Omron TJ1-MC16, TJ1-ML16, TJ1-MC04, TJ1-FL02, TJ1-PRT PROGRAMMING Manual
...
Cat. No.
I51E-EN-03
TJ1-MC04, TJ1-MC16, TJ1-ML04, TJ1-ML16, TJ1-PRT, TJ1-DRT, TJ1-FL02
Notice
OMRON products are manufactured for use according to proper procedures
by a qualified operator and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in
this manual. Always heed the information provided with them. Failure to
heed precautions can result in injury to people or damage to property.
Definition of precautionary information
DANGER
Indicates an imminently hazardous situation, which, if not avoided,
will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation, which, if not avoided,
could result in death or serious injury.
/i
Caution
Indicates a potentially hazardous situation, which, if not avoided,
may result in minor or moderate injury, or property damage.
© OMRON, 2007
Trademarks and Copyrights
PROFIBUS is a registered trademark of PROFIBUS International.
MECHATROLINK is a registered trademark of Yaskawa Corporation.
DeviceNet is a registered trademark of Open DeviceNet Vendor Assoc INC.
CIP is a registered trademark of Open DeviceNet Vendor Assoc INC.
Revision 3.0
Trajexia is a registered trademark of OMRON.
Motion Perfect is a registered trademark of Trio Motion Technology Ltd.
HARDWARE REFERENCE MANUAL 2
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying,
recording, or otherwise, without the prior written permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein.
Moreover, because OMRON is constantly striving to improve its high-quality products, the
information contained in this manual is subject to change without notice. Every precaution
has been taken in the preparation of this manual. Nevertheless, OMRON assumes no
responsibility for errors or omissions. Neither is any liability assumed for damages resulting
from the use of the information contained in this publication.
About this manual
Name Cat. No. Contents
This manual describes the installation and operation of the Trajexia Motion
Control System.
Please read this manual and the related manuals listed in the following table
carefully and be sure you understand the information provided before
attempting to install or operate the Trajexia Motion Control units. Be sure to
read the precautions provided in the following section.
/i
Name Cat. No. Contents
Trajexia motion control system
QUICK START GUIDE
Trajexia motion control system
HARDWARE REFERENCE
MANUAL
Trajexia motion control system
PROGRAMMING MANUAL
Sigma-II Servo Driver manual SIEP S800000 15 Describes the installation and
JUNMA series servo drive
manual
JUSP-NS115 manual SIEP C71080001 Describes the installation and
Revision 3.0
I50E Describes how to get quickly
familiar with Trajexia, moving
a single axis using MECHATROLINK-II, in a test set-up.
I51E Describes the installation and
hardware specification of the
Trajexia units, and explains
the Trajexia system philosophy.
I52E Describes the BASIC com-
mands to be used for programming Trajexia, explains
the communication protocols
and Trajexia Tools software,
gives practical examples and
troubleshooting information.
operation of Sigma-II servo
drives
TOEP-C71080603 01-OY Describes the installation and
operation of JUNMA servo
drives
operation of the MECHATROLINK-II application module
Sigma-III with MECHATROLINK interface manual
V7 Inverter TOEP C71060605 02-OY Describes the installation and
F7Z Inverter TOE S616-55 1-OY Describes the installation and
G7 Inverter TOE S616-60 Describes the installation and
SI-T MECHATROLINK interface for the G7 & F7
ST-T/V7 MECHATROLINK
interface for the V7
MECHATROLINK IO Modules SIE C887-5 Describes the installation and
SYSMAC CS/CJ Series Communications Commands
SIEP S800000 11 Describes the installation and
operation of Sigma-III servo
drives with MECHATROLINK interface
operation of V7 inverters
operation of F7Z inverters
operation of G7 inverters
SIBP-C730600-08 Describes the installation and
operation of MECHATROLINK interfaces for G7 and
F7 inverters
SIBP-C730600-03 Describes the installation and
operation of MECHATROLINK interfaces for V7 inverters
operation of MECHATROLINK input and output modules and the
MECHATROLINK-II repeater
W342 Describes FINS communica-
tions protocol and FINS commands
WARNING
Failure to read and understand the information provided in this
manual may result in personal injury or death, damage to the product, or product failure. Please read each section in its entirety and
be sure you understand the information provided in the section and
related sections before attempting any of the procedures or operations given.
HARDWARE REFERENCE MANUAL 3
Functions supported by unit versions
During the development of Trajexia new functionality was added to the
controller unit after market release.
This functionality is implemented in the firmware, and/or the FPGA of the
controller unit.
In the table below, the overview of the applicable functionality is shown
related to the firmware and FPGA version of the TJ1-MC__.
/i
Functionality TJ1-MC__ Firmware
version
Full support TJ1-FL02 V1.6509 21 and higher.
Support BASIC commands
FINS_COMMS
Support TJ1-DRT V1.6509 All versions
Support TJ1-MC04 and
TJ1-ML04
V1.6509 All versions
V1.6607 21 and higher
TJ1-MC__ FPGA version
Verify the firmware and FPGA versions of the TJ1-MC__
Connect the TJ1-MC__ to Trajexia Tools software. Refer to the
Programming Manual.
Open the terminal window and type the following commands:
Type
PRINT VERSION in the terminal window. The version parameter returns
the current firmware version number of the motion controller.
PRINT FPGA_VERSION SLOT(-1) in the terminal window. The
Type
parameter returns the current FPGA version number of the TJ1-MC__.
Revision 3.0
HARDWARE REFERENCE MANUAL 4
Contents
1 Safety warnings and precautions................................................................................................................................................................8
1.1 Intended audience ............................................................................................................................................................................................................................8
1.2 General precautions .........................................................................................................................................................................................................................8
1.3 Safety precautions............................................................................................................................................................................................................................8
1.4 Operating environment precautions..................................................................................................................................................................................................9
1.5 Application precautions...................................................................................................................................................................................................................10
1.6 Unit assembly precautions..............................................................................................................................................................................................................13
1.7 Conformance to EC Directives Conformance.................................................................................................................................................................................13
1.7.1 Concepts ..........................................................................................................................................................................................................................13
1.7.2 Conformance to EC Directives .........................................................................................................................................................................................13
2 System philosophy .....................................................................................................................................................................................14
2.1 Introduction.....................................................................................................................................................................................................................................14
2.2 Motion control concepts..................................................................................................................................................................................................................16
2.2.1 PTP control.......................................................................................................................................................................................................................17
2.2.2 CP control.........................................................................................................................................................................................................................20
2.2.3 EG control.........................................................................................................................................................................................................................22
2.2.4 Other operations...............................................................................................................................................................................................................25
2.3 Servo system principles..................................................................................................................................................................................................................27
2.4 Trajexia system architecture .........................................................................................................................................................................................................30
2.5 Cycle time ......................................................................................................................................................................................................................................31
2.6 Program control and multi-tasking ..................................................................................................................................................................................................37
2.7 Motion sequence and axes.............................................................................................................................................................................................................40
2.7.1 Profile generator ..............................................................................................................................................................................................................41
2.7.2 Position loop ....................................................................................................................................................................................................................41
2.7.3 Axis sequence .................................................................................................................................................................................................................41
2.7.4 Type of axis .....................................................................................................................................................................................................................41
2.8 Motion buffers ...............................................................................................................................................................................................................................48
2.9 Mechanical system .........................................................................................................................................................................................................................50
3 Hardware reference .................................................................................................................................................................................... 51
3.1 Introduction.....................................................................................................................................................................................................................................51
3.1.1 Trajexia High-Lights .........................................................................................................................................................................................................52
3.1.2 Trajexia Tools ...................................................................................................................................................................................................................53
3.1.3 This manual ......................................................................................................................................................................................................................53
3.2 All units ..........................................................................................................................................................................................................................................54
Revision 3.0
HARDWARE REFERENCE MANUAL 5
3.2.1 System installation ...........................................................................................................................................................................................................54
3.2.2 Environmental and storage for all units ..........................................................................................................................................................................61
3.2.3 Unit dimensions ...............................................................................................................................................................................................................62
3.2.4 Wire the Weidmüller connectors.......................................................................................................................................................................................64
Contents
Revision 3.0
3.3 Power Supply Unit (PSU) ...............................................................................................................................................................................................................66
3.3.1 Introduction.......................................................................................................................................................................................................................66
3.3.2 PSU Connections .............................................................................................................................................................................................................66
3.3.3 PSU Specifications ...........................................................................................................................................................................................................67
3.3.4 PSU box contents.............................................................................................................................................................................................................67
3.4 TJ1-MC__ .....................................................................................................................................................................................................................................68
3.4.1 Introduction.......................................................................................................................................................................................................................68
3.4.2 LED Display......................................................................................................................................................................................................................69
3.4.3 TJ1-MC__ Connections....................................................................................................................................................................................................70
3.4.4 Battery ..............................................................................................................................................................................................................................76
3.4.5 TJ1-MC__ Specification ..................................................................................................................................................................................................77
3.4.6 TJ1-TER ...........................................................................................................................................................................................................................78
3.4.7 TJ1-MC__ box contents ...................................................................................................................................................................................................78
3.5 TJ1-ML__........................................................................................................................................................................................................................................79
3.5.1 Introduction.......................................................................................................................................................................................................................79
3.5.2 LED Description................................................................................................................................................................................................................80
3.5.3 TJ1-ML__ Connection ......................................................................................................................................................................................................80
3.5.4 TJ1-ML__ Specifications .................................................................................................................................................................................................84
3.5.5 TJ1-ML__ box contents ....................................................................................................................................................................................................85
3.5.6 MECHATROLINK-II Servo Drivers Sigma-II series ..........................................................................................................................................................85
3.5.7 MECHATROLINK-II Servo Drivers Junma series.............................................................................................................................................................92
3.5.8 MECHATROLINK-II Inverter V7 .......................................................................................................................................................................................98
3.5.9 MECHATROLINK-II Inverter F7 and G7.........................................................................................................................................................................102
3.5.10 MECHATROLINK-II digital I/O slaves ...........................................................................................................................................................................107
3.5.11 MECHATROLINK-II 4-Channel analogue input module ................................................................................................................................................117
3.5.12 MECHATROLINK-II 2-Channel analogue output module ..............................................................................................................................................123
3.5.13 MECHATROLINK-II repeater .........................................................................................................................................................................................128
3.6 TJ1-PRT .......................................................................................................................................................................................................................................131
3.6.1 Introduction.....................................................................................................................................................................................................................131
3.6.2 LEDs description ............................................................................................................................................................................................................131
3.6.3 Node number selectors ..................................................................................................................................................................................................132
3.6.4 TJ1-PRT Connections ................................................................................................................................................................................................... 132
3.6.5 TJ1-PRT Specifications .................................................................................................................................................................................................133
3.6.6 TJ1-PRT unit box contents .............................................................................................................................................................................................133
3.7 TJ1-DRT .......................................................................................................................................................................................................................................134
3.7.1 Introduction.....................................................................................................................................................................................................................134
3.7.2 LEDs description ...........................................................................................................................................................................................................134
3.7.3 Node number selectors ..................................................................................................................................................................................................135
3.7.4 TJ1-DRT Connections ...................................................................................................................................................................................................136
3.7.5 TJ1-DRT Specifications .................................................................................................................................................................................................137
HARDWARE REFERENCE MANUAL 6
Contents
3.7.6 TJ1-DRT unit box contents.............................................................................................................................................................................................137
3.8 TJ1-FL02 ......................................................................................................................................................................................................................................138
3.8.1 Introduction.....................................................................................................................................................................................................................138
3.8.2 LED description .............................................................................................................................................................................................................139
3.8.3 TJ1-FL02 connections ...................................................................................................................................................................................................140
3.8.4 TJ1-FL02 specifications .................................................................................................................................................................................................146
3.8.5 Incremental encoder.......................................................................................................................................................................................................147
3.8.6 Absolute encoder............................................................................................................................................................................................................149
3.8.7 Stepper ...........................................................................................................................................................................................................................153
3.8.8 Registration ....................................................................................................................................................................................................................153
3.8.9 Hardware PSWITCH ......................................................................................................................................................................................................154
3.8.10 TJ1-FL02 box contents...................................................................................................................................................................................................154
A Differences between Sigma-II and Junma .............................................................................................................................................. 162
Revision 3.0
HARDWARE REFERENCE MANUAL 7
Safety warnings and precautions
1 Safety warnings and precautions
1.1 Intended audience
This manual is intended for personnel with knowledge of electrical systems
(electrical engineers or the equivalent) who are responsible for the design,
installation and management of factory automation systems and facilities.
WARNING
Never short-circuit the positive and negative terminals of the batteries, charge the batteries, disassemble them, deform them by
applying pressure, or throw them into a fire.
The batteries may explode, combust or leak liquid.
1.2 General precautions
The user must operate the product according to the performance
specifications described in this manual.
Before using the product under conditions which are not described in the
manual or applying the product to nuclear control systems, railroad systems,
aviation systems, vehicles, safety equipment, petrochemical plants, and
other systems, machines and equipment that can have a serious influence
on lives and property if used improperly, consult your OMRON
representative.
1.3 Safety precautions
WARNING
Do not attempt to take the Unit apart and do not touch any of the
internal parts while power is being supplied.
Doing so may result in electrical shock.
WARNING
Do not touch any of the terminals or terminal blocks while power is
being supplied.
Doing so may result in electric shock.
Revision 3.0
WARNING
Fail-safe measures must be taken by the customer to ensure
safety in the event of incorrect, missing, or abnormal signals
caused by broken signal lines, momentary power interruptions, or
other causes.
Not doing so may result in serious accidents.
WARNING
Emergency stop circuits, interlock circuits, limit circuits, and similar
safety measures must be provided by the customer as external circuits, i.e., not in the Trajexia motion controller.
Not doing so may result in serious accidents.
WARNING
When the 24 VDC output (I/O power supply to the TJ1) is overloaded or short-circuited, the voltage may drop and result in the
outputs being turned off.As a countermeasure for such problems,
external safety measures must be provided to ensure safety in the
system.
WARNING
The TJ1 outputs will go off due to overload of the output transistors
(protection).As a countermeasure for such problems, external
safety measures must be provided to ensure safety in the system.
HARDWARE REFERENCE MANUAL 8
Safety warnings and precautions
WARNING
The TJ1 will turn off the WDOG when its self-diagnosis function
detects any error.As a countermeasure for such errors, external
safety measures must be provided to ensure safety in the system.
WARNING
Provide safety measures in external circuits, i.e., not in the Trajexia Motion Controller (referred to as "TJ1"), in order to ensure
safety in the system if an abnormality occurs due to malfunction of
the TJ1 or another external factor affecting the TJ1 operation.
Not doing so may result in serious accidents.
WARNING
Do not attempt to disassemble, repair, or modify any Units.
Any attempt to do so may result in malfunction, fire, or electric
shock.
Caution
Confirm safety at the destination unit before transferring a program
to another unit or editing the memory.
Doing either of these without confirming safety may result in injury.
Caution
Pay careful attention to the polarity (+/-) when wiring the DC power
supply.A wrong connection may cause malfunction of the system.
Caution
Tighten the screws on the terminal block of the Power Supply Unit
to the torque specified in this manual.
Loose screws may result in burning or malfunction.
1.4 Operating environment precautions
Caution
Do not operate the Unit in any of the following locations.
Doing so may result in malfunction, electric shock, or burning.
- Locations subject to direct sunlight.
- Locations subject to temperatures or humidity outside the
range specified in the specifications.
- Locations subject to condensation as the result of severe
changes in temperature.
- Locations subject to corrosive or flammable gases.
- Locations subject to dust (especially iron dust) or salts.
- Locations subject to exposure to water, oil, or chemicals.
- Locations subject to shock or vibration.
Caution
Caution
User programs written to the Motion Control Unit will not be automatically backed up in the TJ1 flash memory (flash memory function).
Revision 3.0
Take appropriate and sufficient countermeasures when installing
systems in the following locations.
Inappropriate and insufficient measures may result in malfunction.
- Locations subject to static electricity or other forms of noise.
- Locations subject to strong electromagnetic fields.
- Locations subject to possible exposure to radioactivity.
- Locations close to power supplies.
HARDWARE REFERENCE MANUAL 9
Safety warnings and precautions
Caution
The operating environment of the TJ1 System can have a large
effect on the longevity and reliability of the system.
Improper operating environments can lead to malfunction, failure,
and other unforeseeable problems with the TJ1 System.
Make sure that the operating environment is within the specified
conditions at installation and remains within the specified conditions during the life of the system.
1.5 Application precautions
WARNING
Do not start the system until you check that the axes are present
and of the correct type.
The numbers of the Flexible axes will change if MECHATROLINKII network errors occur during start-up or if the MECHATROLINK-II
network configuration changes.
WARNING
Check the user program for proper execution before actually running it in the Unit.
Not checking the program may result in an unexpected operation.
Caution
Take appropriate measures to ensure that the specified power with
the rated voltage and frequency is supplied. Be particularly careful
in places where the power supply is unstable.
An incorrect power supply may result in malfunction.
Caution
Install external breakers and take other safety measures against
short-circuiting in external wiring.
Insufficient safety measures against short-circuiting may result in
burning.
Caution
Do not apply voltage to the Input Units in excess of the rated input
voltage.
Excess voltage may result in burning.
Caution
Do not apply voltage or connect loads to the Output Units in
excess of the maximum switching capacity.
Excess voltage or loads may result in burning.
Caution
Always use the power supply voltage specified in this manual.
An incorrect voltage may result in malfunction or burning.
Caution
Disconnect the functional ground terminal when performing withstand voltage tests.
Not disconnecting the functional ground terminal may result in
Revision 3.0
HARDWARE REFERENCE MANUAL 10
burning.
Safety warnings and precautions
Caution
Always connect to a class-3 ground (to 100Ω or less) when installing the Units.
Not connecting to a class-3 ground may result in electric shock.
Caution
Always turn off the power supply to the system before attempting
any of the following.
Not turning off the power supply may result in malfunction or electric shock.
- Mounting or dismounting expansion Units, CPU Units, or any
other Units.
- Assembling the Units.
- Setting dipswitches or rotary switches.
- Connecting or wiring the cables.
- Connecting or disconnecting the connectors.
Caution
Be sure that all mounting screws, terminal screws, and cable connector screws are tightened to the torque specified in this manual.
Incorrect tightening torque may result in malfunction.
Caution
Remove the dust protective label after the completion of wiring to
ensure proper heat dissipation.
Leaving the dust protective label attached may result in malfunction.
Caution
Use crimp terminals for wiring. Do not connect bare stranded wires
directly to terminals.
Connection of bare stranded wires may result in burning.
Caution
Double-check all the wiring before turning on the power supply.
Incorrect wiring may result in burning.
Caution
Wire correctly.
Incorrect wiring may result in burning.
Caution
Leave the dust protective label attached to the Unit when wiring.
Removing the dust protective label may result in malfunction.
Caution
Mount the Unit only after checking the terminal block completely.
Caution
Revision 3.0
Be sure that the terminal blocks, expansion cables, and other
items with locking devices are properly locked into place.
Improper locking may result in malfunction.
HARDWARE REFERENCE MANUAL 11
Safety warnings and precautions
Caution
Confirm that no adverse effect will occur in the system before
changing the operating mode of the system.
Not doing so may result in an unexpected operation.
Caution
Resume operation only after transferring to the new CPU Unit the
contents of the VR and table memory required for operation.
Not doing so may result in an unexpected operation.
Caution
When replacing parts, be sure to confirm that the rating of a new
part is correct.
Not doing so may result in malfunction or burning.
Caution
Do not pull on the cables or bend the cables beyond their natural
limit. Doing so may break the cables.
Caution
UTP cables are not shielded. In environments that are subject to
noise use a system with shielded twisted-pair (STP) cable and
hubs suitable for an FA environment.
Do not install twisted-pair cables with high-voltage lines.
Do not install twisted-pair cables near devices that generate noise.
Do not install twisted-pair cables in locations that are subject to
high humidity.
Do not install twisted-pair cables in locations subject to excessive
dirt and dust or to oil mist or other contaminants.
Caution
Use the dedicated connecting cables specified in operation manuals to connect the Units.
Using commercially available RS-232C computer cables may
cause failures in external devices or the Motion Control Unit.
Caution
Outputs may remain on due to a malfunction in the built-in transistor outputs or other internal circuits.
As a countermeasure for such problems, external safety measures
must be provided to ensure the safety of the system.
Caution
Before touching the system, be sure to first touch a grounded
metallic object in order to discharge any static build-up.
Caution
The TJ1 will start operating in RUN mode when the power is
turned on and if a BASIC program is set to Auto Run mode.
Otherwise it might result in a malfunction or damage.
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HARDWARE REFERENCE MANUAL 12
Safety warnings and precautions
1.6 Unit assembly precautions
Caution
Install the unit properly.
Improper installation of the unit may result in malfunction.
Caution
Be sure to mount the TJ1-TER supplied with the TJ1-MC__ to the
right most Unit.
Unless the TJ1-TER is properly mounted, the TJ1 will not function
properly.
1.7 Conformance to EC Directives Conformance
1.7.1 Concepts
The concepts for the directives EMC and Low Voltage are as follows:
EMC Directives
OMRON devices that comply with EC Directives also conform to the related
EMC standards so that they can be more easily built into other devices or
machines. The actual products have been checked for conformity to EMC
standards. Whether the products conform to the standards in the system
used by the customer, however, must be checked by the customer.
EMC-related performance of the OMRON devices that comply with EC
Directives will vary depending on the configuration, wiring, and other
conditions of the equipment or control panel in which the OMRON devices
are installed. The customer must, therefore, perform final checks to confirm
that devices and the over-all machine conform to EMC standards.
1.7.2 Conformance to EC Directives
The Trajexia Motion Controllers comply with EC Directives.
To ensure that the machine or device in which a system is used complies
with EC directives, the system must be installed as follows:
1. The system must be installed within a control panel.
2. Reinforced insulation or double insulation must be used for the DC
power supplies used for the communications and I/O power supplies.
Low Voltage Directive
Revision 3.0
Always ensure that devices operating at voltages of 50 to 1,000 VAC or 75 to
1,500 VDC meet the required safety standards.
HARDWARE REFERENCE MANUAL 13
System philosophy
r
2 System philosophy
2.1 Introduction
The system philosophy is centred around the relationship between:
• System architecture
• Cycle time
• Program control and multi-tasking
• Motion sequence and axes
• Motion buffers
A clear understanding of the relationship between these concepts
is necessary to obtain the best results for the Trajexia system.
2.1.1 Glossary
Motion sequence
The Motion Sequence is responsible for controlling the position of
the axes.
Servo period
Defines the frequency at which the Motion Sequence is executed.
The servo period must be set according to the configuration of the
physical axes. The available settings are 0.5ms, 1ms or 2ms.
Cycle time
Is the time needed to execute one complete cycle of operations in
the TJ1-MC__. The cycle time is divided in 4 time slices of equal
time length, called "CPU Tasks". The cycle time is 1ms if
SERVO_PERIOD 0.5ms or 1ms and 2ms if the
SERVO_PERIOD=2ms.
TJ1-MC16
Progra m Buffer
BASIC PROGRAMS
Process 1
Process 2
Process 3
…
Process 14
Co mms
MC I/O
Ethernet
FINS
Ethernet
BUILT-IN TJ1-ML16
Via
Buffer &
Buffer &
profile
profile
generator
gererat or
TJ1-PRT
Profibus
AXIS CONTROL LOOP
Position
Posit ion
Loop
Loop
TJ1-ML16
-
TJ1 FL02
fig. 1
AXIS TYPE
AXIS TYPE
AXIS TYPE
Servo drive.
Posit ion
Position Loop
Loop
Speed Loop
Speed Loop
Servo drive.
Speed Loop
Torque Loop
To rqu e
Torque Loop
Loop
ENC
All othe
Servo
drives
MOT OR
ENC
MOT OR
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HARDWARE REFERENCE MANUAL 14
System philosophy
CPU tasks
The operations executed in each CPU task are:
CPU task Operation
First CPU task Motion Sequence
Low priority process
Second CPU task High priority process
Third CPU task Motion Sequence (only if SERVO_PERIOD=0.5ms)
LED Update
High priority process
Fourth CPU task External Communications
Program
A program is a piece of BASIC code.
Process
Is a program in execution with a certain priority assigned. Process 0
to 12 are Low priority processes and Process 13 and 14 are High
priority processes. First the process priority, High or Low, and then
the process number, from high to low, will define to which CPU task
the process will be assigned.
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HARDWARE REFERENCE MANUAL 15
System philosophy
2.2 Motion control concepts
The TJ1-MC__ offers these types of positioning control operations:
1. Point-to-Point (PTP) control
2. Continuous Path (CP) control
3. Electronic Gearing (EG) control.
This section introduces some of the commands and parameters
used in the BASIC programming of the motion control application.
Coordinate system
Positioning operations performed by the TJ1-MC__ are based on
an axis coordinate system. The TJ1-MC__ converts the position
data from either the connected Servo Driver or the connected
encoder into an internal absolute coordinate system.
The engineering unit that specifies the distances of travelling can
be freely defined for each axis separately. The conversion is
performed through the use of the unit conversion factor, which is
defined by the UNITS axis parameter. The origin point of the
coordinate system can be determined using the DEFPOS
command. This command re-defines the current position to zero or
any other value.
A move is defined in either absolute or relative terms. An absolute
fig. 2
move takes the axis (A) to a specific predefined position with
respect to the origin point. A relative move takes the axis from the
current position to a position that is defined relative to this current
position. The figure shows an example of relative (command
MOVE) and absolute (command MOVEABS) linear moves.
MOVE(30)
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0
HARDWARE REFERENCE MANUAL 16
MOVEABS(30)
MOVE(60)
MOVEABS(50)
MOVE(50)
50 100
A
System philosophy
2.2.1 PTP control
In point-to-point positioning, each axis is moved independently of
the other axis. The TJ1-MC__ supports the following operations:
• Relative move
• Absolute move
• Continuous move forward
• Continuous move reverse.
Relative and absolute moves
To move a single axis either the command MOVE for a relative
move or the command MOVEABS for an absolute move is used.
Each axis has its own move characteristics, which are defined by
the axis parameters.
Suppose a control program is executed to move from the origin to
an axis no. 0 (A) coordinate of 100 and axis no. 1 (B) coordinate of
50. If the speed parameter is set to be the same for both axes and
the acceleration and deceleration rate are set sufficiently high, the
movements for axis 0 and axis 1 will be as shown in the figure.
At start, both the axis 0 and axis 1 moves to a coordinate of 50 over
the same duration of time. At this point, axis 1 stops and axis 0
continues to move to a coordinate of 100.
fig. 3
B
50
MOVEABS(100) AXIS(0)
MOVEABS(50) AXIS(1)
0
50
100
A
The move of a certain axis is determined by the axis parameters.
Some relevant parameters are:
/i
Parameter Description
UNITS Unit conversion factor
ACCEL Acceleration rate of an axis in units/s
DECEL Deceleration rate of an axis in units/s
SPEED Demand speed of an axis in units/s
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2
2
2
System philosophy
Defining moves
The speed profile in this figure shows a simple MOVE operation.
Axis A is the time, axis B is the speed. The UNITS parameter for
this axis has been defined for example as meters. The required
maximum speed has been set to 10 m/s. In order to reach this
speed in one second and also to decelerate to zero speed again in
one second, both the acceleration as the deceleration rate have
2
been set to 10 m/s
. The total distance travelled is the sum of
distances travelled during the acceleration, constant speed and
deceleration segments. Suppose the distance moved by the MOVE
command is 40 m, the speed profile is given by the figure.
fig. 4
B
010123 456
ACCEL=10
DECEL=10
SPEED=10
MOVE(40)
A
The two speed profiles in these figures show the same movement
with an acceleration time respectively a deceleration time of 2
seconds. Again, Axis A is the time, axis B is the speed.
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fig. 5
B
010123 456
fig. 6
B
010123 456
ACCEL=5
DECEL=10
SPEED=10
MOVE(40)
A
ACCEL=10
DECEL=5
SPEED=10
MOVE(40)
A
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System philosophy
Move calculations
The following equations are used to calculate the total time for the
motion of the axes.
• The moved distance for the MOVE command is D.
• The demand speed is V.
• The acceleration rate is a.
• The deceleration rate is d.
/i
Acceleration time =
Acceleration distance =
Deceleration time =
Deceleration distance =
Constant speed distance =
Total time =
Continuous moves
The FORWARD and REVERSE commands can be used to start a
continuous movement with constant speed on a certain axis. The
FORWARD command moves the axis in positive direction and the
REVERSE command in negative direction. For these commands
also the axis parameters ACCEL and SPEED apply to specify the
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acceleration rate and demand speed.
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System philosophy
Both movements can be canceled by using either the CANCEL or
RAPIDSTOP command. The CANCEL command cancels the
move for one axis and RAPIDSTOP cancels moves on all axes.
The deceleration rate is set by DECEL.
2.2.2 CP control
Continuous Path control enables to control a specified path
between the start and end position of a movement for one or
multiple axes. The TJ1-MC__ supports the following operations:
• Linear interpolation
• Circular interpolation
•CAM control.
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HARDWARE REFERENCE MANUAL 20
System philosophy
Linear interpolation
In applications it can be required for a set of motors to perform a
move operation from one position to another in a straight line.
Linearly interpolated moves can take place among several axes.
The commands MOVE and MOVEABS are also used for the linear
interpolation. In this case the commands will have multiple
arguments to specify the relative or absolute move for each axis.
Consider the three axis move in a 3-dimensional plane in the figure.
It corresponds to the MOVE(50,50,50) command. The speed profile
of the motion along the path is given in the diagram. The three
parameters SPEED, ACCEL and DECEL that determine the multi
axis movement are taken from the corresponding parameters of the
base axis. The MOVE command computes the various
components of speed demand per axis.
A is the time axis, B is the speed axis.
fig. 7
2
1
3
B
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HARDWARE REFERENCE MANUAL 21
A
System philosophy
Circular interpolation
It may be required that a tool travels from the starting point to the
end point in an arc of a circle. In this instance the motion of two
axes is related via a circular interpolated move using the
MOVECIRC command.
Consider the diagram in the figure. It corresponds to the
MOVECIRC(-100,0,-50,0,0) command. The centre point and
desired end point of the trajectory relative to the start point and the
direction of movement are specified. The MOVECIRC command
computes the radius and the angle of rotation. Like the linearly
interpolated MOVE command, the ACCEL, DECEL and SPEED
variables associated with the base axis determine the speed profile
along the circular move.
CAM control
Additional to the standard move profiles the TJ1-MC__ also
provides a way to define a position profile for the axis to move. The
CAM command moves an axis according to position values stored
in the TJ1-MC__ Table array. The speed of travelling through the
profile is determined by the axis parameters of the axis.
The figure corresponds to the command CAM(0,99,100,20). A is
the time axis, B is the position axis.
fig. 8
fig. 9
-50
50
050
B
2.2.3 EG control
Electronic Gearing control allows you to create a direct gearbox link
or a linked move between two axes. The MC Unit supports the
following operations.
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• Electronic gearbox
• Linked CAM
HARDWARE REFERENCE MANUAL 22
A
System philosophy
• Linked move
• Adding axes
Electronic gearbox
The TJ1-MC__ is able to have a gearbox link from one axis to
another as if there is a physical gearbox connecting them. This can
be done using the CONNECT command in the program. In the
command the ratio and the axis to link to are specified.
In the figure, A is the Master axis, and B is the CONNECT axis.
/i
fig. 10
B
2:1
1:1
Axes Ratio CONNECT command
0 1
1:1 CONNECT(1,0) AXIS(1)
2:1 CONNECT(2,0) AXIS(1)
1:2 CONNECT(0.5,0) AXIS(1)
1:2
A
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System philosophy
Linked CAM control
Next to the standard CAM profiling tool the TJ1-MC__ also
provides a tool to link the CAM profile to another axis. The
command to create the link is called CAMBOX. The travelling
speed through the profile is not determined by the axis parameters
of the axis but by the position of the linked axis. This is like
connecting two axes through a cam.
In the figure, A is the Master axis (0) position, and B is the
CAMBOX Axis (1) position.
Linked move
The MOVELINK command provides a way to link a specified move
to a master axis. The move is divided into an acceleration,
deceleration and constant speed part and they are specified in
master link distances. This can be particularly useful for
synchronizing two axes for a fixed period.
The labels in the figure are:
A. Time axis.
B. Speed axis.
C. Master axis (1).
D. Synchronized.
E. MOVELINK axis (0).
fig. 11
B
A
fig. 12
B
DC
E
A
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System philosophy
Adding axes
It is very useful to be able to add all movements of one axis to
another. One possible application is for instance changing the
offset between two axes linked by an electronic gearbox. The TJ1MC__ provides this possibility by using the ADDAX command. The
movements of the linked axis will consists of all movements of the
actual axis plus the additional movements of the master axis.
In the figure, A is the time axis and B is the speed axis.
fig. 13
B
B
BASE(0)
ADDAX(2)
FORWARD
MOVE(100) AXIS(2)
MOVE(-60) AXIS(2)
A
A
B
A
2.2.4 Other operations
Canceling moves
In normal operation or in case of emergency it can be necessary to
Revision 3.0
cancel the current movement from the buffers. When the CANCEL
or RAPIDSTOP commands are given, the selected axis
respectively all axes will cancel their current move.
HARDWARE REFERENCE MANUAL 25
System philosophy
Origin search
The encoder feedback for controlling the position of the motor is
incremental. This means that all movement must be defined with
respect to an origin point. The DATUM command is used to set up
a procedure whereby the TJ1-MC__ goes through a sequence and
searches for the origin based on digital inputs and/or Z-marker from
the encoder signal.
Print registration
The TJ1-MC__ can capture the position of an axis in a register
when an event occurs. The event is referred to as the print
registration input. On the rising or falling edge of an input signal,
which is either the Z-marker or an input, the TJ1-MC__ captures
the position of an axis in hardware. This position can then be used
to correct possible error between the actual position and the
desired position. The print registration is set up by using the
REGIST command.
The position is captured in hardware, and therefore there is no
software overhead and no interrupt service routines, eliminating the
need to deal with the associated timing issues.
Merging moves
If the MERGE axis parameter is set to 1, a movement is always
followed by a subsequent movement without stopping. The figures
show the transitions of two moves with MERGE value 0 and value
1.
In the figure, A is the time axis and B is the speed axis.
fig. 14
B
MERGE=0
Jogging
Jogging moves the axes at a constant speed forward or reverse by
manual operation of the digital inputs. Different speeds are also
selectable by input. Refer to the FWD_JOG, REV_JOG and
FAST_JOG axis parameters.
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HARDWARE REFERENCE MANUAL 26
B
MERGE=1
A
A
System philosophy
2.3 Servo system principles
The servo system used by and the internal operation of the TJ1MC__ are briefly described in this section.
2.3.1 Semi-closed loop system
The servo system of the TJ1-MC__ uses a semi-closed or inferred
closed loop system. This system detects actual machine
movements by the rotation of the motor in relation to a target value.
It calculates the error between the target value and actual
movement, and reduces the error through feedback.
2.3.2 Internal operation of the TJ1-MC__
Inferred closed loop systems occupy the mainstream in modern
servo systems applied to positioning devices for industrial
applications. The figure shows the basic principle of the servo
system as used in the TJ1-MC__.
1. The TJ1-MC__ performs actual position control. The main input
of the controller is the Following Error, which is the calculated
difference between the demand position and the actual
measured position.
2. The Position Controller calculates the required speed reference
output determined by the Following Error and possibly the
demanded position and the measured position. The speed
reference is provided to the Servo Driver.
3. The Servo Driver controls the rotational speed of the servo
motor corresponding to the speed reference. The rotational
speed is proportional to the speed reference.
4. The rotary encoder generates the feedback pulses for both the
speed feedback within the Servo Driver speed loop and the
position feedback within the TJ1-MC__ position loop.
The labels in the figure are:
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A. TJ1-MC__.
B. Servo system.
fig. 15
C
AB
2
1
D
E
3
F
G
4
I
H
J
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System philosophy
C. Demand position.
D. Position control.
E. Speed reference.
F. Speed control.
G. M otor.
H. Encoder.
I. Measured speed.
J. Measured position.
2.3.3 Motion control algorithm
The servo system controls the motor by continuously adjusting the
speed reference to the Servo Driver. The speed reference is
calculated by the motion control algorithm of the TJ1-MC__, which
is explained in this section.
The motion control algorithm uses the demand position (A), the
measured position (D) and the Following Error (B) to determine the
speed reference. The Following Error is the difference between the
demanded and measured position. The demand position, the
measured position and the Following Error are represented by the
axis parameters MPOS, DPOS and FE. Five gain values have
been implemented for the user to be able to configure the correct
control operation for each application.
C is the output signal.
• Proportional gain
The proportional gain K
proportional to the Following Error E.
O
= Kp · E
p
All practical systems use proportional gain. For many just using
this gain parameter alone is sufficient. The proportional gain
axis parameter is called P_GAIN.
• Integral gain
The integral gain K
the sum of the Following Errors that have occurred during the
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system operation.
O
= Ki · ΣE
i
creates an output Op that is
p
creates an output Oi that is proportional to
i
fig. 16
∑
K
vff
K
p
AB C
∑
K
i
Δ
K
d
Δ
K
ov
D
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System philosophy
Integral gain can cause overshoot and so is usually used only
on systems working at constant speed or with slow
accelerations. The integral gain axis parameter is called
I_GAIN.
• Derivative gain
The derivative gain K
produces an output Od that is
d
proportional to the change in the Following Error E and speeds
up the response to changes in error while maintaining the same
relative stability.
O
= Kd · ΔE
d
Derivative gain may create a smoother response. High values
may lead to oscillation. The derivative gain axis parameter is
called D_GAIN.
• Output speed gain
The output speed gain K
proportional to the change in the measured position P
produces an output Oov that is
ov
m
increases system damping.
O
= Kov · ΔP
ov
m
The output speed gain can be useful for smoothing motions but
will generate high Following Errors. The output speed gain axis
parameter is called OV_GAIN.
• Speed feed forward gain
The speed feedforward gain K
proportional to the change in demand position P
produces an output O
vff
d
and
minimizes the Following Error at high speed.
= K
O
vff
vff
· ΔP
d
The parameter can be set to minimise the Following Error at a
constant machine speed after other gains have been set. The
speed feed forward gain axis parameter is called VFF_GAIN.
and
that is
vff
The default settings are given in the table along with the resulting
profiles. Fractional values are allowed for gain settings.
/i
Revision 3.0
Gain Default value
Proportional gain 0.1
Integral gain 0.0
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System philosophy
Gain Default value
Derivative gain 0.0
Output speed gain 0.0
Speed feedforward gain 0.0
2.4 Trajexia system architecture
The system architecture of the Trajexia is dependant upon these
concepts:
• Program control
• Motion Sequence
• Motion buffers
• Communication
• Peripherals
These concepts depend upon the value set in the SERVO_PERIOD
parameter. The relationship between the value of SERVO_PERIOD and the
different concepts of the system architecture are describes as follows.
2.4.1 Program control
Programs make the system work in a defined way. The programs are written
in a language similar to BASIC and control the application of the axes and
modules. 14 Programs can be executed in parallel. The programs can be set
to run at system power-up, started and stopped from other programs and
executed from Trajexia Tools.
Programs execute commands to move the axes, control inputs and outputs
and make communication via BASIC commands.
• Executing the Position loop
• Sending the Axis reference
• Error handling
2.4.3 Motion buffers
Motion buffers are the link between the BASIC commands and the Axis
control loop. When a BASIC motion command is executed, the command is
stored in one of the buffers. During the next motion sequence, the profile
generator executes the movement according to the information in the buffer.
When the movement is finished, the motion command is removed from the
buffer.
2.4.4 Communication
All communication is carried out in the forth CPU task. A set of BASIC
communication commands are used to configure the communications.
When the Trajexia is a communication slave (as in the PROFIBUS
communication) it is only necessary to configure the communication in an
initial task. The values are exchanged from the configured global variables in
a transparent way. When the Trajexia is a communications master, the
BASIC communication commands are used to write and read.
2.4.5 Peripherals
All inputs and outputs are used with the set of parameters (IN, OP, AIN,
AOUT). The inputs and outputs are automatically detected and mapped in
Trajexia. Inverters are considered a peripheral device and have a set of
BASIC commands to control them. Various MECHATROLINK-II input and
output modules can be connected to a TJ1-ML__ unit.
2.4.2 Motion sequence
The motion sequence controls the position of all 16 axes with the actions as
follows:
Revision 3.0
• Reading the Motion buffer
• Reading the current Measured Position (MPOS)
• Calculating the next Demanded Position (DPOS)
HARDWARE REFERENCE MANUAL 30
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