Omron TJ1-PRT, TJ1-MC16, TJ1-ML04, GRT1-ML2, TJ1-FL02 REFERENCE MANUAL

Cat. No.
I51E-EN-05

Trajexia motion control system

TJ1-MC04, TJ1-MC16, TJ1-ML04, TJ1-ML16, TJ1-PRT, TJ1-DRT, TJ1-CORT, TJ1-FL02
GRT1-ML2

HARDWARE REFERENCE MANUAL

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

WARNING

Indicates a potentially hazardous situation, which, if not avoided,
could result in death or serious injury.

Caution

Indicates a potentially hazardous situation, which, if not avoided,
may result in minor or moderate injury, or property damage.

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.
CANopen is a registered trademark of CAN in Automation (CiA).
ModbusTCP is a registered trademark of Modbus IDA.
Trajexia is a registered trademark of OMRON.
Motion Perfect is a registered trademark of Trio Motion Technology Ltd.
All other product names, company names, logos or other designations
mentioned herein are trademarks of their respective owners.

Revision 5.0

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© OMRON, 2010

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.

HARDWARE REFERENCE MANUAL I

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

Sigma-III with
MECHATROLINK
interface manual

Sigma-V Servo
Driver manual

JUNMA series servo

Revision 5.0

drive manual

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 commands to be

used for programming Trajexia, commu­nication protocols and Trajexia Studio
software, gives practical examples and
troubleshooting information.

SIEP S800000 15 Describes the installation and operation

of Sigma-II Servo Drivers

SIEP S800000 11 Describes the installation and operation

of Sigma-III Servo Drivers with MECHA­TROLINK-II interface

SIEP S800000-44-O-OY
SIEP S800000-46-O-OY
SIEP S800000-48-O-OY

TOEP-C71080603 01-OY Describes the installation and operation

Describes the installation and operation
of Sigma-V Servo Drivers

of JUNMA Servo Drivers

V7 Inverter TOEP C71060605 02-OY Describes the installation and operation

of V7 Inverters

F7Z Inverter TOE S616-55 1-OY Describes the installation and operation

of F7Z Inverters

G7 Inverter TOE S616-60 Describes the installation and operation

of G7 Inverters

JUSP-NS115 man­ual

SI-T MECHATRO­LINK interface for
the G7 & F7

ST-T/V7 MECHA­TROLINK interface
for the V7

MECHATROLINK IO
Modules

SYSMAC CS/CJ
Series Communica­tions Commands

Omron Smartslice
GRT1-Series, slice I/
O units, Operation
manual

Omron G-series
user’s manual

Omron Accurax G5
user’s manual

Trajexia Studio user
manual

SIEP C71080001 Describes the installation and operation

of the MECHATROLINK-II application
module

SIBP-C730600-08 Describes the installation and operation

of MECHATROLINK-II interfaces for G7
and F7 Inverters

SIBP-C730600-03 Describes the installation and operation

of MECHATROLINK-II interfaces for V7
Inverters

SIE C887-5 Describes the installation and operation

of MECHATROLINK-II input and output
modules and the MECHATROLINK-II
repeater

W342 Describes FINS communications proto-

col and FINS commands

W455-E1 Describes the installation and operation

of Omron slice I/O units

I566-E1 Describes the installation and operation

of G-series Servo Drivers

I572-E1 Describes the installation and operation

of Accurax G5 Servo Drivers

I56E-EN Describes the use of Trajexia Studio

programming software

HARDWARE REFERENCE MANUAL II

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.

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

Connect the TJ1-MC__ to Trajexia Studio 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.
Type

PRINT FPGA_VERSION SLOT(-1) in the terminal window. The

parameter returns the current FPGA version number of the TJ1-MC__.

Functionality TJ1-MC__ Firmware

version

Full support TJ1-FL02 V1.6509 21 and higher

Support BASIC commands FINS_COMMS V1.6509 All versions

Support TJ1-DRT V1.6509 All versions

Support TJ1-MC04 andTJ1-ML04 V1.6607 21 and higher

Support TJ1-CORT, GRT1-ML2, Mod­busTCP, Sigma-V series Servo Drivers
(except DATUM and REGIST BASIC com-
mands) and allow Inverters to be controlled
as servo axes

Support for G-series Drivers, full support for
Sigma-V series Servo Drivers

Support for Accurax G5 Drivers V1.6720 21 and higher

Revision 5.0

V1.6652 21 and higher

V1.6714 21 and higher

TJ1-MC__ FPGA
version

Verify the firmware and FPGA versions of the TJ1-MC__

HARDWARE REFERENCE MANUAL III

Contents

1 Safety warnings and precautions................................................................................................................................................................1

1.1 Intended audience ............................................................................................................................................................................................................................1

1.2 General precautions .........................................................................................................................................................................................................................1

1.3 Safety precautions ............................................................................................................................................................................................................................1

1.4 Operating environment precautions..................................................................................................................................................................................................2

1.5 Application precautions.....................................................................................................................................................................................................................3

1.6 Unit assembly precautions................................................................................................................................................................................................................5

1.7 Conformance to EC Directives Conformance...................................................................................................................................................................................6

2 System philosophy.......................................................................................................................................................................................7

2.1 Introduction .......................................................................................................................................................................................................................................7

2.2 Motion control concepts ....................................................................................................................................................................................................................8

2.3 Servo system principles ..................................................................................................................................................................................................................19

2.4 Trajexia system architecture .........................................................................................................................................................................................................22

2.5 Cycle time ...................................................................................................................................................................................................................................... 23

2.6 Program control and multi-tasking ..................................................................................................................................................................................................29

2.7 Motion sequence and axes.............................................................................................................................................................................................................30

2.8 Motion buffers ............................................................................................................................................................................................................................... 40

2.9 Mechanical system .........................................................................................................................................................................................................................42

3 Hardware reference ....................................................................................................................................................................................43

3.1 Introduction .....................................................................................................................................................................................................................................43

3.2 All units ..........................................................................................................................................................................................................................................46

3.3 Power Supply Unit (PSU) ...............................................................................................................................................................................................................57

3.4 TJ1-MC__ .....................................................................................................................................................................................................................................59

3.5 TJ1-ML__........................................................................................................................................................................................................................................70

3.6 GRT1-ML2 ....................................................................................................................................................................................................................................143

3.7 TJ1-PRT .......................................................................................................................................................................................................................................158

3.8 TJ1-DRT .......................................................................................................................................................................................................................................162

3.9 TJ1-CORT .................................................................................................................................................................................................................................... 166

3.10 TJ1-FL02 ......................................................................................................................................................................................................................................170

A Differences between Sigma-II and Junma .............................................................................................................................................. 188

Revision history ..............................................................................................................................................................................................189

Revision 5.0

HARDWARE REFERENCE MANUAL IV

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 5.0

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 1

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

User programs written to the Motion Control Unit will not be auto­matically backed up in the TJ1 flash memory (flash memory func­tion).

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

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.

Caution

Revision 5.0

Pay careful attention to the polarity (+/-) when wiring the DC power
supply.A wrong connection may cause malfunction of the system.

HARDWARE REFERENCE MANUAL 2

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.
Not doing so may result in unexpected operation.

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

Always use the power supply voltage specified in this manual.
An incorrect voltage may result in malfunction or burning.

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

Disconnect the functional ground terminal when performing with­stand voltage tests.
Not disconnecting the functional ground terminal may result in
burning.

Revision 5.0

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.

HARDWARE REFERENCE MANUAL 3

Safety warnings and precautions

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

Leave the dust protective label attached to the Unit when wiring.
Removing the dust protective label 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

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

Mount the Unit only after checking the terminal block completely.

Caution

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.

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

Use crimp terminals for wiring. Do not connect bare stranded wires

Revision 5.0

directly to terminals.
Connection of bare stranded wires may result in burning.

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.

HARDWARE REFERENCE MANUAL 4

Safety warnings and precautions

Caution

Do not pull on the cables or bend the cables beyond their natural
limit. Doing so may break the cables.

Caution

Before touching the system, be sure to first touch a grounded
metallic object in order to discharge any static build-up.
Otherwise it might result in a malfunction or damage.

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

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.

Caution

Always check the “Status-Words” of each GRT1-ML2 coupler.
Not doing so can lead to missing or incorrect I/O data.

Caution

Always check the status of the connected MECHATROLINK-II
devices in a BASIC program.
Not doing so may result in an unexpected operation.

Caution

The TJ1-CORT unit is developed to exchange I/O data between
the Trajexia system and a CANopen network.
The TJ1-CORT is not able to exchange motion commands.
Using the TJ1-CORT to exchange motion commands may result in
unexpected operation.

Caution

1.6 Unit assembly precautions

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

Install the unit properly.
Improper installation of the unit may result in malfunction.

Caution

Outputs may remain on due to a malfunction in the built-in transis­tor outputs or other internal circuits.

Revision 5.0

As a countermeasure for such problems, external safety measures
must be provided to ensure the safety of the system.

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.

HARDWARE REFERENCE MANUAL 5

Safety warnings and precautions

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.

Low Voltage Directive

Always ensure that devices operating at voltages of 50 to 1,000 VAC or 75 to
1,500 VDC meet the required safety 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.

Revision 5.0

HARDWARE REFERENCE MANUAL 6

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 TJ1­MC__. 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
SERVO_PERIOD=1ms and 2ms if the SERVO_PERIOD=2ms.

TJ1-MC__

Program Buffer

BASIC PROGRAMS

Process 1

Process 2

Process 3

…

Process 14

Comms

MC I/O

Ethernet

FINS

Ethernet

BUILT-IN TJ1-ML16

Via

Buffer &

Buffer &

profile

profile

gererator

gererator

-

TJ1 PRT

Profibus

AXIS CONTROL LOOP

Position

Position

Loop

Loop

-

TJ1 ML__

-

TJ1 FL02

AXIS TYPE

AXIS TYPE

AXIS TYPE

fig. 1

Servo Driver

Position

Position

Loop

Loop

Speed Loop

Speed Loop

Servo Driver

Speed Loop

Torque

Loop

Torque

Torque

Loop

Loop

ENC

All othe
Servo
Drivers

MOTOR

ENC

MOTOR

CPU tasks

The operations executed in each CPU task are:

CPU task Operation

Revision 5.0

First CPU task Motion Sequence

Low priority process

HARDWARE REFERENCE MANUAL 7

System philosophy

CPU task Operation

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.

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.

Revision 5.0

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

HARDWARE REFERENCE MANUAL 8

System philosophy

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 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.

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.

MOVE(30)

0

fig. 2

MOVEABS(30)

MOVE(60)

MOVEABS(50)

MOVE(50)

50 100

A

Revision 5.0

HARDWARE REFERENCE MANUAL 9

System philosophy

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.

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

2

2

2

50

B

fig. 3

MOVEABS(100) AXIS(0)
MOVEABS(50) AXIS(1)

0

50

100

A

Defining moves

The speed profile in this figure shows a simple MOVE operation. Axis A is

fig. 4

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 been set to 10 m/s

2

. The total distance travelled is the sum of

10

B

ACCEL=10
DECEL=10
SPEED=10
MOVE(40)

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.

Revision 5.0

0

123 456

HARDWARE REFERENCE MANUAL 10

A

System philosophy

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.

10

10

fig. 5

B

0

123 456

fig. 6

B

0

123 456

ACCEL=5
DECEL=10
SPEED=10
MOVE(40)

A

ACCEL=10
DECEL=5
SPEED=10
MOVE(40)

A

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

Revision 5.0

Acceleration time =

HARDWARE REFERENCE MANUAL 11

System philosophy

Acceleration distance =

Deceleration time =

Deceleration distance =

Constant speed distance =

To tal tim e =

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 acceleration rate
and demand speed.
Both movements can be cancelled 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 TJ1­MC__ supports the following operations:

• Linear interpolation

Revision 5.0

• Circular interpolation

• CAM control.

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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

A

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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.

fig. 8

50

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.

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.

• Electronic gearbox

•Linked CAM

Revision 5.0

• Linked move

• Adding axes

-50

050

fig. 9

B

A

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System philosophy

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

B

fig. 10

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

Revision 5.0

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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 TJ1-MC__ 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.

B

B

fig. 13

BASE(0)
ADDAX(2)
FORWARD
MOVE(100) AXIS(2)
MOVE(-60) AXIS(2)

A

A

B

A

Revision 5.0

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System philosophy

2.2.4 Other operations

Cancelling moves

In normal operation or in case of emergency it can be necessary to 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.

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.

Revision 5.0

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System philosophy

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.

2.3 Servo system principles

The servo system used by and the internal operation of the TJ1-MC__ 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.

A

B

MERGE=1

A

Revision 5.0

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System philosophy

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:
A. TJ1-MC__.
B. Servo system.
C. Demand position.
D. Position control.
E. Speed reference.
F. Speed control.
G. M otor.
H. Encoder.
I. Measured speed.
J. Measured position.

C

fig. 15

AB

2

1

D

E

3

F

G

4

I

H

J

2.3.3 Motion control algorithm

The servo system controls the motor by continuously adjusting the speed

Revision 5.0

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.

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System philosophy

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

creates an output Op that is proportional to the

p

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

creates an output Oi that is proportional to the sum

i

of the Following Errors that have occurred during the system operation.

O

= Ki · ΣE

i

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 proportional to the

d

change in the Following Error E and speeds up the response to changes
in error while maintaining the same relative stability.

O

= Kd · ∆E

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
the change in the measured position P

O

= Kov · ∆P

ov

Revision 5.0

m

produces an output Oov that is proportional to

ov

and increases system damping.

m

fig. 16

∑

K

vff

K

p

AB C

∑

K

i

∆

K

d

∆

K

ov

D

HARDWARE REFERENCE MANUAL 21

System philosophy

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

and minimizes the

d

that is

vff

Following Error at high speed.

O

= K

vff

· ∆P

d

vff

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.

The default settings are given in the table along with the resulting profiles.
Fractional values are allowed for gain settings.

/i

Gain Default value

Proportional gain 0.1

Integral gain 0.0

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

Revision 5.0

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.

2.4.2 Motion sequence

The motion sequence controls the position of all 16 axes with the actions as
follows:

• Reading the Motion buffer

• Reading the current Measured Position (MPOS)

• Calculating the next Demanded Position (DPOS)

• 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

HARDWARE REFERENCE MANUAL 22

System philosophy

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.

2.5 Cycle time

All processes in the Trajexia system are based on the cycle time. The cycle
time is divided into four CPU tasks:

•250µs time intervals for a SERVO_PERIOD of 0.5 and 1.0ms

•500µs time intervals for a SERVO_PERIOD of 2.0ms

The processes that can be carried out in each time interval depends on the
SERVO_PERIOD that is set.
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

Fourth CPU task External Communications

Revision 5.0

Note

1

Motion Sequence (only if SERVO_PERIOD=0.5ms)

LED Update.
High priority process

The Motion sequence execution depends on setting of the
SERVO_PERIOD parameter.

250µs

1

500 µs

1

fig. 17

2

Cycle time = 1ms

fig. 18

2

Cycle time = 2 ms

3

3

4

4

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System philosophy

2.5.1 Servo period

The SERVO_PERIOD can be set at 0.5, 1 or 2ms. The processes that take
place within the cycle time depend on the setting of the SERVO_PERIOD
parameter. The SERVO_PERIOD parameter is a Trajexia parameter that
must be set according to the system configuration.
The factory setting is 1ms (SERVO_PERIOD=1000). A change is set only
after a restart of the TJ1-MC__.

Note

Only the Sigma-III Servo Driver and the Sigma-V Servo Driver
support the 0.5 ms transmission cycle.

Example 1

The SERVO_PERIOD has a value of 0.5ms and the motion sequence is
executed every 0.5ms.

CPU task 1

CPU task 2

fig. 19

Motion sequence

Low priority task (0,1,2,3...)

High priority task (13,14)

CPU task 3

CPU task 4

Revision 5.0

Motion sequence

LED refresh
High priority task (13,14)

Communication

1ms

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System philosophy

Example 2

The SERVO_PERIOD has a value of 1ms and the motion sequence is
executed every 1ms. As the motion sequence is not executed during CPU
task 3, there is more time for the program execution. High priority programs
run faster.

CPU task 1

CPU task 2

fig. 20

Motion sequence

Low priority task (0,1,2,3...)

High priority task (13,14)

Example 3

The SERVO_PERIOD has a value of 2ms and the motion sequence is
executed every 2.0ms.

Servo period rules

The number of axes and MECHATROLINK-II devices in the Trajexia system
determines the value of the SERVO_PERIOD system parameter.
There are 3 types of MECHATROLINK-II devices that are supported by the
TJ1-MC__ units:

• Servo Drivers
The TJ1-MC__ considers Servo Drivers as axes.

• Inverters
The TJ1-MC__ does not consider Inverters as axes.

• I/O units and slice bus couplers
The TJ1-MC__ does not consider I/O units (analog and digital, counter
and pulse) and slice bus couplers as axes.

CPU task 3

CPU task 4

CPU task 1

CPU task 2

CPU task 3

CPU task 4

LED refresh
High priority task (13,14)

Communication

fig. 21

Motion sequence

Low priority task (0,1,2,3...)

High priority task (13,14)

LED refresh
High priority task (13,14)

Communication

1ms

2ms

You must obey the most restrictive rules when you set the SERVO_PERIOD
parameter. An incorrect value of the SERVO_PERIOD parameter results in
an incorrect detection of the MECHATROLINK-II devices.

Revision 5.0

The most restrictive rules are given in the tables below. For each unit the
table lists the maximum number of devices the unit can control at the given

SERVO_PERIOD setting.

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