MELSEC-Q
QD75M Positioning Module
User's Manual (Details)
-QD75M1
-QD75M2
-QD75M4
SAFETY INSTRUCTIONS
(Always read these instructions before using this equipment.)
Before using this product, please read this manual and the relevant manuals introduced in this manual
carefully and pay full attention to safety to handle t he product correctly .
The instructions given in this manual are concerned with this product. For the safety instructions of the
programmable logic controller system, please read the CPU module User's Manual.
In this manual, the safety instructions are ranked as "DANGER" and "CAUTION".
DANGER
!
CAUTION
!
Note that the !CAUTION level may lead to a serious consequence according to the circumstances.
Always follow the instructions of both levels because they are important to personal safety .
Please save this manual to make it accessible when required and always forward it to the end user.
Indicates that incorrect handling may cause hazardous conditions,
resulting in death or severe injur y.
Indicates that incorrect handling may cause hazardous conditions,
resulting in medium or slight personal injury or physical damage.
[Design Instructions]
!
DANGER
Provide a safety circuit out side the progr ammable logic contr oller so t hat t he entire sy st em will
operate safely even when an external power supply error or PLC fault occurs.
Failure to observe this could lead to accidents for incorrect outputs or malfunctioning.
(1) Configure an emergency stop circuit and interlock circuit such as a positioning upper
limit/lower limit to prevent mechanical damage outside the PLC.
(2) The machine OPR operation is controlled by the OPR direction and OPR speed data.
Deceleration starts when the near-point dog turns ON. Thus, if the OPR direct ion is
incorrectly set, deceleration w ill not star t and t he machine will cont inue to tr av el. Configure
an interlock circuit to prevent mechanical damage outside the PLC.
(3) When the module detects an error, normally deceleration stop or sudden stop w ill take
place according to the parameter stop group settings. Set the parameters to the positioning
system specifications.
Make sure that the OPR parameter and positioning data are within the parameter setting
values.
A - 1
[Design Instructions]
!
CAUTION
Do not bundle or adjacently lay the control wire or communication cable with the main circuit or
power wire.
Separate these by 100mm (3.94in.) or more.
Failure to observe this could lead to malfunctioning caused by noise.
[Mounting Instructions]
!
CAUTION
Use the PLC within the general specifications environment given in this manual.
Using the PLC outside the general specification range environment could lead to electric
shocks, fires, malfunctioning, product damage or deterioration.
While pressing the installation lever located at the bottom of module, insert the module fixing
tab into the fixing hole in the base unit until it stops. Then, securely mount the module wit h the
fixing hole as a supporting point.
Incorrect loading of the module can cause a malfunction, failure or drop.
When using the module in the environment of much vibration, tighten the module with a screw.
Tighten the screws within the specified torque range.
Undertightening can cause a drop, short circuit or malfunction.
Overtightening can cause a drop, short circuit or malfunction due to damage to the screws or
module.
Completely turn off the externally supplied power used in the syst em before installing or
removing the module. Not doing so may damage the product.
Do not directly touch the module's conductive parts and electronic components of the module.
Touching the conductive parts and electronic components of the module could cause an
operation failure or give damage to the module.
Make sure that the connectors for the servo amplifier and peripheral devices have been
securely installed until a click is heard.
Not doing so could lead to a poor connection, resulting in erroneous input and output.
When the servo amplifier is not installed, install the connector cover without fail.
Failure to observe this could lead to a malfunction.
[Wiring Instructions]
!
DANGER
Always confirm the terminal layout before connecting the wires to the module.
A - 2
[Startup/Maintenance Instructions]
!
CAUTION
Completely turn off the externally supplied power used in the syst em before clearing or
tightening the screws.
Not doing so may cause electric shocks.
Never disassemble or modify the module.
Failure to observe this could lead to trouble, malfunctioning, injuries or fires.
Completely turn off the externally supplied power used in the syst em before installing or
removing the module.
Not doing so may cause an operation failure or damage to the module.
Before starting test operation, set the parameter speed limit value to the slow est v alue, and
make sure that operation can be stopped immediately if a hazardous state occurs.
Always make sure to touch the grounded metal to discharge the electricity charged in the body ,
etc., before touching the module.
Failure to do so may cause a failure or malfunctions of the module.
[Precautions for use]
!
CAUTION
Note that when the reference axis speed is designated for interpolation operation, the speed of
the partner axis (2nd axis, 3rd axis and 4th axis) may be larger than the set speed (larger than
the speed limit value).
[Disposal Instructions]
!
CAUTION
When disposing of the product, handle it as industrial waste.
A - 3
REVISIONS
Print Date
Manual Number Revision
Dec., 2002 IB (NA) 0300062-A First edition
Apr., 2004 IB (NA) 0300062-B
Partial corrections and additions
SAFETY INSTRUCTIONS, CONTENTS, Generic Terms and
Abbreviations, Section 1.1.1, Section 1.1.4 to Section 1.1.6,
Section 1.2, Section 2.1, Section 2.2 to Section 2.4, Section 3.1 to
Section 3.5, Section 4.1.1, Section 4.1.2, Section 4.3.1, Section
4.4.1, Section 5.1.1 to Section 5.1.3, Section 5.1.5 to Section 5.1.9,
Section 5.2.1 to Section 5.2.10, Section 5.3 to Section 5.6, Section
6.1 to Section 6.3, Section 6.5.1 to Section 6.5.6, Section 7.1 to
Section 7.2, Section 8.1 to Section 8.2, Section 9.1.1 to Section
9.1.3, Section 9.1.5, Section 9.1.6, Section 9.2, Section 10.1 to
Section 10.6, Section 11.1.1 to Section 11.2.4, Section 11.3 to
Section 11.4, Section 12.1 to Section 12.7, Section 13.1 to Section
13.4, Section 14.1 to Section 14.6, Section 15.1 to Section 15.3,
Appendix 1 to Appendix 8, INDEX
Jun., 2005 IB (NA) 0300062-C
Partial corrections and additions
SAFETY INSTRUCTIONS, CONTENTS, About manuals, Section
1.1.1, Section 1.1.4, Section 1.2.3, Section 2.2, Section 2.3, Section
3.2.1, Section 3.2.4, Section 3.4.3, Section 3.5, Section 4.1.2,
Section 4.2.1, Section 4.3.1, Section 4.5.1, Section 5.1.1, Section
5.1.5, Section 5.1.8, Section 5.1.9, Section 5.2.3, Section 5.2.4,
Section 5.2.5, Section 5.2.6, Section 5.2.7, Section 5.2.9, Section
5.5, Section 5.6.2, Section 5.7.1, Section 6.1, Section 6.2, Section
6.5.6, Section 7.2, Section 8.1.1, Section 8.2.3, Section 8.2.4,
Section 9.1.4, Section 9.2.3, Section 9.2.4, Section 9.2.16, Section
11.2.3, Section 11.4.1, Section 11.4.3, Section 12.2.1, Section
12.2.2, Section 12.3.2, Section 12.4.4, Section 12.5.3, Section
12.5.4, Section 12.3.2, Section 12.7.8, Section 12.8.2, Section 13.4,
Section 14.3, Section 14.5, Section 15.2.1, Section 15.3, Appendix 1
, Appendix 5.2, Appendix 6, Appendix 7, INDEX
The manual number is given on the bottom left of the back cover.
Japanese Manual Version IB-0300030
This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent licenses.
Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which
may occur as a result of using the contents noted in this manual.
2002 MITSUBISHI ELECT RIC CO RPO RAT IO N
A - 4
INTRODUCTION
Thank you for purchasing the Mitsubishi general-purpose programmable logic controller MELSEC-Q Series.
Always read through this manual, and fully comprehend the functions and performance of the Q Series PLC
before starting use to ensure correct usage of this product.
CONTENTS
SAFETY INSTRUCTIONS............................................................................................................................A- 1
REVISIONS...................................................................................................................................................A- 4
INTRODUCTION...........................................................................................................................................A- 5
CONTENTS...................................................................................................................................................A- 5
About Manuals ..............................................................................................................................................A- 13
Using This Manual.........................................................................................................................................A- 13
Conformation to the EMC Directive..............................................................................................................A- 13
Generic Terms and Abbreviations................................................................................................................A- 14
Component List .............................................................................................................................................A- 14
Section 1 Product Specifications and Handling
1. Product Outline 1- 1 to 1- 28
1.1 Positioning control....................................................................................................................................1- 2
1.1.1 Features of QD75..............................................................................................................................1- 2
1.1.2 Purpose and applications of positioning control............................................................................... 1- 5
1.1.3 Mechanism of positioning control .....................................................................................................1- 7
1.1.4 Overview of positioning control functions.........................................................................................1- 8
1.1.5 Outline design of positioning system...............................................................................................1- 18
1.1.6 Communicating signals between QD75 and each module.............................................................1- 19
1.2 Flow of system operation........................................................................................................................1- 22
1.2.1 Flow of all processes........................................................................................................................1- 22
1.2.2 Outline of starting .............................................................................................................................1- 24
1.2.3 Outline of stopping ...........................................................................................................................1- 26
1.2.4 Outline for restarting.........................................................................................................................1- 27
2. System Configuration 2- 1 to 2- 8
2.1 General image of system.........................................................................................................................2- 2
2.2 Component list .........................................................................................................................................2- 4
2.3 Applicable system .................................................................................................................................... 2- 6
2.4 How to check the function version and SERIAL No. ..............................................................................2- 8
3. Specifications and Functions 3- 1 to 3- 22
3.1 Performance specifications......................................................................................................................3- 2
3.2 List of functions .......................................................................................................................................3- 4
3.2.1 QD75 control functions......................................................................................................................3- 4
3.2.2 QD75 main functions......................................................................................................................... 3- 6
A - 5
3.2.3 QD75 sub functions and common functions ....................................................................................3- 8
3.2.4 Combination of QD75 main functions and sub functions................................................................3- 12
3.3 Specifications of input/output signals with PLC CPU ............................................................................3- 14
3.3.1 List of input/output signals with PLC CPU.......................................................................................3- 14
3.3.2 Details of input signals (QD75
3.3.3 Details o f ou tp ut sig nal s (P L C CPU
3.4 Specifications of interfaces with external devices..................................................................................3- 18
3.4.1 Electrical specifications of input signals ..........................................................................................3- 18
3.4.2 Signal layout for external device connection connector..................................................................3- 19
3.4.3 List of input signal details.................................................................................................................3- 20
3.4.4 Interface internal circuit....................................................................................................................3- 21
3.5 External circuit design.............................................................................................................................3- 22
4. Installation, Wiring and Maintenance of the Product 4- 1 to 4- 16
4.1 Outline of installation, wiring and maintenance....................................................................................... 4- 2
4.1.1 Installation, wiring and maintenance procedures............................................................................. 4- 2
4.1.2 Names of each part...........................................................................................................................4- 3
4.1.3 Handling precautions ........................................................................................................................4- 5
4.2 Installation ................................................................................................................................................4- 7
4.2.1 Precautions for installation................................................................................................................4- 7
4.3 Wiring........................................................................................................................................................4- 9
4.3.1 Precautions for wiring........................................................................................................................4- 9
4.4 Confirming the installation and wiring.....................................................................................................4- 14
4.4.1 Items to confirm when installation and wiring are completed.........................................................4- 14
4.5 Maintenance............................................................................................................................................4- 15
4.5.1 Precautions for maintenance...........................................................................................................4- 15
4.5.2 Disposal instructions ........................................................................................................................4- 15
PLC CPU) ..................................................................................3- 15
QD75)................................................................................3- 17
5. Data Used for Positioning Control (List of buffer memory addresses) 5- 1 to 5-162
5.1 Types of data............................................................................................................................................5- 2
5.1.1 Parameters and data required for control.........................................................................................5- 2
5.1.2 Setting items for positioning parameters..........................................................................................5- 5
5.1.3 Setting items for OPR parameters....................................................................................................5- 7
5.1.4 Setting items for servo parameters...................................................................................................5- 8
5.1.5 Setting items for positioning data.....................................................................................................5- 10
5.1.6 Setting items for block start data .....................................................................................................5- 12
5.1.7 Setting items for condition data .......................................................................................................5- 13
5.1.8 Types and roles of monitor data......................................................................................................5- 14
5.1.9 Types and roles of control data .......................................................................................................5- 18
5.2 List of parameters ...................................................................................................................................5- 22
5.2.1 Basic parameters 1 ..........................................................................................................................5- 22
5.2.2 Basic parameters 2 ..........................................................................................................................5- 26
5.2.3 Detailed parameters 1......................................................................................................................5- 28
5.2.4 Detailed parameters 2......................................................................................................................5- 36
5.2.5 OPR basic parameters.....................................................................................................................5- 48
5.2.6 OPR detailed parameters ................................................................................................................5- 54
A - 6
5.2.7 Servo basic parameters...................................................................................................................5- 58
5.2.8 Servo adjustment parameters..........................................................................................................5- 64
5.2.9 Servo expansion parameters...........................................................................................................5- 74
5.2.10 Servo expansion parameters 2...................................................................................................... 5- 78
5.3 List of positioning data ............................................................................................................................5- 82
5.4 List of block start data ............................................................................................................................. 5- 98
5.5 List of condition data ..............................................................................................................................5-104
5.6 List of monitor data.................................................................................................................................5-110
5.6.1 System monitor data .......................................................................................................................5-110
5.6.2 Axis monitor data.............................................................................................................................5-120
5.7 List of control data..................................................................................................................................5-138
5.7.1 System control data ........................................................................................................................5-138
5.7.2 Axis control data..............................................................................................................................5-140
6. Sequence Program Used for Positioning Control 6- 1 to 6- 72
6.1 Precautions for creating program...........................................................................................................6- 2
6.2 List of devices used................................................................................................................................. 6- 5
6.3 Creating a program .................................................................................................................................6- 15
6.3.1 General configuration of program....................................................................................................6- 15
6.3.2 Positioning control operation program.............................................................................................6- 16
6.4 Positioning program examples...............................................................................................................6- 20
6.5 Program details.......................................................................................................................................6- 53
6.5.1 Initialization program ........................................................................................................................6- 53
6.5.2 Start details setting program............................................................................................................6- 54
6.5.3 Start program....................................................................................................................................6- 56
6.5.4 Continuous operation interrupt program..........................................................................................6- 65
6.5.5 Restart program ...............................................................................................................................6- 67
6.5.6 Stop program....................................................................................................................................6- 70
7. Memory Configuration and Data Process 7- 1 to 7- 20
7.1 Configuration and roles of QD75 memory ..............................................................................................7- 2
7.1.1 Configuration and roles of QD75 memory........................................................................................7- 2
7.1.2 Buffer memory area configuration .................................................................................................... 7- 5
7.2 Data transmission process ...................................................................................................................... 7- 8
A - 7
Section 2 Control Details and Setting
8. OPR Control 8- 1 to 8- 14
8.1 Outline of OPR control.............................................................................................................................8- 2
8.1.1 Two types of OPR control.................................................................................................................8- 2
8.2 Machine OPR........................................................................................................................................... 8- 4
8.2.1 Outline of the machine OPR operation.............................................................................................8- 4
8.2.2 Machine OPR method.......................................................................................................................8- 5
8.2.3 OPR method (1): Near-point dog method ........................................................................................8- 6
8.2.4 OPR method (2): Count method 1) ..................................................................................................8- 8
8.2.5 OPR method (3): Count method 2) .................................................................................................8- 10
8.2.6 OPR method (4): Data set method..................................................................................................8- 12
8.3 Fast OPR.................................................................................................................................................8- 13
8.3.1 Outline of the fast OPR operation....................................................................................................8- 13
9. Major Positioning Control 9- 1 to 9-116
9.1 Outline of major positioning controls .......................................................................................................9- 2
9.1.1 Data required for major positioning control ......................................................................................9- 4
9.1.2 Operation patterns of major positioning controls .............................................................................9- 5
9.1.3 Designating the positioning address................................................................................................ 9- 15
9.1.4 Confirming the current value............................................................................................................9- 16
9.1.5 Control unit "degree" handling.........................................................................................................9- 18
9.1.6 Interpolation control..........................................................................................................................9- 21
9.2 Setting the positioning data ...................................................................................................................9- 25
9.2.1 Relation between each control and positioning data ......................................................................9- 25
9.2.2 1-axis linear control ..........................................................................................................................9- 27
9.2.3 2-axis linear interpolation control.....................................................................................................9- 29
9.2.4 3-axis linear interpolation control.....................................................................................................9- 33
9.2.5 4-axis linear interpolation control.....................................................................................................9 -39
9.2.6 1-axis fixed-feed control................................................................................................................... 9- 44
9.2.7 2-axis fixed-feed control (interpolation) ...........................................................................................9- 46
9.2.8 3-axis fixed-feed control (interpolation) ...........................................................................................9- 48
9.2.9 4-axis fixed-feed control (interpolation) ..........................................................................................9- 52
9.2.10 2-axis circular interpolation control with sub point designation ....................................................9- 54
9.2.11 2-axis circular interpolation control with center point designation ................................................9- 60
9.2.12 1-axis speed control.......................................................................................................................9- 68
9.2.13 2-axis speed control.......................................................................................................................9- 71
9.2.14 3-axis speed control.......................................................................................................................9- 74
9.2.15 4-axis speed control.......................................................................................................................9- 78
9.2.16 Speed-position switching control (INC mode)...............................................................................9- 83
9.2.17 Speed-position switching control (ABS mode)..............................................................................9- 91
9.2.18 Position-speed switching control ...................................................................................................9- 99
9.2.19 Current value changing.................................................................................................................9-106
9.2.20 NOP instruction .............................................................................................................................9-111
A - 8
9.2.21 JUMP instruction...........................................................................................................................9-112
9.2.22 LOOP.............................................................................................................................................9-114
9.2.23 LEND .............................................................................................................................................9-115
10. High-Lev el Po si ti oni ng Co nt rol 10- 1 to 1 0 - 2 6
10.1 Outline of high-level positioning control ..............................................................................................10- 2
10.1.1 Data required for high-level positioning control............................................................................10- 3
10.1.2 "Block start data" and "condition data" configuration...................................................................10- 4
10.2 High-level positioning control execution procedure ............................................................................10- 6
10.3 Setting the block start data ..................................................................................................................10- 7
10.3.1 Relation between various controls and block start data..............................................................10- 7
10.3.2 Block start (normal start) ..............................................................................................................10- 8
10.3.3 Condition start ..............................................................................................................................10- 10
10.3.4 Wait start.......................................................................................................................................10- 11
10.3.5 Simultaneous start ......................................................................................................................10- 12
10.3.6 Repeated start (FOR loop) .........................................................................................................10- 13
10.3.7 Repeated start (FOR condition) ..................................................................................................10- 14
10.3.8 Restrictions when using the NEXT start......................................................................................10- 15
10.4 Setting the condition data ...................................................................................................................10- 16
10.4.1 Relation between various controls and the condition data.........................................................10- 16
10.4.2 Condition data setting examples .................................................................................................10- 19
10.5 Multiple axes simultaneous start control............................................................................................10- 20
10.6 Start program for high-level positioning control .................................................................................10- 23
10.6.1 Starting high-level positioning control..........................................................................................10- 23
10.6.2 Example of a start program for high-level positioning control ....................................................10- 24
11. Manual Control 11- 1 to 11- 36
11.1 Outline of manual control ....................................................................................................................11- 2
11.1.1 Three manual control methods.....................................................................................................11- 2
11.2 JOG operation......................................................................................................................................11- 4
11.2.1 Outline of JOG operation..............................................................................................................11- 4
11.2.2 JOG operation execution procedure ............................................................................................11- 7
11.2.3 Setting the required parameters for JOG operation.....................................................................11- 8
11.2.4 Creating start programs for JOG operation.................................................................................11- 10
11.2.5 JOG operation example...............................................................................................................11- 13
11.3 Inching operation.................................................................................................................................11- 17
11.3.1 Outline of inching operation.........................................................................................................11- 17
11.3.2 Inching operation execution procedure.......................................................................................11- 20
11.3.3 Setting the required parameters for inching operation ...............................................................11- 21
11.3.4 Creating a program to enable/disable the inching operation......................................................11- 22
11.3.5 Inching operation example...........................................................................................................11- 25
11.4 Manual pulse generator operation......................................................................................................11- 27
11.4.1 Outline of manual pulse generator operation..............................................................................11- 27
11.4.2 Manual pulse generator operation execution procedure............................................................11- 31
11.4.3 Setting the required parameters for manual pulse generator operation ....................................11- 32
11.4.4 Creating a program to enable/disable the manual pulse generator operation...........................11- 33
A - 9
12. Control Sub Functions 12- 1 to 12- 98
12.1 Outline of sub functions .......................................................................................................................12- 2
12.1.1 Outline of sub functions ................................................................................................................12- 2
12.2 Sub functions specifically for machine OPR ....................................................................................... 12- 4
12.2.1 OPR retry function.........................................................................................................................12- 4
12.2.2 OP shift function ...........................................................................................................................12- 8
12.3 Functions for compensating the control.............................................................................................12- 11
12.3.1 Backlash compensation function.................................................................................................12- 11
12.3.2 Electronic gear function ...............................................................................................................12- 13
12.3.3 Near pass function .......................................................................................................................12- 20
12.4 Functions to limit the control...............................................................................................................12- 23
12.4.1 Speed limit function......................................................................................................................12- 23
12.4.2 Torque limit function.....................................................................................................................12- 25
12.4.3 Software stroke limit function.......................................................................................................12- 29
12.4.4 Hardware stroke limit function .....................................................................................................12- 35
12.5 Functions to change the control details..............................................................................................12- 37
12.5.1 Speed change function ................................................................................................................12- 37
12.5.2 Override function..........................................................................................................................12- 44
12.5.3 Acceleration/deceleration time change function .........................................................................12- 47
12.5.4 Torque change function ...............................................................................................................12- 51
12.6 Absolute position system....................................................................................................................12- 54
12.7 Other functions....................................................................................................................................12- 56
12.7.1 Step function.................................................................................................................................12- 56
12.7.2 Skip function.................................................................................................................................12- 61
12.7.3 M code output function.................................................................................................................12- 64
12.7.4 Teaching function.........................................................................................................................12- 68
12.7.5 Target position change function ..................................................................................................12- 74
12.7.6 Command in-position function.....................................................................................................12- 78
12.7.7 Acceleration/deceleration processing function............................................................................12- 81
12.7.8 Pre-reading start function.............................................................................................................12- 84
12.7.9 Deceleration start flag function...................................................................................................12- 89
12.7.10 Stop command processing for deceleration stop function.....................................................12- 93
12.8 Servo ON/OFF ....................................................................................................................................12- 96
12.8.1 Servo ON/OFF .............................................................................................................................12- 96
12.8.2 Follow up function ........................................................................................................................12- 97
12.9 Precautions for MR-J2M-B connection ..............................................................................................12- 98
13. Common Functions 13- 1 to 13- 8
13.1 Outline of common functions...............................................................................................................13- 2
13.2 Parameter initialization function........................................................................................................... 13- 3
13.3 Execution data backup function ..........................................................................................................13- 5
13.4 External I/O signal logic switching function.........................................................................................13- 7
13.5 External I/O signal monitor function ....................................................................................................13- 8
A - 10
14. Dedicated Instructions 14- 1 to 14- 18
14.1 List of dedicated instructions ...............................................................................................................14- 2
14.2 Interlock during dedicated instruction is executed..............................................................................14- 2
14.3 PSTRT1, PSTRT2, PSTRT3, PSTRT4...............................................................................................14- 3
14.4 TEACH1, TEACH2, TEACH 3, TEACH 4...........................................................................................14- 7
14.5 PFWRT................................................................................................................................................14- 11
14.6 PINIT....................................................................................................................................................14- 15
15. Troubleshooting 15- 1 to 15-106
15.1 Error and warning details.....................................................................................................................15- 2
15.2 List of errors .........................................................................................................................................15- 6
15.2.1 QD75 detection error.....................................................................................................................15- 6
15.2.2 MR-H-BN detection error.............................................................................................................15- 34
15.2.3 MR-J2-B detection error...............................................................................................................15- 46
15.2.4 MR-J2S-B detection error............................................................................................................15- 56
15.2.5 MR-J2-Jr detection error..............................................................................................................15- 66
15.2.6 MR-J2M-B detection error ...........................................................................................................15- 76
15.3 List of warnings ...................................................................................................................................15- 90
15.3.1 QD75 detection warning ..............................................................................................................15- 90
15.3.2 MR-H-BN detection warning........................................................................................................15- 96
15.3.3 MR-J2-B detection warning .........................................................................................................15- 98
15.3.4 MR-J2S-B detection warning......................................................................................................15-100
15.3.5 MR-J2-Jr detection warning........................................................................................................15-102
15.3.6 MR-J2M-B detection warning .....................................................................................................15-104
15.4 LED display functions ........................................................................................................................15-106
Appendices Appendix- 1 to Appendix-76
Appendix 1 Functions........................................................................................................................Appendix- 3
Appendix 1.1 Multiple CPU correspond function..........................................................................Appendix- 3
Appendix 1.2 The combination of software package for QD75 and QCPU................................Appendix- 3
Appendix 2 Positioning data (No.1 to 600) List of buffer memory addresses.................................Appendix- 4
Appendix 3 Connection with servo amplifiers .................................................................................Appendix- 28
Appendix 3.1 Connection of SSCNET cables.............................................................................Appendix- 28
Appendix 3.2 Wiring of SSCNET cables .....................................................................................Appendix- 30
Appendix 4 Connection with external device connector.................................................................Appendix- 34
Appendix 4.1 Connector...............................................................................................................Appendix- 34
Appendix 4.2 Wiring of manual pulse generator cable ...............................................................Appendix- 36
Appendix 5 Comparisons with conventional positioning modules..................................................Appendix- 37
Appendix 5.1 Comparisons with QD75P model..........................................................................Appendix- 37
Appendix 5.2 Comparisons with A1SD75M1/A1SD75M2/ A1SD75M3 models........................Appendix- 38
A - 11
Appendix 6 Positioning control troubleshooting ..............................................................................Appendix- 57
Appendix 7 List of buffer memory addresses..................................................................................Appendix- 63
Appendix 8 External dimension drawing.........................................................................................Appendix- 75
INDEX Index- 1 to Index - 10
INDEX.....................................................................................................................................................Index - 1
A - 12
About Manuals
The following manuals are also related to this product.
In necessary, order them by quoting the details in the tables below.
Related Manuals
Manual Name
Type QD75M Positioning M odule U ser's Manual (Hardware)
Describes the performance, specifications, Input interface, component names, and startup procedure of
the respective positioning modules: Type QD75M
(The manual is supplied with the module.)
GX Configurator-QP Operating Manual
Describes how to use GX Configurator-QP for the following and other purposes: creating data
(parameters, positioning data, etc.), sending the data to the module, monitoring the positioning
operations, and testing.
(The manual is supplied with the software.)
Using This Manual
The symbols used in this manual are shown below.
Pr.
Da.
....... Symbol indicating positioning parameter and OPR parameter item.
....... Symbol indicating positioning data, block start data and condition
data item.
Md.
Cd.
....... Symbol indicating monitor data item.
....... Symbol indicating control data item.
(A serial No. is inserted in the
mark.)
Conformation to the EMC Directive
The CE logo is printed on the rating plate on the main body of the PLC that
conforms to the EMC directive and low voltage instruction.
To make this product conform to the EMC directive and low voltage instruction,
please refer to section 4.3.1 "Precautions for wiring" of the chapter 4 "Installation,
Wiring and Maintenance of the Product" and the EMC Installation Guidelines
(IB(NA)67339).
Representation of numerical values used in this manual.
Buffer memory addresses, error codes and warning codes are represented in
decimal.
X/Y devices are represented in hexadecimal.
Setting data and monitor data are represented in decimal or hexadecimal. Data
ended by "H" or "h" are represented in hexadecimal.
(Example) 10.........Decimal
10H......Hexadecimal
Manual Number
(Model Code)
IB-0300031
(1XB750)
SH-080172
(13JU19)
A - 13
Generic Terms and Abbreviations
Unless specially noted, the following generic terms and abbreviations are used in this
manual.
Generic term/abbreviation Details of generic term/abbreviation
PLC CPU Generic term for PLC CPU on which QD75 can be mounted.
QD75
MR-H-BN Servo amplifier: Abbreviation for MR-H-BN/MR-HB.
MR-J2-Jr Servo amplifier: Abbreviation for MR-J2-03B5.
MR-J2-B Servo amplifier: Abbreviation for MR-J2-B/MR-J2S-B/MR-J2-Jr/MR -J2M-B.
Peripheral device
GX Developer Abbreviation for GX Developer (SW4D5C-GPPW-E or later).
GX Configurator-QP Abbreviation for GX Configurator-QP (SW2D5C-QD75P-E or later).
Servo amplifier (drive unit) Abbreviation for SSCNET compatible servo amplifier (drive unit).
Manual pulse generator Abbreviation for manual pulse generator (MR-HDP01) (prepared by user).
DOS/V personal computer IBM PC/AT® and compatible DOS/V compliant personal computer.
Personal computer Generic term for DOS/V personal computer.
Workpiece Generic term for moving body such as workpiece and tool, and for various control targets.
Axis 1, axis 2, axis 3,
axis 4
1-axis, 2-axis, 3-axis,
4-axis
OPR Generic term for "Home position return".
OP Generic term for "Home position".
SSCNET
(Note)
Generic term for positioning module QD75M1, QD75M 2 and Q D75M4.
The module type is described to indicate a specific module.
Generic term for DOS/V personal computer that can run the following "GX Dev eloper" and
"GX Configurator-QP".
Indicates each axis connected to QD75.
Indicates the number of axes. (Example: 2-axis = Indicates two axes such as axis 1 and axis 2,
axis 2 and axis 3, and axis 3 and axis 1.)
High speed synchronous communication network between QD75 and serv o amplifier.
(Note): SSCNET: Servo System Controller NETwork
Component List
The table below shows the component included in respective positioning modules:
Module name
QD75M1 QD75M2 QD75M4
QD75M1 positioning module 1
QD75M2 positioning module 1
QD75M4 positioning module 1
Quantity
A - 14
Section 1
Section 1 Product Specifications and Handling
Section 1 is configured for the following purposes (1) to (5).
(1) To understand the outline of positioning control, and the QD75 specifications
and functions
(2) To carry out actual work such as installation and wiring
(3) To set parameters and data required for positioning control
(4) To create a PLC program required for positioning control
(5) To understand the memory configuration and data transmission process
When diverting any of the program examples introduced in this manual to the actual
system, fully verify that there are no problems in the controllability of the target system.
Read "Section 2" for details on each control.
Chapter 1 Product outline .............................................................................................. 1- 1 to 1- 28
Chapter 2 System configuration .................................................................................... 2- 1 to 2- 8
Chapter 3 Specifications and Functions........................................................................ 3- 1 to 3- 22
Chapter 4 Installation, Wiring and Maintenance of the Product ................................... 4- 1 to 4- 16
Chapter 5 Data Used for Positioning Control................................................................ 5- 1 to 5-162
Chapter 6 PLC Program Used for Positioning Control ................................................. 6- 1 to 6- 72
Chapter 7 Memory Configuration and Data Process.................................................... 7- 1 to 7- 20
MEMO
1
Chapter 1 Product Outline
The purpose and outline of positioning control using QD75 are explained in this chapter.
Reading this chapter will help you understand what can be done using the positioning
system and which procedure to use for a specific purpose.
By understanding "What can be done", and "Which procedure to use" beforehand, the
positioning system can be structured smoothly.
1.1 Positioning control ........................................................................................................1- 2
1.1.1 Features of QD75 ...........................................................................................1- 2
1.1.2 Purpose and applications of positioning control ............................................1- 5
1.1.3 Mechanism of positioning control...................................................................1- 7
1.1.4 Overview of positioning control functions.......................................................1- 8
1.1.5 Outline design of positioning system.............................................................1- 18
1.1.6 Communicating signals between QD75 and each module ..........................1- 19
1.2 Flow of system operation ............................................................................................1- 22
1.2.1 Flow of all processes .....................................................................................1- 22
1.2.2 Outline of starting...........................................................................................1- 24
1.2.3 Outline of stopping.........................................................................................1- 26
1.2.4 Outline for restarting ......................................................................................1- 27
1 - 1
1 PRODUCT OUTLINE
1.1 Positioning control
1.1.1 Features of QD75
The features of the QD75 are shown below.
(1) Av ailability of one, two, and four axis modules
(2) Wide variety of positioning control functions
MELSEC-Q
(a) One, two and four axis positioning modules are available.
They can be selected according to the PLC CPU type and the number of
required control axes. (Refer to Section 2.2.)
(b) For connecting any of the QD75 modules to the base unit, a single slot and
32 dedicated I/O channels are required.
Within the limit imposed by the maximum number of inputs and outputs
supported by the PLC CPU, up to 64 modules can be used. (Refer to
Section 2.3.)
(a) A wide variety of positioning control functions essential to any positioning
system are supported: positioning to an arbitrary position, fixed-feed
control, equal-speed control, and so on. (Refer to Section 5.3 and 9.2.)
1) Up to 600 positioning data items, including such information as
positioning addresses, control systems, and operation patterns, can be
prepared for each axis.
Using the prepared positioning data, the positioning control is
performed independently for each axis. (In addition, such controls as
interpolation involving two to four axes and simultaneous startup of
multiple axes are possible.)
2) Independent control of each axis can be achieved in linear control
mode (executable simultaneously over four axes).
Such control can either be the independent positioning control using a
single positioning data or the continuous positioning control enabled by
the continuous processing of multiple positioning data.
3) Coordinated control over multiple axes can take the form of either the
linear interpolation through the speed or position control of two to four
axes or the circular interpolation involving two axes.
Such control can either be the independent positioning control using a
single positioning data or the continuous positioning control enabled by
the continuous processing of multiple positioning data.
(b) For each positioning data, the user can specify any of the following control
systems: position control, speed control, speed-position switching control,
position-speed switching control, and so on. (Refer to Section 5.3 and 9.2.)
1 - 2
1 PRODUCT OUTLINE
(3) Quick startup (Refer to Section 3.1.)
(4) SSCNET makes the connection to the servo amplifier possibl e
(5) Easy application to the absolute positi on sy stem
MELSEC-Q
(c) Continuous positioning control using multiple positioning data can be
executed in accordance with the operation patterns the user assigned to
the positioning data. (Refer to Section 5.3 and 9.1.2.)
Continuous positioning control can be executed over multiple blocks, where
each block consists of multiple positioning data. (Refer to Section 10.3.2.)
(d) OPR control is given additional features (Refer to Section 8.2.)
Four different machine OPR methods are provided: the near point dog
method, two count methods, and the data set method.
(e) Two acceleration/deceleration control methods are provided: automatic
trapezoidal acceleration/deceleration and S-pattern acceleration/
deceleration. (Refer to Section 12.7.7.)
A positioning operation starts up quickly taking as little as 6 ms to 7.
When operation using simultaneous start function or interpolation operation is
executed, the axes start without delay.
(Example) Axis 1 and Axis 3 are started by the : No delay in Axis 1 and
simultaneous start function Axis 3 start
Axis 2 and Axis 4 are started by the : No delay in Axis 2 and
interpolation operation Axis 4 start
(a) The QD75 can be directly connected to the servo amplifier using the
MELSERVO (Mit subi sh i' s serv o a mplifie r: M R-H-B N, MR -H-BN4 , M R-J2-B ,
MR-J2S-B, MR-J2-Jr, MR-J2M-B) and SSCNET.
(b) Because the SSCNET cable is used to connect the QD75 and the servo
amplifier, or servo amplifiers, saving wiring can be realized. The cable
between the QD75 and servo amplifier or servo amplifiers can be extended
up to 30m.
(c) The servo parameters can be set on the QD75 side to write or read them
to/from the servo amplifier using the SSCNET.
(d) The actual current value and error description contained in the servo can
be checked by the buffer memory of the QD75.
(a) The absolute position-corresponding servo amplifier is connected to have
an application to the absolute position system.
(b) Once the OP have been established, the OPR operation can also be made
unnecessary when the power is supplied.
(c) With the absolute position system, the data set method OPR is used to
establish the OP.
(d) When the setting unit is "degree", the absolute position system with
unlimited length feed can be configured.
1 - 3
1 PRODUCT OUTLINE
(6) Control can be realiz ed with the mechanical system input
(7) Easy maintenance
(8) Support of intelligent function module dedicated instructions
(9) Setups, monitoring, and testing thr oug h GX C onfig ur ator- QP
MELSEC-Q
The external inputs, such as external start, stop, and speed/position switching is
used to perform the positioning control without using the PLC program.
Each QD75 positioning module incorporates the following improvements in
maintainability:
(a) Data such as the positioning data and parameters can be stored on a flash
ROM inside the QD75, eliminating the need of a battery for retaining data.
(Refer to Section 7.1.1.)
(b) Error messages are classified in more detail to facilitate the initial
troubleshooting procedure. (Refer to Section 15.1.)
(c) The module retains 16 error messages and 16 warning messages recently
output, offering more complete error and warning histories.
(Refer to Section 5.6.1.)
Dedicated instructions such as the positioning start instruction, and teaching
instruction are provided.
The use of such dedicated instruction simplifies PLC programs.(Refer to Chapter
14.)
Using GX Configurator-QP, the user can control the QD75 parameters and
positioning data without having to be conscious of the buffer memory addresses.
Moreover, GX Configurator-QP has a test function which allows the user to check
the wiring before creating a PLC program for positioning control, or test operation
the QD75 using created parameters and positioning data for checking their
integrity.
The control monitor function of GX Configurator-QP allows the user to debug
programs efficiently.
1 - 4
1 PRODUCT OUTLINE
1.1.2 Purpose and applications of positioning control
"Positioning" refers to moving a moving body, such as a workpiece or tool (hereinafter,
generically called "workpiece") at a designated speed, and accurately stopping it at the
target position. The main application examples are shown below.
Punch press (X, Y feed positioning
Gear and ball screw
Y axis
servomotor
Servo
amplifier
Y axis
Palletizer
Press head
Servo
amplifier
Conveyor control
Servomotor
(with brakes)
Servo
amplifier
Y axis
X axis
servomotor
G
Reduction
gears
Ball screw
(From QD75)
Conveyor
)
X axis
Y axis
X axis
Gear and rack & pinion
160mm
320mm
Press
punching
12s
PLC
MELSEC-Q
X axis
Position detector
Palletizer
Unloader control
QD75
15m/min
(2000r/min)
15m/min
(1875r/min)
MELSEC-Q
•
To punch insulation material or leather, etc.,
as the same shape at a high yield, positioning
is carried out with the X axis and Y axis
servos.
•
After positioning the table with the X axis
servo, the press head is positioned with the Y
axis servo, and is then punched with the
press.
•
When the material type or shape changes, the
press head die is changed, and the positioning
pattern is changed.
•
Using the servo for one axis, the palletizer is
positioned at a high accuracy.
•
The amount to lower the palletizer according to
the material thickness is saved.
PLC
MELSEC-Q
QD75
Compact machining center (ATC magazine positioning)
Servo
amplifier
QD75
Servomotor
Coupling
Positioning
pin
PLC
MELSEC-Q
Reduction
gears
ATC tool
magazine
Tool
(12 pcs., 20 pcs.)
Rotation direction
for calling
11, 12, 1, 2 or 3
1
2
12
11
<No. of tools: 12> <No. of tools: 20>
3
Current
value
410
95
8
7
retrieval
position
6
Rotation direction
for cal ling 5, 6, 7, 8, 9 or 10
1
220
19
18
17
16
15
14
13
10
12
11
Rotation direction
for calling
17 to 20, 1 to 5
3
4
Current
5
value
6
retrieval
7
8
position
9
Rotation direction
for calling 7 to 16
1 - 5
•
The ATC tool magazine for a compact
machining center is positioned.
•
The relation of the magazine's current value
and target value is calculated, and positioning
is carried out with forward run or reverse run to
achieve the shortest access time.
r
1 PRODUCT OUTLINE
Lifter (Storage of Braun tubes onto aging rack)
B conveyor
Lifter
Counterweight
Reduction
gears
Servomotor
(with brakes)
G1
A conveyor
Loader
C conveyor
G2
Servomotor
Servo
amplifier
Aging rack
Index table (High-accuracy indexing of angle)
PLC
MELSEC-Q
Digital switch
QD75
Unloader
Loader/unloader
Servo
amplifier
PLC MELSEC-Q
QD75
Servo
amplifie
MELSEC-Q
•
During the aging process of Braun tubes,
storage onto the rack is carried out by
positioning with the AC servo.
•
The up/down positioning of the lifter is carried
out with the 1-axis servo, and the horizontal
position of the aging rack is positioned with the
2-axis servo.
•
The index table is positioned at a high accuracy
using the 1-axis servo.
Index table
Worm gears
Inner surface grinder
PLC
MELSEC-Q
Inverter
220VAC
60Hz
QD75
Servomotor
G
Servo
amplifier
Motor
IM
Fix the grinding
stone, feed the
workpiece, and grind.
Operation panel
Workpiece
a
b
c
Grinding stone
d
e
G
Detector
Servomotor
Motor
G
IM
Inverter
a. Total feed
amount (µm)
b. Finishing
feed amount (µm)
c. Compensation
amount (µm)
d. Rough grind ing speed (µm/s)
e. Fine grinding
speed (µm/s)
•
The grinding of the workpiece's inner surface
is controlled with the servo and inverter.
•
The rotation of the workpiece is controlled with
the 1-axis inverter, and the rotation of the
grinding stone is controlled with the 2-axis
inverter. The workpiece is fed and ground with
the 3-axis servo.
1 - 6
1 PRODUCT OUTLINE
1.1.3 Mechanism of positioning control
In the positioning system using the QD75, various software and devices are used for
the following roles. The QD75 realizes complicated positioning control when it reads in
various signals, parameters and data and is controlled with the PLC CPU.
MELSEC-Q
Creates control order and
conditions as a sequence
program.
GX Developer
GX
Configurator
-QP
Sets the parameters and
positioning data for control.
Outputs the start command for
JOG operation, etc., during test
operat i on with t he test mo de.
Monitors the positioning operation.
PLC CPU
QD75 positioning
module
Servo
amplifier
Stores the created program.
The QD75 outputs the start signal and
stop signal following the stored program.
QD75 errors, etc., are detected.
Outputs signals such as the start
signal, stop signal, limit signal and
control changeover signal to the QD75.
External signal
Stores the parameter and data.
Outputs datas to the servo according to the
instructions from the PLC CPU, GX Configurator-QP,
external signals and manual pulse generator.
Manual pulse
generator
Receives positioning commands and control
commands from QD75, and drives the motor.
Outputs the positioning data of the motor
data and etc. to the QD75 by the SSCNET.
Issues commands by
transmitting pulses.
Motor
Carries out the actual work according to commands
from the servo.
Workpiece
(Note): For QD75M1, 2 and 4, use SW2D5C-QD75P or later of the GX Configurator.
1 - 7
1 PRODUCT OUTLINE
1.1.4 Overview of positioni ng contr ol functions
The outline of the "overview of positioning control" and "overview of individual
positioning control and continuous positioning control", "overview of block positioning
control" and "overview of acceleration/deceleration processing control" is shown below.
Positioning control
An overview of positioning using positioning data described below.
(1) Linear control
(a) 1-axis linear control
This performs positioning from the start point address (location the axis is
presently stopped) defined on the specified axis to the specified position.
[Control using the absolute system]
1) This performs positioning from the start point address to the specified
position.
2) The start point address and the specified address determine the
movement direction.
[Example]
The following figure shows the operations when the start point address
is 5000 and the positioning address are 2000 and 8000:
2000 5000 8000
MELSEC-Q
Positioning when the specified
address is 2000
Positioning when the specified
address is 8000
Start point address
[Control using the increment system]
1) This performs positioning from the specified increment of travel from the
start point address.
2) The sign of the travel increment determines the direction of travel.
• For positive travel increment…….Positioning in the positive direction
(direction of address increase)
• For negative travel increment…...Positioning in the negative direction
(direction of address decrease)
[Example]
The following figure shows the operations when the start point address
is 5000 and the travel increments are 3000 and -3000:
2000 5000 8000
Movement direction for a negative
movement amount.
Movement direction for a positive
movement amount.
Positioning when the specified
address is -3000.
Positioning when the specified
address is 3000.
Start point address
1 - 8
t
1 PRODUCT OUTLINE
MELSEC-Q
(b) 2-axis linear interpolation control
(Note)
This controls interpolation along a linear locus from the start point address
(current stop position) defined by two axes.
[Control using the absolute system]
1) This performs linear interpolation using two axes from the start point
address to the endpoint address.
2) The start point address and the specified address determine the
direction of travel.
[Example]
The operation when the start point address is 800 for axis 1 and 2000
for axis 2 and the positioning address specified to 2000 for axis 1 and
8000 for axis 2, is shown below.
Axis 1
2000
Start point address
(2000, 800)
800
0
2000
Specified address
(8000, 2000)
Positioning operation
8000
Axis 2
[Control using the increment system]
1) This performs positioning from the specified increment of travel from the
start point address.
2) The sign of the travel increment determines the direction of travel.
• For positive travel increment…….Positioning in the positive direction
(direction of address increase)
• For negative travel increment…….Positioning in the negative direction
(direction of address decrease)
[Example]
The operation when the start point address is 800 for axis 1 and 2000
for axis 2 and the positioning address specified to 1200 for axis 1 and
2000
6000 for axis 2, is shown below.
Axis 1
Start point address
(2000, 800)
End position when the travel incremen
is 1200 for axis 1 and 6000 for axis 2.
800
0
2000
Positioning operation
8000
Axis 2
REMARK
(Note): The interpolation speed during linear interpolation control can be selected
from "synthesized axis" and "reference-axis speed" using the detailed
parameter 1. (Refer to the Section 5.2.3 information about setting "
Interpolation speed designation method" of the detailed parameter 1.)
1 - 9
Pr.20
1 PRODUCT OUTLINE
MELSEC-Q
(2) Circular interpolati on control
(Note)
There are two types of circular interpolation controls: circular interpolation with a
specified sub point and circular interpolation with the specified center point.
(a) Circular interpolation with a specified sub point
Circular interpolation is performed using the specified endpoint address and
sub point (passing point) address.
Two methods are available: absolute system and increment system.
Forward
direction
Reverse
direction
Sub point
Start point
address
Reverse
direction
End point
Center point
(Calculated by the QD75)
Forward
direction
(b) Circular interpolation with the specified center point
Circular interpolation is performed using the specified endpoint address and
center point address.
Two methods are available: absolute system and increment system.
Also, the direction of movement can be selected from clockwise or
counterclockwise.
Forward
direction
End poi nt
Reverse
direction
Stop position
Reverse
direction
Center point
Forward
direction
REMARK
(Note): The interpolation speed during circular interpolation control may only be set
to "synthesized speed" for the interpolation speed of the detailed parameter
1. (Refer to the Section 5.2.3 information about setting "
speed designation method" of the detailed parameter 1.)
1 - 10
Pr.20
Interpolation
t
1 PRODUCT OUTLINE
(3) Fixed-feed control
Positioning direction
[1-axis fixed-feed control]
MELSEC-Q
This performs positioning for the specified increment of travel. The fixed-feed
control includes 1-axis control and 2-axis control through linear interpolation
using the specified two axes.
Operation timing
V
Stop position
Forward directionReverse direction
Movement direction for
a negative movement amount
[2-axis fixed-feed control]
Forward
direction
Travel along
axis 1
Reverse
direction
Stop position
Reverse
direction
Movement direction for
a positive movement amount
Travel along axis 2
Positioning
direction
Forward
direction
Start
command
Start
ON
OFF
(4) Speed control
After command is executed, control continues with the command speed until the
stop command is input.
V
t
ON
Positioning start
signal
BUSY signal
Axis stop signal
OFF
ON
OFF
ON
OFF
(By the PLC
program creation)
1 - 11
1 PRODUCT OUTLINE
(5) Speed-position switching contr ol
MELSEC-Q
This starts positioning under speed control, and switches to position control
according to the input of the QD75 speed-position switching signal and perform
positioning for the specified increment of travel.
V
Specified travel
increment
Dwell time
t
(By the PLC
program creation)
Positioning start signal
BUSY signal
Speed-position switching
signal (external signal)
Speed-position switching
enable flag
Speed control Position control
ON
OFF
ON
OFF
ON
OFF
ON
OFF
1 - 12
1 PRODUCT OUTLINE
Individual positioning control and continuous positioning control
The QD75 performs positioning according to the user-set positioning data, which is a
set of information comprised of the control method (position control, speed control,
speed-position switching control), positioning address, operation pattern, and so on.
Up to 600 of positioning data are assigned respectively to positioning data Nos. 1 to
600 per axis and registered to the QD75.
The operation pattern set in each positioning data by the user determines whether to
perform positioning operation with one positioning data item or to perform continuous
positioning operation with multiple positioning data items.
(1) Independent positioning control (oper ati on patter n = 00: posi ti oning
MELSEC-Q
complete)
The operation completed upon completion of positioning for the specified
positioning data. The positioning completion of this operation pattern is also used
as the operation pattern for the last positioning data of continuous positioning and
continuous-locus positioning.
V
Positioning complete (00)
Dwell time
t
ON
Positioning start signal
Positioning start
complete signal
BUSY signal
Positioning complete
signal
OFF
ON
OFF
ON
OFF
ON
OFF
(By the PLC
progr am creation)
1 - 13
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