Transcript Rockwell Automation External LTS Template

Flux Vector AC Drive
Control VS
Servo Drive Control
Presented by:
Kevin Miller- Motion Automation Eng
Schaedler-Yesco
Darryl Jacobs- Technical Consultant
Rockwell Automation
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
1
Today’s Agenda
1. Flux Vector AC drive theory (FORCE)
2. Servo Drive Control theory
3. Application Examples
4. Technical performance comparisons
5. Rockwell Automation solutions
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
2
Basic Control Classes for AC drives
Basic Volts/Hertz
Volts/Hertz
Control
(V/Hz)
Enhanced V/Hz
V/Hz with current
limiting, boost, and
slip comp
I heard of space vector, sensorless vector, flux
vector and just about every under the sun
vector drive. What does all this mean?
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Vector Control
Sensorless Vector
Control with
slip comp.
Flux Vector or
Field Oriented
Control
w/ out Encoder
Flux Vector or
Field Oriented
Control
w/ Encoder Fdbk
3
Breaking through the “vector” messages
• Older and less expensive drives were limited to a volts per hertz ratio
output. You could cap or limit the output current, add some boost start
voltage level and more advanced drives allowed recalculating the voltage
ratio to frequency or vector delta. Motor thermal protection was limited to
current levels and Klixon contacts.
• More advance systems such as sensorless vector added I2T motor thermal
modeling, better processors to calculate for faster response to load
changes, takes into account the flux producing or magnetizing current that
develops motor torque. Essentially sensorless vector offered best
breakaway current torque performance across the entire speed range. Still
the flux producing current is set to a level but not controlled.
• Adding encoder feedback options adds more finite samples in hard speed
reference to supplement speed control and shorten response time.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
4
Vector Control vs Flux Vector
Vector Control
– Acknowledges that motor current is the vector sum of
the torque and flux currents and uses this information
to provide better control of motor speed/torque.
Flux Vector Control
– The ability to independently control the flux and
torque in a motor for the purpose of accurate torque
and power control.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
5
What is Flux Vector Control ?
The ability to independently control the flux and torque producing
components of current in an motor for the purpose of accurate torque and
power control. The significance of this is now beyond simply controlling the
total current and voltage we can control the torque producing components
in the motor just as independently as we can control voltage and overall
current.
Now the need for slip compensation to make up for a calculated
torque slip factor of the motor is not needed as we now control what the
torque differential is. Standard NEMA type induction motors always have a
slip in design. This means we have control of production torque current
across the speed range, not exclusively dependent on the motor natural
torque curve.
Adding a feedback device enhances all control regulation.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
6
What advantage does flux vector offer?
• Offers pure torque control to not break shafts or hold a web tension.
• Allows for holding torque at very low or zero speeds. Great for lifts or
momentary hold in place until a brake can be applied or released.
• Maximizes with control how much torque can be produced out of a motor.
• This becomes a DC drive displacer as faster current response and torque
control are equal to or better than DC drives. This does away with the
typical DC motor wear issues with more standard induction motors.
• Flux vector offers a better bus regulation system as now more factors other
than simply reducing output frequency are used to keep the DC bus level in
check.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
7
What is field oriented control?
• In Allen Bradley it’s referred to as FORCE technology.
• This kicks the flux vector control level up a notch by adding a voltage
component to the flux control feedback. Typically flux vector control
calculates this value where FORCE will control all components of the flux
producing magnetic field. Motor thermal calculations are now part of the
control, not reacting.
• What this allows is even better bandwidth control, response and low speed
torque control. Improving the bandwidth now tightens positional reference
drift simply because the numbers are more finite. This means more torque
and better low speed response.
• The same bandwidth improvement offers more advantages with high
resolution feedback and works high torque/high speed/low power motors
such as permanent magnet servo motors with low inertia.
• With FORCE keeping tighter controls of all facets of the motor it permits
more servo like applications requiring tighter motor control.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
8
Sensorless Vector – Encoderless
PowerFlex70 5HP-ND Tuned Settings
PowerFlex70 5HP-ND Tuned Settings
Torque (Per-Unit)
3
2
1.5
1
0.5
0
2.5
2
1.5
1
0.5
0
0
10
20
30
40
50
60
70
80
90
100
0
2
4
Frequency (HZ)
6
8
10
12
Frequency (HZ)
Separates current and voltage control
PowerFlex70 5-HP Tuned Settings
3
Torque (Per-Unit)
Torque (Per-Unit)
3
2.5
2.5
2
1.5
1
0.5
0
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2.2
Frequency (HZ)
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
9
Flux Vector Encoderless
AB PF700VC 5Hp - Optimized Settings
AB PF700VC 5Hp - Optimized Settings
2.5
3.0
Torque (Per-Unit)
2.0
1.5
1.0
0.5
0.0
0
10
20
30
40
50
60
70
80
90
100
Frequency (HZ)
2.5
2.0
1.5
1.0
0.5
0.0
0
2
4
6
8
10
12
Frequency (HZ)
AB PF700VC 5Hp - Optimized Settings
3.0
Torque (Per-Unit)
Torque (Per-Unit)
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
Frequency (HZ)
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
10
Flux Vector w/ Encoder
AB PF700VC 5Hp - Optimized Settings
(With Encoder)
Torque (Per-Unit)
3.0
2.5
2.0
1.5
1.0
0.5
0.0
-2
0
2
4
6
8
10
12
Frequency (HZ)
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
11
FOC w/ Encoder
AB PF700S 5Hp - With Encoder Feedback
3.5
3.0
2.5
3.0
Torque (Per-Unit)
3.5
2.0
1.5
1.0
0.5
0.0
2.5
2.0
1.5
1.0
0.5
0.0
0
10
20
30
40
50
60
70
80
90
100
0
2
4
Frequency (HZ)
6
8
10
12
Frequency (HZ)
AB PF700S 5Hp - Encoder Feedback
3.5
Torque (Per-Unit)
Torque (Per-Unit)
AB PF700S 5Hp - With Encoder Feedback
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
Frequency (HZ)
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
12
Performance Comparison
Control Mode
Fan/Pump
or Custom
V/Hz with
slip comp
SVC with
slip comp
SVC with
feedback
FOC or Flux
Vector without
feedback
FOC or Flux
Vector with
feedback
Typical DC
Speed Regulation
(% of base
speed)
+/- 0.5%
+/- 0.5%
+/- 0.1%
+/- 0.1%
+/- 0.001%
+/- 0.001 %
Operating Speed
Range
40:1
80:1
80:1
120:1
1000:1
1000:1
Speed Bandwidth
10 rad/sec
20 rad/sec
20 rad/sec
50 rad/sec
250 rad/sec (VC)
300 rad/sec (S)
100 rad/sec
Torque Regulation
NA
NA
NA
+/-10 %
+/- 5 %
+/- 5%
Torque Bandwidth
NA
NA
NA
600 rad/sec
2500 rad/sec
950 rad/sec
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
13
What is …..
• The Difference between Field Oriented Control (700S) and Flux
Vector Control (700VC)
– No voltage feedback on 700VC, voltage fdbk is approximated
Both the Powerflex 70 Enhanced control and Powerflex 700
offer the setting options of sensorless vector or flux vector
control in the same drive.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
14
Let’s discuss what motion control is
So far with AC drives we have discussed speed and torque
control. What servo motion control adds to the mix:
*Maintaining position control
*Speed, torque and position adjustments on the fly
*Coordinating drive/motor running profiles or axis together
*Having velocity and acceleration independent
*Homing to a known start position
*Repeatable and concise steps
*Camming or following a pattern beyond just a speed ratio
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
15
The blurry line between drives and servos today.
The Powerflex 700 VC drive today can do:
Torque Proving with fast brake control
Indexing function with homing
Speed profile blending
…all without a PLC, using a standard induction motor and
standard encoder feedback.
This offers an option to use standard like
parts across small and large HP ranges.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
16
The blurry line between drives and servos today.
The Powerflex 700S with Drivelogix goes even further in offering:
*Electronic Gearing *Absolute Position Control
*High resolution feedback capable *Dual feedback device capable
*High speed Synchlink control (50 microsec) and co-orination
*Will run standard AC motors and servo motors
*Uses standard AC drive components and accessories
*Accepts 25 most common
RSLogix5000 motion commands.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
17
Powerflex 700 applications
• Powerflex 70 and 700 handle a wide
variety of VT and CT applications with
common AC induction motors.
• Fans Pumps Conveyors
• Palletizers
Lifts
• Automated Storage and Retrieval
• Food
Packaging
Machine Tool
• …virtually anywhere motor speed or
torque control is applied.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
19
PowerFlex 700S / Applications
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• Backery Line
Coating Lines
• Roll Grinding
Tenter Frames
• Hoist
Bottling
Re-winder
Plaster board Line
Accelerator rolls
Stamping
Nip Rolls
Copper Line
Converting Lab Lines
Spline Rolling Machine
Coating Lab Line
Lay on Roll for Turret Winder
Turntable Transfer
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
20
Where do servo drives make more sense…
• Where speed regulation is precise.
• Where positioning in precise and must be repeatable.
• Where gearing and transmissions are required while maintaining position
accuracy.
• Much easier to coordinate multiple axis operation.
• Where many different move types with varying accel/decel profiles are
required.
• When precise speed, torque, position and axis move coordination are all
required to perform the task.
• Where getting the best match motor to match the load requires is essential
for best performance at the best cost.
• In short something designed for the job.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
21
Some basic servo motion control differences
• Motion control typically runs in a very tight accuracy range for speed and
position. A feedback device is almost always used.
• Servo tackles moving a load with high speed motors attached to low
gearing. This affords high accuracy at slow speeds, higher velocity points
and smallest possible hardware. It’s the current that costs real money in
hardware.
• Servo motors and drives are designed to handle very quick acceleration
and deceleration ramps. This high velocity ramp affords tremendous torque.
Zero speed for holding torque is common with motor brakes just for parking.
• Motion controllers have the ability to adjust to maintain a positional
reference, can maintain a home position reference via tracking and/or
absolute feedback.
• Servo motors typically can produce 2 to 2.5 times their rated torque in peak
delivery. As such most servo drives peak at 200%
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
22
Comparing Performance
PF700S with
Drivelogix
Ultra3000
Ultra5000
Kinetix 6000
Position Loop Task
Update Time
1msec
1msec
500 usec
125 usec
Velocity Loop Task
Update Time
250 usec
250 usec
250 usec
125 usec
Sercos Minimum
Cycle Time
N/A
1 msec
N/A
500 usec
Registration input
time
8msec
4-8 usec
4-8 usec
3usec
Torque Control
Task Update Time
125 - 250 usec
125 usec
250 usec
125 usec
Across the board servo drives are design for much faster
control update rates.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
23
Some basic servo motion control differences
Servo motor permanent magnet design
is high torque delivery, low inertia, high
speed with quick acceleration to fit in
tight spaces. Mountings and shafts are
design for plum direct mounting. The
longer case design is to maximize torque
at all speeds with great heat dissipation
for quick speed changes over a very
wide speed range. This same design
offers very incremental concise moves.
Same no blower design to 7250RPM
A fast response drive to control this type
of motor.
Standard round frame AC motors are
designed with gaps in 2 to 8 pole
configurations more suitable speed and
torque regulation, not positioning. The motor
itself is really a transformer with the stator to
rotor pull being the secondary.
The exception is a true laminated motor.
More poles means more torque
but usually more slip.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
24
Motion Control via Servo
– “Closed Loop Position Servo ” Motion Control
• Definition
• Standard Drives -vs- “Closed Loop Position Servo” Motion Control
• Position control with the ability to stay on track. Typical drive application will
allow position to slip with no means of recovery without manual homing.
• Applications include:
–
–
–
–
–
Converting Industry Example
Packaging Industry Example
Food & Beverage Example
Assembly Example
Metal Forming Example
Servo Motion Control
Define “Closed Loop Position Servo” Motion Control
Motion Control is the process of managing or
directing the movement of machinery or
equipment.
Automated equipment employing “Closed
Loop Position Servo” Motion Control will
provide machine movement that is:
•Accurate- Capable of moving to a
precise position!
Repeatable- Capable of moving to the
same precise position every time the
machine is commanded to do so!
Servo Motion Control
Define “Closed Loop Position Servo” Motion Control
The “Pick & Place” motion application on the right is used in a
variety of industries. Application examples include product
transfer lines, component insertion, etc.. The “Pick & Place”
example further clarifies the concept of “Accurate” and
“Repeatable”.
Accurate: The “Pick & Place” unit is typically commanded to
precise locations to assure that packages or components are
inserted to specification. Precision is determined by the
application requirements. Position accuracy of XX.0010”
(accurate to 1 thousandth of an inch) are common.
Pick and Place
Position 2
Position 1
Servo Motion Control
Define “Closed Loop Position Servo” Motion Control
Repeatable: Closed Loop Position Servos
are frequently applied in a production
environment where thousands of identical
assemblies are manufactured daily. To
assure product quality and reliability,
components must be assembled to tight
tolerances (identical). Motion Controllers
typically move to multiple positions each time
a part is manufactured. It must be capable of
repeating those exact movements for each
part. Pick and Place
Position 2
Position 1
Servo Motion Control
Define “Closed Loop Position Servo” Motion Control
Standard Drives –vs-Closed Loop Position Servo
Frequently, people ask, “What is the
difference between a ‘Standard Drive’ and
a ‘Closed Loop Position Servo’?”
Speed controlled by
a “Standard Drive”
Typically, In Standard Drive applications,
speed (velocity) is the main control
parameter.
Rotary Knives are frequently used in industry to cut material to
specified lengths. In this Rotary Knife example a “Standard
Drive” is used to control the speed of the Material(aka “Web”)
feed.
Rotary Knife
Servo Motion Control
Define “Closed Loop Position Servo” Motion Control
Standard Drives –vs-Closed Loop Position Servo
In Closed Loop Position Servo applications
position is the main control parameter. Velocity
can vary to maintain position.
Position of Knife
controlled by
“Closed Loop
Position Servo”
The Closed Loop Position Servo ( AKA “Servo”) is
used to position the cutter to cut the material to the
desired length.
Rotary Knife
Servo Motion Control
Application Examples of Motion Control in Industry
In packaging applications, Servo Driven “Smart
Belts” are used to position randomly spaced
packages into evenly spaced packages. The
evenly spaced packages are fed to downstream
equipment for further processing. “Smart Belts”
typically use photo-eyes to detect product. These
Photo-eyes are typically wired to a special motion
controller “high speed” input called a “Registration
Input”.
Smart Belt
Photo-eye wired to
Motion Controller’s
“Registration Input”
Servo Motion Control
Application Examples of Motion Control in Industry
Vertical Form, Fill & Seal machines are used in the
food industry for a wide variety of packaging
applications. Applications include high speed
candy packaging and low speed coffee packaging.
Typically, product is fed into a pouch and sealed
on both ends. Servos are used to feed the
packaging material and to seal/cut the pouch on
both ends of the package. Servos eliminate waste
by feeding the packaging material to the proper
length while synchronizing the cutter.
Vertical
Servo driven
packaging material
feed.
Servo driven cutter in
synchronization with
material feed.
Servo Motion Control
Application Examples of Motion Control in Industry
In the semiconductor industry, the Wet Bench
is used for transferring sliced semiconductor
wafers through a series of chemical baths to
clean and remove residue left from the slicing
of the semiconductor wafer.
A servo driven mechanical actuator is used to
lift the boat of wafers out of the dip tank. A
longer horizontal servo driven actuator is used
to shuttle the load from one tank to another.
Ball Screw Actuator
converts rotary motion
to linear motion.
Wet Bench
Belt Actuator converts
rotary motion to linear
motion
Servo Motion Control
Application Examples of Motion Control in Industry
Press feeds are used to feed sheet steel in to a
mechanical press. Press machinery is used in a
variety of industries including automotive and
motor manufacturing.
Servos are used to feed material into the press in
correct lengths. In this application, the servo
motors rotates pinch rolls( apply pressure and pull
material). Product lengths can be modified in the
motion controller.
Press Feed
Basics of Motion Hardware and Factors
Basic Motion Hardware
These are some of the basic hardware items involved in motion.
•Servo Motor
•Servo Drive
•Actuator
•Transmission Stage
•Motor Current
•Motor Voltage
•Motion Controller
•Motion Controller Software
•Overtravel Switch
•Home Switch
•Brake
•Control, feedback, brake and power cables.
Basic Motion Application Sizing and Operation
*Total and Mismatch Inertia
*Bus Utilization
*Cycle Profile or Indexing
*Registration
*Gearing
*Shunt Requirements
*Rotary or Linear load
*Absolute Feedback
Peak Torque/Velocity/Current
*Continuous and Peak Stall Torque
Basics of Motion Hardware
Basic Motion Hardware
The “Pick and Place” example is an interesting
linear application to study in greater detail. It
employs the basic motion components.
Motor
with
Feedback
Transmission Stage
Movement
Negative
Overtravel Limit
Switch
Home Limit
Switch
Load
Table
Ballscrew
Machinery
Positive
Overtravel Limit
Switch
Basics of Motion Hardware
Basic Motion Hardware
The shaded area below identifies the major controller components of a motion control
system. In the next series of slides, we’ll define the basic operation of each component and
explain how they interact with each other to function as a system.
Machinery
Transmission Stage
Movement
Motor
with
Feedback
Negative
Overtravel Limit
Switch
Home Limit
Switch
Positive
Overtravel Limit
Switch
Load
Table
Motor
Power
Ballscrew
Position
Feedback
Command Signal
Servo
Drive
Motion
Controller
Position Feedback
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Motion
Software
37
Basics of Motion Control in Operation
Basic Motion Hardware
Motion Controller Functions
Control the Motion
When executing motion programs, motion controllers provide precise control of:
•Position
•Velocity
•Acceleration
In a typical AC drive application the acceleration rate
is a constant 0 to maximum speed value unless set
by another action such as a digital input.
Motion Controllers maintain precision by continually comparing the machine’s actual
position (Position Feedback) to “where it should be” (Commanded position). The
Command Signal to the machine corrects errors very quickly.
Machine
Motion
Command Signal
Position Feedback
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Motion
Controller
38
Basics of Motion Hardware
Basic Motion Hardware
The Motion Controller is the “Brains” of the system. Motion controllers serve (3) primary
functions:
Motion Controller Functions
Motor
with
Feedback
•Store and Execute Motion Programs
Motor
Power
•Store Configuration Parameters
•Control the Motion
Position
Feedback
Command Signal
Servo
Drive
Motion
Controller
Position Feedback
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Motion
Software
39
Basics of Motion
Basic Motion Hardware
Servo Drives interpret the Motion Controller command signal
and control the amount of speed and torque delivered by the
motor. Drives accomplish this task by converting plant power to
the voltage and current levels required by the motor to control
the application. The commands can be analog, digital, networks
or fiber interface. One thing to take notice of here is we’re
getting into more control cabling and addition
programming than a typical drive application.
Motor
with
Feedback
Motor
Power
Plant
Power
Position
Feedback
Command Signal
Servo
Drive
Motion
Controller
Position Feedback
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Motion
Software
40
This sounds complicated…any way to simplify?
• Selecting the best solution has
never been easier. It starts with a
good machine concept and hard
mechanical load data. Rockwell
Automation Motion Analyzer
software can walk through the
moves, offer hardware choices and
show all possible solutions in
graphic detail. Best part is it’s a
free download.
• Most important is consult with your
Schaedler-Yesco motion specialist.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
41
That sure looks like a lot of wires…
• For applications where a single axis,
simple digital, analog or pulse reference
control is required, Allen Bradley offers:
• Ultra 1500 (115V & 230V)
• Ultra 3000 (230V and 460V)
• Ultra 3000 Indexer
• Ultra 3000 Devicenet (w/Indexer too)
• Ultra 5000 stand alone controller
• Ultraware drive set up software
• A huge variety of pre-molded control and
feedback cables and breakout terminal
boards
• Micrologix with pulse output control
• Contrologix 2 axis analog servo control
card
• …but there is a better way…
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
42
Motion in Integrated Architecture
• A motion control system that allows
you to connect over a SERCOS fiber
optic ring to the following drives:
–
–
–
–
•
•
Kinetix 6000
Kinetix 7000
Ultra3000
1394
A combination of
architecture, world class AB motion products, and
motion application
expertise.
Kinetix motion is part of
Integrated Architecture.
• A cost effective integrated solution that provides you with
everything you need to be cost-effective and competitive.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
43
Where does Kinetix fit?
•
pick and place robotics
Any application that requires:
–
–
–
–
–
accurate positioning of product
rapid acceleration/deceleration
precise speed control with varying loads
repeatability, accuracy, cycle timing,
maintenance of mechanical clutches/brakes
an entire Rockwell Automation machine system
solution
case packing
positioning conveyors
canning
pharmaceutical
packaging
wrapping
tire assembly
cartoning
automated assembly
metal forming
food processing
palletizing
press feed
electronic line shafting
flow wrapping
laminating
labeling
bottling
pouch filling
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
44
Motion control already in RSLogix5000
• components are eliminated
– one integrated sequential and motion controller
– one software package
1 Processor
2 Software
Packages
1 Software
Package
2 Programming
Languages
1 Programming
Language
Extra
Communication
Logic
Extra
Coordination
Logic
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
45
Time is money
• less expensive and easier to wire
– fewer axis module cards required
– two fiber connections replace 18 discrete wires per drive, eliminating 36
terminations per axis
– fewer components to wire
– Completely digital interface
analog terminal block
fiber optic connection
• less time required to implement
–
–
–
–
–
already integrated
plug and play modules
easy to add axes
faster to start up
easier to troubleshoot
• only one software package
to purchase and learn
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
46
Less connections, faster uptime, lower total cost
• smaller enclosure panel requirements
– saves money and floor space
– Eliminates lots of cabling for each axis
– All motion controller function resides in the Contrologix
• ControlLogix SERCOS Interface Motion Modules
– M16SE and PM16SE
• 16 axes SERCOS Module/Card with one fiber cable
– M08SE M03SE
• 8 and 3 axes SERCOS Module and 1756-L60M03SE
• Compactlogix 1768-M04SE 4 axis module
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
47
Overall Wiring Reduction With
Kinetix Integrated Motion Using The Kinetix 6000
Kinetix
Traditional
The new science of integrated motion
Motion
Controller
8 axis system example
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
48
Overall Wire Terminations Reduction
485
Same 8 axis example
showing control and power
wiring comparison.
157
Total
134
90
58
Total
28
48
4
16
3 Phase Power Wiring
Kinetix
The new science of integrated motion
136
Traditional
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
49
What was that box feeding the servo drives?
Line Interface Module (LIM)
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
50
How else is it easier to use?
• Start up is easier
– Drop down boxes and wizards
– High resolution feedback eliminates the need to tune
servo drives in all but the most extreme cases
• Drives located remote from the control
– each segment (node-to-node) of a SERCOS ring can
be up to 32 meters in length using economical plastic
fiber, or up to 200 meters using glass fiber.
• RSLogix 5000 Direct Commands
– Online direct execution of motion commands -- no
application program needed
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
51
What are the facts on speed of commissioning?
• One software package (RSLogix 5000)
• Information enabled devices allow
configuration, tuning, programming
and monitoring out of one single
package. Plug and play from one
place.
• Typical time savings
of 20% per axis
– One example of 40%
total time saved
• SERCOS allows drive replacement without reconfiguration
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
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How else is it easier to use?
• Simpler to Program
– 37 motion instructions
• simple to add motion commands to the
application program.
• No need to learn a cryptic motion programming
language.
• Choice of three IEEE-61131-3 languages:
– Ladder
– Structured Text (ST)
– Sequential Function Chart (SFC)
– Extensive use of graphical tools simplifies creating
and implementing complex motion profile.
– RSLogix5000 is the only programming package
required to completely configure, program, and
commission a motion system.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
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How can this help me?
• High performance
– high resolution feedback option improves positioning accuracy and
reduces cycle times
– absolute feedback option eliminates time consuming homing cycles
– super fast, up to 64ms loop closure ensures
accurate load positioning
– digital commands replace range limited
analog signals
• Improved diagnostics
– detailed drive and motor status information is available in RSLogix
5000 and the ControlLogix/Compactlogix/SoftLogix application
program
– drive fault and status information is displayed in descriptive text,
eliminating the need to interpret cryptic codes
– graphical trending allows important motion parameters to be collected
and viewed
– All built in to RSLogix 5000
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
54
Where does Kinetix make more sense…
• Multiple axis set up and control start to finish is far quicker with Kinetix.
• Coordinating axis is inherently easier.
• Information enabled hardware enhances time to running. Configure, tune
and program all from the same software.
• Widest offering of motor ranges and accessories.
• SERCOS reduced connection count with outstanding performance.
• Simpler code reuse
• Better integration for monitoring and diagnostics
• Kinetix space saving rack mount design
• Reduced cabling time and cost
• Single control connection system
• Integral safety relay system
• …In short products designed to do the job with the best time to market.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
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So when do I use a standard drive or servo drive?
•
•
•
•
•
•
•
Evaluate your installed base of hardware, controllers and trained staff.
Evaluate how repeatable and accurate the application is.
Review what has to be mechanically interfaced.
Identify the required speed and power range.
Do you need to know where in the process you are if power fails.
Review how distributed the application control is.
Does the hardware configuration make more sense to connect via a
network or digital interface?
• Review the needs of the application with which approach is best addressed
with standard hardware.
• Discuss the application with your Schaedler-Yesco Allen Bradley
automation specialist.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
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Allen Bradley drives solutions
•
•
•
•
•
•
•
115V to 6190V
.5HP to 10,000HP
Standard NEMA1 to 4X
Configured boxed solutions
Application Solutions software
Common accessories, look and feel
Drives for simple and challenging
applications
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
57
Kinetix Family of Servo Drives
.1 KW
.25 KW
1.2 KW
6.6 KW
15 KW 18 KW 22 KW
93 KW
150 KW
Ultra3000
Kinetix 2000*
Kinetix 6000
CompactLogix with
SERCOS Interface
4 axis control
Highly integrated motion control – SERCOS
over the entire power range with Kinetix
Kinetix 7000
* Available summer 2006
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
58
Thanks for your attention!
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
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