...
Page 35 Operation manual as appropriate. 1. Drive Parameters: The first step in setting up the PCM-22 is to define the parameters in the Drive Parameters screen. A description of the parameters in this screen can be found in the Software Setup and Operation section of the 230V/460V FX Drives Setup and Programming Operator’...
Page 36 PCM-22 Rotary Knife Controller 6. Homes and Indexes: Determine the type of Home or Index reference move and other motion operations as needed. See Homes and the Follower Zero Position and Homes and the Follower Zero Position.. The Homes and Indexes screens are found by selecting Drive Setup then Define Motion from the PCX menu.
Page 37: Master Axis
Signal Polarity Signal Interpretation Sync Output Signal from In addition to running Cycle Profiles, the PCM-22 also has the ability to run synchronized Homes, Indexes and Jogs. The remaining parameters on this screen are listed below and used for these synchronized operations.
Page 38 PCM-22 Rotary Knife Controller WARNING! The maximum Master axis frequency into the PCM-22 module must not exceed 210 kHz (210,000 steps/second). © EMERSON Motion Control...
Page 39: Master Axis Setup
Select the origin of the synchronization (also referred to as “ sync” ) signal (Drive or Encoder) used for Master axis positional information. When Drive is selected, the Follower axis (PCM-22) is receiving its synchronization source from a FX/DX upstream drive, the Counts Per Revolution becomes 4096 counts per revolution.
Page 41 Signal Interpretation The signal interpretation feature allows you to define how the Follower reacts to clockwise and counterclockwise motion of the synchronization source. WARNING! The COMP+ mode must be used when running Follower Cycles on the PCM-22. P/N 400274-01 Revision A7...
Page 42 PCM-22 Rotary Knife Controller The following signal interpretation modes apply to all the synchronization modes of operation. Mode 1 (+ and -): When the Master axis moves either CW or CCW, the Follower axis will move in its commanded direction. If the Master axis changes direction the Follower axis will continue in the original commanded direction.
Page 43 PCM-22 Software Setup WARNING! The maximum frequency into the PCM-22 module must not exceed 210 kHz (210,000 steps/second). Sync Velocity User Units This parameter sets the units to be associated with all sync velocities. User units can be any three letter combination, such as IPS (inches per second), RPM (revolutions per minute), FPM (feet per minute), etc.
Page 44 PCM-22 Rotary Knife Controller   A p p l i e d V o l t a g e   A c t u a l T o r q u e M a x T o rq u e ...
Page 45: Master Cycles
Master Cycles A Master Cycle Length is defined as the distance between successive Master zero positions. The FX drive, with the PCM-22 acting as the Follower axis, will produce one or more cycles of motion for every cycle produced by an independent (Master) axis while maintaining a phase relationship.
Page 46 When the Master Cycle is Defined by Sensor and the distance from the last Zero Master Cycle sensor input is greater than the 150 percent of Average Master Length, the PCM-22 will assume that the Master axis target was missed. If so, the sync position from the last sensor plus the Average Master Length will be used.
Page 47 WARNING! The Master Length Lower Limit must be large enough for the PCM-22 Follower axis to be able to perform the next cycle. The PCM-22 needs to be able to reach the velocity required to handle this short product length. See Operational Timing and Maximum Master Velocity.
Page 48: Master Phase Distance
PCM-22 Rotary Knife Controller Master Phase Distance The Master Phase Distance is the distance that determines how far the Master zero position lags behind the Master Cycle Point. If the Master Phase Distance is longer than the Average Master Length, the Average...
Page 49 When an input is received from the Zero Master Cycle sensor input and a difference is found to exist between the Current Average Master Length and the length determined by the new sensor input, the PCM-22 corrects for a percentage of that difference in the next Master cycle.
Page 50: Follower Cycles
The PCM-22 allows the drive to position and maintain a phase relationship of its motor to an independent axis. The FX drive, with the PCM-22 acting as the Follower axis, will produce one or more cycles of motion for every cycle produced by the Master axis.
Page 51: Cycle Number
When an input is received from the Zero Follower Cycle sensor input and a difference is found to exist between the current average Follower length and the length determined by the new sensor input, the PCM-22 corrects for a percentage of that difference in the next Follower cycle.
Page 52: Follower Length Upper Limit
When the Follower Cycle is Defined By a Registration Sensor and the distance from the last Zero Follower Cycle sensor input is greater than the 150 percent of Average Follower Length, the PCM-22 will assume that the Follower axis target was missed. If so, the sync position from the last sensor plus the Average Follower Length will be used.
Page 53: Follower Length Lower Limit
PCM-22 Software Setup will be activated while the condition is occurring. See the Follower Sensor Missing output function, Figure 25 and the CQ serial command. WARNING! Follower Sensor Missing operation is independent of the Follower Sensor Valid Zone. When this condition occurs, it is possible to get...
Page 54: Cycle Defined By Registration Sensor
PCM-22 Rotary Knife Controller Cycle Defined By a Registration Sensor This parameter determines if the Follower Length and position are defined by Zero Follower Cycle sensor inputs “ Yes” , or if not Defined By a Registration sensor “ No” .
Page 55: Phase Correction Limit
Average Length and the length determined by the new Zero Master Cycle or Zero Follower Cycle sensor input (i.e., the measured length). The PCM-22 uses a percentage of that difference to correct for the phase variation in the next corresponding Master or Follower cycle.
Page 56: Phase Correction Deadband
PCM-22 Rotary Knife Controller Phase Correction Deadband This is a +/- value. If the phase variation is outside this range, it will be corrected for. The phase variation will be ignored if it is within this range. This is important because even small corrections can affect consistency at higher speeds.
Page 57: Cycle Count
PCM-22 Software Setup When the batch counter reaches the programmed batch count, the Batch Count Reached output is activated and the batch counter is cleared. The output will be de-activated automatically on the next Cycle Count. The batch counter may also be cleared by the Reset Batch Counter input function 75.
Page 58: Working Ratio
PCM-22 Rotary Knife Controller The largest Working Segment value allowed is: Master Length Lower Limit Working Segment ≥ Working Ratio See Figures 4, 5 and Cycle Inter-Relationships. Note: The Working Segment may need to be reduced, the product speed reduced or the Working Ratio may need to be increased if there is a significant inertial load mismatch on the motor.
Page 59: Offset/Phase Fine Increment
PCM-22 Software Setup Offset/Phase Fine Increment This parameter is the amount of adjustment which occurs in the next cycle when the Working Offset Increment / Working Offset Decrement or Master Phase Increment / Master Phase Decrement, input functions 68, 69, 72 and 73 respectively, are toggled while the Phase Fine Inc Select input function 77 is active.
Page 60: Input Functions
Setup and Programming Operator's Manual (P/N 400310-00) or 525 Programmable Motion Controller Installation and Operation Manual (P/N 400276-01) as appropriate. The input functions which are specific to the PCM-22 are discussed in this section. Figure 28 Input Functions Screen To assign an input function, use the up/down arrows to move the cursor to the desired input function, type in the desired line number and then press Enter.
Page 61: Description Of Input Functions
This edge triggered input function is used only if the Follower cycle is Defined By Registration Sensor. It establishes the executing Follower cycles’ zero position. It also allows the PCM-22 to sense and refine the Follower Cycle Length and phase position. See Follower Length Upper Limit, Follower Length Lower Limit and Follower Sensor Valid Zone.
Page 62: Working Offset Increment
PCM-22 Rotary Knife Controller Master Length Increment This edge triggered input function increments the Master Cycle Length by the Length Change Increment value each time an input signal is received. It is checked against the Master Length Upper Limit and the Cycle Inter-Relationships.
Page 63 PCM-22 Software Setup Working Segment Increase This edge triggered input function increments the Working Segment value by the Length Change Increment value each time an input signal is received. It is checked against the Upper Working Segment Limit and the Cycle Inter-Relationships. See Cycle Inter-Relationships, Follower Cycles screen and the PH4 serial command.
Page 64 PCM-22 Rotary Knife Controller Reset Master Performs the same function as the Force Reset Master Processing flag described in the FF command. It is intended for troubleshooting purposes. Note: Resetting the Master Cycle Processing will only occur when a Follower Cycle is not executing and the Follower axis is not moving.
Page 65: Typical Input Assignments
PCM-22 Software Setup • If the Cycle Drop Out input function is active, then the Cycle Exit input function is activated, and the Cycle Drop Out input function is deactivated, then the Follower will exit the cycle at the end of the current Working Segment.
Page 66: Output Functions
Activates when the Follower axis is in sync with the Master axis (i.e. the acceleration portion of the Index is complete). This is not used during PCM-22 Follower Cycles, it is only used for synchronized Indexes. © EMERSON Motion Control...
Page 67 Indicates that the programmed length reached a count that should have initiated another flying cutoff but the FX drive was not in position to initiate the flying cutoff operation. This is not used during PCM-22 Follower Cycles, it is only used for synchronized Indexes.
Page 68 PCM-22 Rotary Knife Controller Follower Sensor Missing Activates if the Follower distance traveled from the last Zero Follower Cycle sensor input is greater than 1½ times (default) the average Follower Cycle Length. The Follower Sensor Missing output is deactivated when a valid Follower sensor input is received. It is only functional in a cycle.
Page 69 Cycle Error This output function activates in situations where a serious profile error was detected and it is not possible for the PCM-22 to execute the specified profile. 1) Activates when a cycle is started without executing a Home or Index reference move first.
Page 70: Recommended Output Assignments
PCM-22 Rotary Knife Controller Recommended Output Assignments It has been found that the following output arrangement allows the greatest diagnostic and system control capability. The output functions should be assigned but do not all need to be wired to the panel outputs.
Page 71: Programming
This section describes the unique PCM-22 functions. Please refer to your FX Drives manual for a complete description of all other programming functions.
Page 72: Example Program
PCM-22 Rotary Knife Controller Time Base This code determines whether the Time Base for any programming function placed after the Time Base function code in a program (including Dwells) is Synchronized (sync encoder), Real Time (normal) or Analog. It is important to remember that if you want a limited number of program steps done in Synchronized mode, you must restore the Time Base to Real Time after those program steps.
Page 73 and could be fed to the stop motion input of the material feed (master) axis. The exiting Follower axis velocity will automatically become the starting velocity of the next motion command, a real time, incremental Index in this example. See Cycle Exit. P/N 400274-01 Revision A7...
Page 75: Example Applications
Operation As the leading edge of the printed image is sensed, the distance from the last image is computed. This allows the PCM-22 to compute a correction necessary to compensate for any phase or length variation on the next cycle. When the product reaches the correct position, the PCM-22 will have positioned the leading edge of the knife assembly at the correct position and will be matching the speed of the product.
Page 76: Seal And Cut Off Packages
When the product reaches the correct position, the PCM-22 will have positioned the leading edge of the seal/cut assembly at the correct position and will be matching the speed of the product.
Page 77: Flexible Bag Maker
The die axis tracks the seal positions and automatically by speeds up or slows down to punch at the correct position relative to the seal position. The PCM-22’ s will match the speed of the product while they are in contact with it.
Page 78: Pick And Place
Solution A FX positioning drive with a PCM-22 Rotary Knife Controller using an SCS-4 encoder measuring the movement of the molding process, a master registration (product) sensor on the process (Master axis) and a follower proximity sensor on the vacuum pick up take away assembly (Follower axis).
Page 79: Imprinter
Solution A FX positioning drive with PCM-22 Rotary Knife Controller, a master axis synchronization encoder, a master (product) registration sensor and a proximity follower sensor for the imprint (Follower) axis.
Page 80 PCM-22 Rotary Knife Controller A flexible system capable of precise placement and control over an imprint. © EMERSON Motion Control...
Page 81: Maximizing Profile Performance
To achieve maximum performance, the PCM-22 motion profile needs to be adjusted before production use. IMPORTANT! The performance of the PCM-22 will only be as good as the information it gets from the registration sensor(s) and synchronization source. Before the system can be adjusted for performance, it is critical that the sensors are producing a strong, distinct signal and that the encoder is riding on the product without slipping or vibrating.
Page 82: Commands Referenced
PCM-22 Rotary Knife Controller Commands Referenced The following commands will be referenced during the tuning process. PCM-22 Firmware, P/N: 401167-01, version A6 and higher is required to support all of these commands. New Commands FM7: Master Phase Variation - user units...
Page 83 Maximizing Profile Performance 3) Query FM9 and FM10 serial commands, the Master Length Variation and Follower Length Variation respectively. Each are updated once per cycle. 4) Choose the larger value of the two and query ML11 for FM9 or FL11 for FM10 .
Page 84: Minimizing Phase Variation
PCM-22 Rotary Knife Controller responsiveness of the system will over compensate and make the length variations worse. Minimizing Phase Variation Once the Master and Follower length variation are minimized, you may start adjusting the Phase Correction Limit (PH1 serial command).
Page 85 Maximizing Profile Performance 3) Perform the process for Minimizing Length Variation again. 4) Adjust the Working Segment wider or narrower by 5 percent. 5) Adjust the EG gain by increments of 0x10, upwards first. P/N 400274-01 Revision A7...
Page 86 PCM-22 Rotary Knife Controller 6) Decrease the DG gain by increments of 0x1. The length and phase variation should be re-checked after any of the six possible adjustments above. Once the total phase variation is reduced as much as possible, the final adjustment if desired, is the Phase Correction Dead Band (PH0 serial command).
Page 87 P/N 400274-01 Revision A7...
Page 88: Tips And Troubleshooting
See Operational Timing. Product Ranges and Limits The behavior of the PCM-22 is controlled by the limits/parameters entered. They must match the product for correct operation. This is why it is a not a good idea to attempt a “ one size fits all” approach (i.e., one set of product parameters for a wide range of product lengths).
Page 89: Follower Cycle Will Not Start
Tips and Troubleshooting Follower Cycle Will Not Start Symptom When the Y Execute Follower Cycle function code is reached in the PCX program an F External Distance Error fault occurs and the Cycle Error output function 66 is activated. Cause 1) The Working Segment is overlapping the Follower zero position.
Page 90: Issues Maintaining Phase
PCM-22 Rotary Knife Controller Issues Maintaining Phase Phase issues may be caused by a number of different reasons: 1) Master / Product control issues. 2) Master phase variations are primarily a combination of product slippage, encoder slippage, material stretch and sensor latency. This will become worse as the system speed increases if not compensated for by the Follower and/or mechanical adjustments.
Page 91: System Calibration Issues
System Calibration Issues Symptom The measured Master Length or Follower length does not match the values returned by the PCM-22 using the FM12 or FM13 serial commands which return the average Master Length or Follower Length in user units respectively.
Page 92: Running Into A Length Limit
PCM-22 Rotary Knife Controller B) The Follower Cycle Length entered is wrong when the Follower cycle is not defined by sensor. C) One or more of the following are set incorrectly: Master Cycle Length Correction Limit, Follower Cycle Length Correction Limit and Phase Correction Limit.
Page 93: Missing Sensor Issues
Tips and Troubleshooting Missing Sensor Issues Symptoms One or more of the following symptoms would be observed: 1. The Master Sensor Missing output function 25 is active. 2. The Follower Sensor Missing output function 26 is active. 3. The Cycle Error output function 66 is active. and the CQ serial command returns 0x810 or 0x820.
Page 94: Extra Sensor Issues
PCM-22 Rotary Knife Controller Extra Sensor Issues Symptoms One or more of the following symptoms would be observed: 1. The Cycle Limit Reached output function 41 is active. 2. The CQ serial command returns 0x10 or 0x20. 3. The Extra Master Sensor output function 47 is active.
Page 95: Common Operation Issues
Common Operation Issues Symptom Drive displays an E but motion can not be initiated and the motor shaft has torque in both directions. Possible Causes • A Home Lock is active. • A Jog Lock is active. • The Stop input function 11 is active. •...
Page 96: Appendix A - Serial Commands
The command is query only. See FT serial command. CQ - Cycle Status Query The PCM-22 will detect and prevent learned and user changes which would invalidate the Cycle Inter-Relationships. The cycle limit flags are set when a condition occurs. The flags indicate what the error condition is.
Page 97 Serial Commands CQ- Cycle Status Query Continued User Ratio Limit 0x08 User tried to adjust past the Working Ratio limits. Master Length Limit 0x10 User tried to adjust the Master Cycle Length past the Master Length Limits. If the Master Cycle is Defined By a Registration Sensor: 1) Master Length Limit is encountered.
Page 98 PCM-22 Rotary Knife Controller Reading CQ Flags Following are some typical examples of various issues, diagnostic codes and their definitions. Starting issues Example: CQ = 0x84 The Working Offset is too short or too long for the size of the Working Segment which is overlapping the Follower zero position.
Page 99: Ff - Follower Cycle Flags
Serial Commands FF - Follower Cycle Flags The Follower Cycle Flags are a bit map in hexadecimal containing selections for the control of operational and starting modes on a cycle by cycle basis. More than one flag may be set or cleared at a time as the flags are additive.
Page 100: Fm7 - Master Phase Variation In User Units
PCM-22 Rotary Knife Controller Disable Master Processing Reset Upon Fault 0x40 This command allows the user to disable resetting the Master processing upon clearing a fault. Note: This should be used for diagnostic purposes only. The default setting for the Disable Master Processing Reset Upon Fault flag is zero for all cycles by default, because the Master and Follower relationships are lost when a fault occurs.
Page 101: Fm10 - Follower Length Variation In Resolver Counts
Serial Commands FM10 - Follower Length Variation In Resolver Counts This is the difference from the current Average Follower Length to the new Average Follower Length. This command is used for Maximizing Profile Performance and diagnosis. It is only supported in Follower defined by sensor mode and is query only.
Page 102: Fn1 - Follower Cycles Per Follower Sensor
PCM-22 Rotary Knife Controller FN1 - Follower Cycles Per Follower Sensor This command sets the number of Follower cycles which occur between two successive Zero Follower Cycle inputs. The Follower Cycle Length entered should be the average distance between Follower sensor inputs.
Page 103: Ml11 - Current Master Length In Master Steps
This would overwrite any “ learned” information and cause Master Cycle zero to behave like all other Master cycles. This is done because Master Cycle zero is used when the FX/PCM-22 is first powered-up and may learn some random Master information which may not be usable when the Follower cycle is started.
Page 104: Appendix B - Pcx Cycle Screens To Fx Command Cross Reference
Appendix B PCX Cycle Screens to FX Command Cross Reference PCM-22 Master Cycles Screen Screen Parameter Serial Command Master Cycle Number ------------------- Master Cycle Length ------------------- +-> Master Length Upper Limit ------ +-> Master Length Lower Limit ------ ML10 Master Phase Distance ----------------- Master Cycle Defined by Sensor ---------- +->...
Page 105: Pcm-22 Follower Cycles Screen
Appendix C PCM-22 Follower Cycles Screen Screen Parameter Serial Command Cycle Number -------------------------- Follower Cycle Length ----------------- - Follower Length Correction Limit - - Follower Length Upper Limit ------ - Follower Length Lower Limit ------ FL10 Cycle Defined By a Registration Sensor - +->...
Page 106: Appendix C - Master Signal Components
PCM-22 Rotary Knife Controller Appendix C Master Signal Components Encoder Operation The SCS-2, 3 and 4 sync encoders are two channel amplified sine wave encoders. Each of the channels has 1000, 2500 and 3000 lines respectively. The inputs are A, A {complement}, B and B {complement}.
Page 107: Encoder To Drive Cables
Index Encoder to Drive Cables If an external encoder is used as a Master signal source, the connection of the external encoder to the first axis is accomplished with the MSC- XXX cable. As many as 10 axes can be synchronized to a single encoder. Figure 32 MSC-XXX Encoder Cable Wiring Diagram The MSC-XXX cable is provided in different lengths.
Page 108: Index
PCM-22 Rotary Knife Controller Index Error Gain ............74 Extra Master Sensor ..36, 37, 42, 58, 81, 82, 83 Extra Sensor ............83 At Sync..............56 Average Length ............8, 35, 36, 39, 42, 43, 45, 59, 71, 73, 74, 86, 89, FE ...............
Page 109 Index Follower Phase Variation ....72, 74, 75, 81, 89 Master Velocity.... 15, 19, 36, 37, 42, 85, 90, 92 Follower Sensor Averaging ........94 Maximum Master Velocity....19, 36, 37, 42 Follower Sensor Missing......57, 58, 82 MF ..........13, 14, 17, 91, 93 Follower Sensor Valid Zone Missing Sensor Issues ...........
Page 110 PCM-22 Rotary Knife Controller System Calibration ..........80 Working Offset Decrement ........52 Working Offset Increment ........52 Working Ratio ... 5, 7, 15, 19, 48, 55, 86, 92, 94 Working Ratio Change Increment....55, 92 TA ............15, 38, 53, 93 Working Ratio Decrement ......

Emerson PCM-22 Manual

Table of Contents

Introduction

Theory of Operation

Installation Guidelines

Software Setup

Example Applications

Maximizing Profile Performance

Tips and Troubleshooting

Appendix A - Serial Commands

Appendix B - PCX Cycle Screens to FX Command Cross Reference

Pcm-22 Follower Cycles Screen

Quick Links

Chapters

Related Manuals for Emerson PCM-22

Summary of Contents for Emerson PCM-22

Table of Contents