Rockwell Automation Motion Analyzer User Manual

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User Manual

Motion Analyzer Software

Version 7.00

Important User Information

IMPORTANT

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/ important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

available from

) describes some

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, Kinetix, MP-Series, ProposalWorks, Rockwell Automation, Rockwell Software, RSLogix, TechConnect, TL-Series, and Ultra are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual contains new and updated information.

Summary of Changes

New and Updated Information

This table contains the changes made to this revision.

Top ic Pa ge

Removed the Activation Wizard section. N/A

Added Group/Ungroup and Add Drive Group descriptions to the Home Tab section. 16

Updated Power Data, Shunt, and Energy tab examples for the Power Supply/Accessories - Single-axis Drive Systems section.

Added Power Supply/Accessories – AC/DC Power Sharing Systems (Kinetix 5500 drives) section. 51

Updated the Output Format Selection dialog boxes in the Export to RSLogix 5000 Wizard section. 65

Added new Explorer View examples and updated the Drives Group Node description. 78

Updated the Solution List dialog box example. 209

Added Preferred Product section. 210

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Summary of Changes

Notes:

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Preface

About This Publication

Who Should Use This Manual

Conventions Used in This Manual

System Requirements

The versatility of Motion Analyzer software lets users of various application complexities and experience levels use one software package to size their systems. This manual is designed to accommodate basic users, advanced users, and everyone in between.

This manual is intended for engineers directly involved in the selecting, sizing, and optimizing of drives and motors or actuators for a motion control system.

The following conventions are used throughout this manual:

• Bulleted lists such as this one provide information, not procedural steps.

• Numbered lists provide sequential steps or hierarchical information.

• Hyperlinks are embedded throughout this document so that you can easily

navigate to and obtain information that is relevant to your particular application.

Motion Analyzer software requires the following operating conditions.

Attribute Description

Compute r hardware requ irements

Operating systems supported

Microsoft Office software supported

• Pentium IV processor

• 1 GB RAM minimum

• 1280x800 screen resolution

• Windows XP - 32 Bit (SP2)

• Windows XP - 64 Bit (SP2)

• Windows Vista - 32 Bit

• Office 2007

• Office 2010

• 500 MB free space in the

installation directory

• .NET Framework 2.0

• Windows Vista - 64 Bit

• Windows 7 - 32 Bit

• Windows 7 - 64 Bit

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

Download Motion Analyzer software from:

http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software

Kinetix Motion Control Selection Guide, publication GMC-SG001

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.

Product Certifications website, http://www.ab.com

Comprehensive motion application sizing tool used for analysis, optimization, selection, and validation of your Kinetix® Motion Control system.

Overview of Kinetix servo drives, motors, actuators, and motion accessories designed to help make initial decisions for the motion control products best suited for your system requirements.

Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at

http:/www.rockwellautomation.com/literature/

. To order paper copies of technical documentation, contact your local Allen-Bradley® distributor or Rockwell Automation sales representative.

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Preface

Notes:

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Welcome to Motion Analyzer Software

Top ic Pa ge

Before You Begin Sizing 8

Database Updater Program 8

Welcome to Motion Analyzer 13

Menu Bar and Quick Access Toolbar 14

File Tab 15

Home Tab 16

Graphical View 17

Group View 22

Multiple Profile View 26

Power Supply/Accessories View 29

Preferences Tab 62

Export – Import Tab 65

Export to RSLogix 5000 Wizard 65

Bill of Materials (BOM) Tab 76

Help Tab 76

Explorer View 78

Chapter 1

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Chapter 1 Welcome to Motion Analyzer Software

TIP

1.1. Before You Begin Sizing

After downloading and starting Motion Analyzer software, you’ll want to update the Motion Analyzer database with the latest Allen-Bradley products available for motion control applications. This section steps you through that process.

Download Motion Analyzer software from

http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software

1.1.1. Database Updater Program

The Motion Analyzer Database Updater program updates your Motion Analyzer software with the latest database available for the version currently installed on your personal computer.

1. To start the Motion Analyzer database updater program, go to Start>All Programs>Rockwell Automation>Motion Analyzer 7.00> Database Updater.

To update the software version, download Motion Analyzer software from

http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software

The Motion Analyzer Database Updater wizard opens.

Table 1 - Database Updater Analysis

Attribute Description

Installed Motion Analyzer version

Installed database version

Indicates the version of Motion Analyzer software currently installed.

Indicates the database version currently installed.

2. Click Next.

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The program checks for database updates.

If the program finds that you already have the current database installed, the following dialog box opens.

3. Click Finish.

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4. If the program finds that a database update is available, a dialog box opens with the following information:

• Installed software and database versions

• Available database version

• Database download file size

• Summary of new features and products in the new database

5. Click Update.

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6. If the database updater program detects that your current version of Motion Analyzer software is running, a dialog box opens with the following instructions.

7. If the program finds that a new software version is available, a dialog box opens with the following options:

• Click the link to download the new version of Motion Analyzer

software

• Click Next to skip the download and just update your current database

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8. When the database updater program begins the update, this dialog box opens.

9. When the database updater program completes the update, this dialog box opens.

10. Click Finish.

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1.1.2. Welcome to Motion Analyzer

The Welcome to Motion Analyzer dialog box opens when the software application is launched. Two modes of operation are possible.

Figure 1 - Welcome to Motion Analyzer Dialog Box

Table 2 - Motion Analyzer Modes of Operation

Mode Description

Size and Select

Just Quote Creates only a bill of materials so no sizing input is required.

Intuitive workflow to help size, select, and optimize the motion control system. This mode also creates a bill of materials.

Click either of the New option modes to start a new application or click Browse to open a previously configured application.

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Menu Bar

Quick Access Toolbar

1.2. Menu Bar and Quick Access Toolbar

Your Motion Analyzer application file opens and the menu bar appears across the top of the dialog box. Above the menu bar is the Quick Access toolbar.

Figure 2 - Size and Select Dialog Box

The Quick Access toolbar provides shortcuts to commonly used functions. These functions include New, Open, Save, and Print.

Table 3 - Me nu Bar Ta b Descrip tion s

Options Description Page

File Tab

Home Tab

Preferences Tab Setting /View user preference option. 62

Export – Import Tab All data Export – Import functionality. 65

Bill of Materials (BOM) Tab

Help Tab Standard Help menu options. 76

Standard File menu options. 15

Most commonly used actions across different views in Motion Analyzer software.

Useful shortcuts for navigating through the Bill of Materials view. 76

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1.2.1. File Tab

The File tab is similar to the file menu in many computer applications.

Figure 3 - File Tab Options

Table 4 - File Tab Descriptions (refer to Figure 3

Options Description

New Click New to go to the Welcome dialog box in Motion Analyzer software.

Open

Save Click to save the running Motion Analyzer application. Standard Save functionality.

Save As

Recent Files

Sample Applications

Help This is similar to the Help Tab

Exit Click to close the running application.

Click Open to browse folders and open Motion Analyzer applications. Standard Open functionality.

Click to launch a dialog box, browse to the path on your computer, and save the current application to an.mba file.

Click for the list of recently opened applications. You can open one of these applications directly from this shortcut.

Lets you open Motion Analyzer sample applications present in the Motion Analyzer installation.

Print Click to print the application data.

Print Preview Click to see a preview of printable application data.

)

on page 76.

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1.2.2. Home Tab

The Home tab contains five sections.

Figure 4 - Home Tab Options

Table 5 - Home Tab De scription s

Option Description

Used to access the different views available in Motion Analyzer software.

Click to open the Graphical view on page 17.

Click to open the Multiple Profile view on page 26.

Click to open the Power Supply/Accessories view on page 29.

Click to open the Axis view on page 82.

Click to open the BOM view on page 36.

Click to sort the axes in Drives group for Multi Axis Family application by Axis Power. Sort is valid at the Rack, Group, or IPIM level.

Select multiple axes in Exp lorer view and clic k Group to create a Power Sharing Drive Group. This feature is available only for families that support AC and DC power sharing (Kinetix 5500 drives).

Select Power Sharing Drive Group in the Explorer view and click Ungroup to ungroup the axes of the selected group.

Add a new IPIM module in the selected Drives Group in Explorer hierarchy view.

Add a new axis in the Drives Group/Unallocated Group or IPIM based on user’s current selection in Explorer hierarchy view.

Add a new Drives Group under the Project node in the Explorer hierarchy view. This feature is available only for families that support AC and DC sharing (Kinetix 5500 drives).

View s (label 1 in Figure 4

Clipboard (label 2 in Figure 4)

Edit (label 3 in Figure 4

Add (label 4 in Figure 4

Too l s (label 5 in Figure 4

Graphical View

Group View Click to open the Group view on page 22.

Multiple Profile View

Power Supply/

)

Accessories View

Identify Your Load Axis View

System Bill of Materials (BOM) View

Used to access the Cut, Copy, and Paste functions. Click to perform these functions that are common to many software programs.

Used to access these editing functions. Each one works on the entity selected in Explorer hierarchy view.

Rename Click to rename the selected entity.

Delete Click to delete the selected entity from the ap plication.

Sort by Power

)

Allocate Allocate the axis from Un-allocate Axes Group to Drives Group.

Unallocate Un-allocate the axis from Drives Group to un-allocate Axes Group.

Group/Ungroup

Used to access these add functions. Each one works on the entity selected in Explorer hierarchy view.

Add IPIM

)

Add Axis

Add Drive Group

Motion Analyzer/SolidWorks Integration is used to launch the SolidWorks Integration wizard.

)

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1.2.2.1. Graphical View

The Graphical view applies to multi-axis drive families and provides graphical representation of the current (Bulletin 2093 and 2094) power rail and Kinetix 6000M integrated drive-motor system configurations.

Figure 5 - Graphical View Example

Table 6 - Graphical View Options (refer to Figure 5

Options Description Page

Power R ail View

Power Inte rface Module View

Displays the graphical representation of the current Bulletin 2093 or 2094 power rail configuration.

Displays the graphical representation of the Kinetix 6000M integrated drivemotor system on the Bulletin 2094 power rail.

)

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1.2.2.1.1. Power Rail View

The Power Rail view displays the graphical representation of the current Bulletin 2093 or 2094 power rail configuration.

Figure 6 - Power Rail View Example

Table 7 - Power Rail View Options

Options Description

Product Rack Summary (label 1 in Figure 6

Image view (label 2 in Figure 6

Module Information (label 3 in Figure 6

Additional Module Information (inside red box)

Part Number Displays the selected power rail catalog number.

Total No. of Slots Displays the total number of slots available in the selected power rail.

)

Slots Occupied Displays the number of slots currently occupied in the selected power rail.

Graphical representation of the power rail with the drive modules and empty slots are displayed along with the selected catalog numbers. Power rail configurations like Axis – Slot mapping can be configured using options available in this view.

)

Right-click the modules and choose operations to perform from the menu (refer to Figure 7

Selected Slot Module

Part Number Catalog number of the selected drive module.

)

Slot Number Power rail slot number occupied by the selected drive module.

Axis Name Name you assigned to the axis associated with the selected drive module.

View Axi s

Un- allocate Un-allocates the axis associated with the selected drive modules.

View Prod uct Guide

Refers to the type of the module that is currently selected in the power rail. For example, axis module (AM), integrated axis module (IAM), power interface module (IPIM), or empty slot.

Click to launch the Axis view of the axis associ ated with the selected drive module.

Click to open the Kinetix Motion Control Selection Guide. The page displayed from the selection guide corresponds to the selected drive module.

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Figure 7 - Operations to Perform Example

Additionally, you can click, drag, and drop a module to reposition that module on the power rail (refer to Figure 8

Figure 8 - Drag and Drop Modules to Reposition on Power Rail

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1.2.2.1.2. Power Interface Module View

The integrated drive-motor power interface module (IPIM) mounts to the Bulletin 2094 power rail and connects (daisy-chains) with up to sixteen integrated drive-motor (IDM) units.

Figure 9 - Power Rail View Example (Kinetix 6000M integrated drive-motor system)

Table 8 - Power Rail View Options (Kinetix 6000M integrated drive-motor system)

Options Description

Slot Number Power rail slot number occupied by the selected IPIM module.

IPIM Summary (label 1 in Figure 9)

Image view (label 2 in Figure 9

Selected Slot Module (label 3 in Figure 9)

Additional Module Information (inside red boxes)

Number of Associated Axis

Number of Additional Axis Allowed

Graphical representation of the Kinetix 6000M integrated drive-motor system are displayed with the selected catalog numbers. Power rail configurations, like the order of IDM axes, can be configured using options available in this view.

)

Right-click an IDM unit and choose operations to perform from the menu (refer to Figure 10

Selected Slot Module

Part Number Catalog number of the selected unit or module.

IDM Position

Axis Name Name you assigned to the axis associated with the selected IDM unit.

View Axi s

Un- allocate Un-allocates the axis associated with the selected IDM unit.

View Product Guide

Back to Rack Click to switch bac k to the power rail view.

Displays the number of axes currently associated with the selected IPIM module.

Displays the additional number of axis that can be added in this IPIM module.

Refers to the type of the module that is currently selected in the power rail. For example, integrated drive-motor unit (IDM) or power interface module (IPIM).

The position of the selected unit or module, assuming the IDM unit closest to the IPIM module is identified as 1.

Click to launch the Axis view of the axis associated with the selected IDM unit.

Click to open the Kinetix Motion Control Selection Guide. The page displayed from the selection guide corresponds to the selected IDM unit.

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Figure 10 - Operations to Perform Example

Additionally, you can click, drag, and drop an IDM unit to reposition that unit in the daisy-chain configuration (refer to Figure 11

Figure 11 - Drag and Drop to Reposition IDM Units

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1.2.2.2. Group View

The Group view provides a summary of all the axes associated with the drive group. Additionally, the Group view gives a visual representation of the axis mapping in the power rail for multi-axes drive families. Group view varies depending on the Application mode selected. Refer to Figure 12 for examples of each.

Figure 12 - Group View Example (Select and Size mode)

and Figure 13

Figure 13 - Group View Example (Just Quote mode)

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There are two areas of interest in the Group view, as illustrated in Figure 14.

Figure 14 - Group View Example

Table 9 - Power Rail View Options

Options Description Page

Power Rail Image

(label 1 in Figure 14)

Axis Summary Image

(label 2 in Figure 14)

Power rail image based on the current system configuration. This graphic only applies to multi-axis drive families.

Displays a summary of the current axis configurations including drive module and motor/actuator catalog numbers.

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1.2.2.2.1. Power Rail Image

The power rail image only applies to multi-axis drive families. In this example, the current configuration of Kinetix 6000 servo drives is shown on an eight-axis Bulletin 2094 power rail.

Figure 15 - Bulletin 2094 Power Rail Image

Table 10 - Power Rail Slot Example (refer to Figure 15

Option Description

IAM Module (slots 1 and 2)

AM Modules (slots 3…5) Axis modules (AM) are always right of the IAM module.

Empty Slots (slots 6…8)

Integrated axis module (IAM ) is always the first drive module on the power rail. In this case, the IAM module is a double-wide module, so it occupies two slots.

Empty slots are always to the far right on the power rail and must be occupied by slotfiller modules.

)

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1.2.2.2.2. Axis Summary Image

The axis summary images apply to all drive families. In this example, the current configuration of Kinetix 6000 servo drives includes the drive/motor combination featured below.

Figure 16 - Axis Summary Bar (servo drive)

Table 11 - Axis Summary Example

Option Description

Axis Solution Status icon indicates the status of the selected solution. Axis solution status is defined in Solution

208.

A warning triangle icon indicates a warning with this axis, which requires your attention.

Selected motor catalog number.

on page

Title Band (label 1 in Figure 16

Axis Bar (label 2 in Figure 16

Short-cuts to Axis view (label 3 in Figure 16

)

Axis Solution Status Icon

Warning Icon

Axis Name Name of the Axis.

Displays information about the selected drive/motor axis or IPIM module.

(1)

Motor

Drive Selected drive module catalog number.

Gearbox Selected gearbox catalog number.

RBM Selected RBM module catalog number.

Icons are a graphical representation of the selected axis components. Click icons to switch to the corresponding data page in the Axis view.

(1) Configure Motor BOM is availab le for the selected motor. Click to launch the Configure Motor dia log box.

In this example, the current configuration includes a Kinetix 6000M power interface module (IPIM).

Figure 17 - Kinetix 6000M Power Interface Module

IPIM module icon along with the catalog number of the selected IPIM module is displayed in this bar. Click + to access the IPIM child nodes (IDM units).

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.3. Multiple Profile View

The Multiple Profile view permits viewing profiles of multiple axes simultaneously and defining axes synchronization and offsets among the axes.

Figure 18 - Multiple Profile View Example

Table 12 - Multiple Profile View Options

Options Description Page

Top Ba nd

(label 1 in Figure 18)

Graph View

(label 2 in Figure 18)

Lets you define the Time Span to which all graphs should be scaled. Additionally, this view lets you select a subset of the available axes to view.

Profiles of all axes are displayed in this section with the shorter profiles being repeated to fit the length of the longest profile.

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1.2.2.3.1. Top Band

This area lets you define the Time Span to which all graphs should be scaled. Additionally, this view lets you select a subset of the available axes to view.

Figure 19 - Top Band of Multiple Profile View

Table 13 - Top Band Example

Option Description

Modify Time Span (label 1 in Figure 19)

Show Axis (label 2 in Figure 19

Sort By (label 3 in Figure 19)

Time span is the length of x-axis on which all the profiles are plotted. Use this option to zoomin or zoom-out on the time scale. Enter the minimum and maximum value of the time scale of interest and click Apply to re-plot all graphs to this scale.

Select All to display all axes.

Select Selected (Change) to choose the axis of interest (refer to Figure 20

)

box).

This option lets you sort the axes in the graph area according to the Slot Number or Axis Name.

for typical dialog

Figure 20 - Selected Axis Example

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1.2.2.3.2. Graph View

The Graph view displays profiles of all axes with the shorter profiles being repeated to fit the length of the longest profile.

Figure 21 - Graph View Example

Table 14 - Graph View Options (refer to Figure 21

Option Description

The phase relationship between the various axis profiles in a common DC bus system affects the peak bus current requirement. For example, if all axes accelerate simultaneously, the bus current demand is much greater than if each axis accelerates in turn.

From the Synchronized with pull-down menu, choose the random or synchronized operation for each axis.

Synchronized with

Offset

Set at least one axis to Random as the reference axis. Set other axes to be synchronized with the reference axis or Random.

The safe setting for system sizing is all Random. In this case the worst case current demand for each axis is automatically lined up by adjusting the phase relationship of the axis profiles.

If the phase relationship is known and will not change, the Cycle Profiles should be set up in the correct relationship and Synchronized with set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected.

If all axis profiles are the same length and start at their correct respective positions, then the offsets will be zero. Otherwise, the offset may be used to align the profiles correctly.

)

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1.2.2.4. Power Supply/Accessories View

In Axis view, you matched a drive with your motor. However, if there are power components needed for your application, you’ll select them in Power Supply/ Accessories view.

1.2.2.4.1. Power Supply/Accessories - Multi-axis Drive Systems

If your drive family is Kinetix 2000, Kinetix 6000, or Kinetix 6200/6500, you’ll also need to configure the IAM module and select the appropriate power rail.

Figure 22 - Power Supply/Accessories Dialog Box

Table 15 - Power Supply/Accessories Tabs (refer to Figure 22

Parameters Description Page

Power Data Tab

IAM and Shunt Tab

IAM Control Power Tab

Analysis Tab

Energy Tab

Configure Power Supply BOM Tab

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View regeneration and motoring data for each axis. 30

Select drive modules and external shunt resistors for multi -axis systems. 31

Displays total auxiliary input power, input VA, input current, and power distribution across the axes. These are the installation ratings for the IAM module.

Analyze the drive module activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters.

View Input Current values, System Power values, Shunt Power, and Energy Savings Estimates.

Configure the bill of materials (BOM) for the power supply after fully sizing the application.

)

Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.1.1. Power Data Tab

Use the Power Data tab to view regeneration and motoring data for each axis.

Table 16 - Power Data Tab Properties (refer to Figure 22)

Parameters Description

Axis Histograms

Random/Sync Relationship

Offset

The axis histograms show a multi-axis representation of axis currents including Peak Motoring, Average Motoring, Peak Regenerating, and Average Regenerating.

The phase relationship between the various axis motion profiles in a common DC bus system affects the peak bus-current requirement. For example, if all axes accelerate simultaneously (for example, synchronous operation), the bus current demand is much greater than if each accelerates in turn. The pull-down menu lets you choose Random or Synchronized mode for axes operation. At least one axis should be set to Random as the reference axis. Other axes may be set to Synchronized or Random relative to the reference axis. The safe setting for system sizing is all Random. In this case, the worst case current demand for each axis is automatically lined up by adjusting the phase relationship of the axis motion profiles. If the phase relationship is known and will not change, the Cycle Profiles should be set up in the correct relationship and appropriate synchronized set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected.

If all axis motion profiles are the same length and start at their correct respective positions at the default time, then the offsets will be zero. Otherwise, a specified time offset may be used to align the motion profiles correctly.

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1.2.2.4.1.2. IAM and Shunt Tab

Click Search to automatically configure the IAM and/or shunt module catalog number.

Figure 23 - IAM and Shunt Tab

Table 17 - IAM and Shunt Tab Properties

Parameters Description

Click Search to configure the IAM module (Kinetix 2000, Kinetix 6000, and Kinetix 6200/6500 drives) based on the selection made in Axis view, and/or an external shunt module, should an existing internal shunt for a given drive be outside its rating. Where multiple external

IAM & Shunt Selection (label 1 in Figure 23)

Utilizations (label 2 in Figure 23)

Component Listings of Kinetix Shunts (label 3 in Figure 23)

shunts exist, these can be readily chosen by searching for a shunt. Both the drive module and shunt module have automatic and manual selection options. You can manually select a drive or IAM module and the compatible shunt. The manual

selection of only one of the two components is also provided. This means that you can have manual drive and automatic shunt selection or vice versa.

The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed. Use the forward or backward arrows to scroll through other drive and shunt options. Click the drive module or shunt module catalog number to view their product specifications.

This window is available only for the Kinetix multi-axis drive families after a valid IAM module and shunt solution is found. This window displays the shunt resistance, power, and capacitance values for all the components involved in the IAM and shunt module solution. The components may include converter (IAM), all the inverters (AM), shunt module and shunt resistor. The Shunt Protect limit is also shown in order to reflect the shunt power utilization of the component.

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1.2.2.4.1.3. IAM Control Power Tab

The IAM Control Power tab displays total auxiliary input power, input VA, input current, and power distribution across the axes. These are the installation ratings for the IAM module.

Figure 24 - IAM Control Power Tab

Table 18 - IAM Control Power Tab Properties

Parameters Description

Auxiliary AC Voltage (label 1 in Figure 24)

Power Rail Summary (label 2 in Figure 24)

Power Rail De tails (label 3 in Figure 24

Auxiliary AC Voltage is a user input value. The value can lie within the IAM Control Voltage Range. Refer to the Kinetix Servo Drives Technical Data, publication GMC-TD003, for servo drive power specifications.

This view shows the total auxiliary input power, input VA, and input current in a tabular format.

This view contains the slots occupied, slot number, drive module, and continuous output power distribution details in tabular format. The IPIM module is available as line item (axis

)

level item) in this view.

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1.2.2.4.1.4. Analysis Tab

Click Analysis to conduct detailed analysis of the drive module activity in terms of bus volts and system current, along with the capability of simulating changes to the system parameters.

Figure 25 - Analysis Tab Dialog Box

Parameters Description

Simulation Parameters (refer to Figure 25)

Zoom Window (refer to Figure 25

Adjust these parameters to observe how changes to the parameters impact the bus voltage and current.

Time From/ Voltage From

)

Time Slice

Table 19 - Analysis Tab Properties

Check these boxes to adjust the X- and Y-axis values for the plot.

The Time Slice variable sets the time interval for the Analysis display. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is equal to the longest axis cycle. In the case of a very long length of time, it is suggested that a longer time slice be used for early checks, but a time slice of less 0.1 ms should be used for the final selection.

If the time is increased, this error message often appears.

This time slice message may also appear as soon as you click Solution on the main taskbar. In this case, clicking Yes or No still takes you to the Solution tab, but if you click No, some pre-calculations are not performed.

This time slice message often appears if one of the motion cycles is a cam, which often has very short time segments. In this case, click No to ignore the message.

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.1.5. Energy Tab

Click Energy to display the main power supply parameters including Input Current, System Power, Shunt Power and Energy Savings Estimates.

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1.2.2.4.1.6. Configure Power Supply BOM Tab

Click the Configure Power Supply BOM tab to complete the bill of materials (BOM) for the Power Supply after fully sizing the application. In this tab, you select options for the power rail, shunt module, filters, circuit breakers, and fuses.

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.1.7. System Bill of Materials (BOM) View

Click BOM view to review the entire BOM (bill of materials) for the system and add any additional parts that may be needed.

Table 20 - BOM View Tabs

Parameters Description Page

Configuration Summary Tab

Software and Accessories Tab

Additional Parts Tab

BOM Tab

Shows all the axis components in axis order. 37

Contains the Controllers, Software, and other Accessories to complete your system.

Select any additional components. 39

Displays the full bill of materials (BOM). 40

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1.2.2.4.1.7.1. Configuration Summary Tab

Click Configuration Summary to display all the axis components and descriptions in axis order. Scroll down to see all the axes.

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1.2.2.4.1.7.2. Software and Accessories Tab

Click Software and Accessories to complete your system.

To assist in selecting the Sercos cables, click Auto Select to automatically build a set of these cables with the required lengths to link the axes according to their slot configuration.

Break-out boards, cables, kits, and various connectors are available to complete cabling from drive to motor.

Other components such as connectors, safe-off headers, and line filters for example, are available.

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1.2.2.4.1.7.3. Additional Parts Tab

Click Additional Parts to add any additional components you may need.

From the Product Family pull-down menu, choose the Family, Motor Series, and then by component category to reduce the time required to search for motion control components. If you know the catalog number, entering that is the quickest way to find your part.

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.1.7.4. BOM Tab

Click BOM to display the full bill of materials (BOM) in the same section headings as the other tabs.

This BOM can be exported to Microsoft Word or Microsoft Excel software by clicking the appropriate button.

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Welcome to Motion Analyzer Software Chapter 1

1.2.2.4.2. Power Supply/Accessories - Integrated Drive-Motor (IDM) Systems

The integrated drive-motor (IDM) power interface module (IPIM) is effectively a power management module for the DC link to a group of individual IDM units, but to the 2094 power rail it looks like an axis module. Each IPIM module can handle up to 16 axes, with certain limitations.

Table 21 - IPIM Module Configuration

Options Description Page

Power Data Tab

IPIM Module Selection Tab Lets you select the IPIM module. 42

Cable Length Tab

Control Power Tab

Configure IPIM Module BOM Tab

View regeneration and motoring data for each IDM unit. 41

Cable selection for connecting IPIM module-to-IDM unit and IDM unit-to-IDM unit.

• Bar graph for control power

• Summary view

• Details view

Configure the bill of materials (BOM) for the power supply after fully sizing the application.

1.2.2.4.2.1. Power Data Tab

Click the Power Data tab to view regeneration and motoring data for each IDM unit.

Figure 26 - Power Data Tab

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Chapter 1 Welcome to Motion Analyzer Software

Table 22 - Power Data Tab Descriptions

Options Description

Label 1 in Figure 26

IDM Axis view (label 2 in Figure 26

Back to Power Rail (label 3 in Figure 26)

Name of the power rail and selected IPIM module slot is displayed here. Click the power rail name label switches the view from IPIM view to Power Rail - Power Supply view.

Summary of the all IDM units associated with the selected IPIM module along with the Axis

)

Motoring Bus Current and Axis Regenerating Bus Current values of each IDM unit.

Click to switch the view from IPIM view to Power Rail - Power Supply view.

1.2.2.4.2.2. IPIM Module Selection Tab

Click the IPIM Module Selection tab to select an IPIM module.

Figure 27 - IPIM Selection Tab

Table 23 - IPI M Selection Tab De scri ptio ns

Options Description

Automatic

Selection mode (label 1 in Figure 27

Utilizations (label 2 in Figure 27

42 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Manual Select Manual to manually select the IPIM module.

Current Selection

Search Search button is disabled because only one catalog number is available.

IPIM

DC Bus Current RMS Limit

)

DC Bus Current Instantaneous Limit

Select Automatic for Motion Analyzer software to search for the best IPIM module solution for the selected slot.

Displays the selected IPIM module catalog number.

Arrows provide the means to scroll forward/backwa rd to smaller/larger IPIM module catalog numbers.

Graphical representation of DC bus current rms limit for the selected IPIM module.

Graphical representation of DC bus current instantaneous limit for the selected IPIM module.

Welcome to Motion Analyzer Software Chapter 1

1.2.2.4.2.3. Cable Length Tab

Click the Cable Length tab to select cables for connecting IPIM module-to-IDM unit and IDM unit-to-IDM unit.

Figure 28 - Cable Length Tab

Table 24 - Cable Length Tab Descriptions

Options Description

From the Cable Length pull-down menus, choose the appropriate cable length for connecting IPIM module-to-IDM unit and IDM unit-to-unit. The maximum cable lengths in an IDM system are specified as 25 m (82 ft) IDM unit-to-IDM unit and 100 m (328 ft) total cable length.

IDM Cables (label 1 in Figure 28

IDM System Graphic (label 2 in Figure 28

Cable For Specifies the modules the cables will join.

Cable Length Specifies the cable length.

Total Length Specifies the total length of the cables.

Graphical representation of IPIM module, associated IDM units and joining cables. Cable length

)

is displayed over the cables.

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1.2.2.4.2.4. Control Power Tab

Click the Control Power tab for utilization views and to select the number of sensor inputs and outputs.

Figure 29 - Control Power Tab

Table 25 - Con trol Power Tab Desc riptio ns

Options Description

Utilizations (label 1 in Figure 29

Selection for Control Power Usag e (label 2 in Figure 29

Detailed View (label 3 in Figure 29

Control Power

Total Displays the sum of power utilized by all the IDM units.

IPIM Displays the maximum power that can be supplied by the selected IPIM module.

Summary view

)

Click the Details arrow (refer to Figure 30

)

This table is hidden by default.

This bar graph displays the percentage of power utilized by all IDM units to the maximum power that can be supplied by IPIM module.

From the pull-down menu, choose the quantity of each of I/O Sensor. Summary view displays the control power usage and control voltage for each IDM unit.

Figure 30 - Control Power Tab (details arrow)

) to display complete information for each IDM unit.

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Figure 31 - Control Power Tab (details revealed)

1.2.2.4.2.5. Configure IPIM Module BOM Tab

Click the Configure IPIM Module BOM tab to select hybrid and network cables, and other IDM system accessory items.

Figure 32 - Configure IPIM Module BOM Tab

Table 26 - Configure IPIM Module BOM Tab Descriptions

Options Description

Step 1 (Figure 32) IPIM module IPIM module selected on the IPIM Module tab is displayed here.

Step 2 (Figure 32

Step 3 (Figure 32

Step 4 (Figure 32) Hybrid coupler The hybrid coupler connects between two hybrid cables, to bypass an IDM unit.

Step 5 (Figure 33

) Hybrid cables Hybrid cable lengths selected on the Cable Lengths tab are displayed here.

)Network cables

Network

)

bulkhead adapter

Network cables can be routed with the hybrid cables, so network cable lengths should be the same as the hybrid cable. The IPIM-to-IDM1 cable must have a straight connector to the IPIM module.

Use the network bulkhead adapter for securing network cables as they pass through the cabinet.

Figure 33 - Configure IPIM Module BOM Tab

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.3. Power Supply/Accessories - Single-axis Drive Systems

If your drive family is single axis, for example, Kinetix 300, Kinetix 350, Kinetix 3, or Ultra™3000, Ultra5000, and Ultra1500, you must configure a shunt or specify no shunt required.

Figure 34 - Power Supply/Accessories Dialog Box

Table 27 - Power Supply/Accessories Tabs (refer to Figure 34

Parameters Description Page

Power Data Tab View the regeneration and motoring data for each axis. 47

Shunt Tab

Analysis Tab

Energy Tab

Configure Power Supply BOM Tab

46 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Select the external shunt resistors for single-axis systems. 47

Analyze the drive module activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters.

View input current values and energy savings estimates for each axis. 49

Configure the bill of materials (BOM) for the power supply after fully sizing the application.

)

Welcome to Motion Analyzer Software Chapter 1

1.2.2.4.3.1. Power Data Tab

Use the Power Data tab to view regeneration and motoring data for each axis.

Table 28 - Power Data Tab Properties (refer to Figure 34)

Parameters Description

Axis Histograms

The axis histograms show a multi-axis representation of axis currents including Peak Motoring, Average Motoring, Peak Regenerating, and Average Regenerating.

1.2.2.4.3.2. Shunt Tab

Click Search to automatically configure the shunt module catalog number for each axis.

Figure 35 - Shunt Tab

Table 29 - Shunt Tab Properties

Parameters Description

Shunt selection (refer to Figure 23

Continuous Current utilization bar (refer to Figure 23 )

Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012 47

Click Search to configure external shunts if an existing internal shunt for a given drive is outside its rating. If you need more than one external shunt, click search to select multiple

)

shunt modules. You can also select a compatible shunt manually.

The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed in percentage form. Click the drive module or shunt catalog number to view its product specification.

Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.3.3. Analysis Tab

Click Analysis to display plots of drive module activity in terms of the DC bus voltage and DC bus current:

• The red line is the bus voltage trip point.

• The green line is the DC bus voltage.

• The grey line is the bus current.

Figure 36 - Analysis Tab Dialog Box

Table 30 - Analysis Tab Properties

Parameters Description

Shunt On The voltage level where the shunt enables.

Shunt Off The voltage level where the shunt turns off.

(1)

Simulation Parameters (refer to Figure 25)

Zoom (refer to Figure 25

(1) Click Apply to implement these changes.

48 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Trip The voltage level where the drive trips on an overvoltage fault by changing the trip volts.

Resistance The shunt resistance level in ohms.

Power Changing the power value modifies how much energy the shunt resistor can dissipate continuously.

Capacitance Changing the capacitance value changes the DC bus capacitance.

Time From/ Voltage From

)

Time Slice

Check these boxes to adjust the X- and Y-axis values for the plot. Click Plot to implement these changes.

The Time Slice variable sets the time interval for the Analysis tab. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selec tion (0.1 ms, for example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is equal to the longest axis cycle.

Welcome to Motion Analyzer Software Chapter 1

If the time slice variable is increased, this error message often appears.

This time slice message often appears if one of the motion cycles is a cam, which often has very short time segments. In this case, click No to ignore the message.

1.2.2.4.3.4. Energy Tab

Click the Energy tab to display the main power supply parameters including input current, cost of system energ y, and cost of shunt energy.

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.3.5. Configure Power Supply BOM Tab

Click the Configure Power Supply BOM tab to complete the bill of materials (BOM) for the Power Supply after fully sizing the application. In this tab, you select options for the shunt module, filters, circuit breakers, and fuses.

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1.2.2.4.4. Power Supply/Accessories – AC/DC Power Sharing Systems (Kinetix 5500 drives)

If your drive family is Kinetix 5500, you must define a valid power sharing configuration and then configure a shunt and capacitor, or specify if no shunt or capacitor are required.

Figure 37 - Power Supply/Accessories

Parameters Description

DC Sharing

Power Configuration options (label 1 in Figure 37

Axes sharing – AC/DC (label 2 in Figure 37

)

AC Sharing Only

Select the AC and DC sharing option for each axis individually.

Table 31 - Power Configuration Options (refer to label 1 in Figure 37

Use this option for shared AC/DC or common bus configuration. The following restrictions are imposed on the number of drives allowed in common bus, or shared AC/DC configuration, based on the converter capacity and/or connectors:

• Single phase operation is not allowed.

• The bus master drive or drives with an AC connection should have the same power rating (catalog number).

• The bus master drive or drives should always have a rating equal to, or greater than, the followers.

• The number of bus master drives cannot exceed the following rule: Frame 3 = two drives; Frame 2 = four drives;

Frame 1 = eight drives.

• The number of follower drives is driven by the frame of the master drive or drives, and cannot exceed this rule: Frame 1 drive = only four more bus followers can be added; Frame 2 drive = only six more bus followers can be added.

• Converter power output should be reduced by 30% of the sum of the individual converter power capacities of drives configured for shared AC/DC.

• The maximum number of drives in a bus power sharing group is eight drives.

3-phase AC input power can be shared among drives with the same power rating. No DC bus connections are allowed in this configuration. AC power sharing allows you to minimize the system components, such as circuit breakers and fuses. The following limitations apply when drives are configured for sharing AC input power:

• Single-phase operation is not allowed.

• All drives must be configured for the same converter voltage rating.

• Drives with the same power rating (catalog number) can be used for this configuration.

• The maximum number of drives that can be configured for shared AC operation is limited by the amp capacity of

the AC input connector. The following rules apply: Frame 1 drives can share AC with up to five drives of the same rating; Frame 2 drives can share AC with up to three drives of the same rating; Frame 3 drives can share AC with up to two drives of the same rating.

)

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.4.1. DC Sharing

Use the DC Sharing configuration to group axes to share a common DC bus and input AC supply (optional).

Table 32 - Power Supply/Accessories Tabs (refer to Figure 37)

Parameters Description

Power Data Tab View regeneration and motoring data for each axis.

Conver ter and Shunt Tab Select the shunts and capacitor for your system.

Analysis Tab

Energy Tab View input current values and energy savings estimates for each axis.

Configure Power Supply BOM Tab

Analyze the drive module activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters.

Configure the bill of materials (BOM) for the power supply after fully sizing the application.

1.2.2.4.4.1.1. Power Data Tab

Click the Power Data tab to view regeneration and motoring data for each axis.

Parameters Description

Axis histograms

Random/Sync relationship

Offset

The axis histograms show a multi-axis representation of axis currents including peak motoring, average motoring, peak regenerating, and average regenerating.

The safe setting for system sizing is all Random mode. In this case, the worst case current demand for each axis is automatically lined up by adjusting the phase relationship of the axis motion profiles. If the phase relationship is known and will not change, the cycle profiles should be set up in the correct relationship and appropriate synchronized set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected.

Figure 38 - Power Data Tab

Table 33 - Power Data Tab Properties (refer to Figure 38

)

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1.2.2.4.4.1.2. Converter and Shunt Tab

Select shunt and capacitor modules for your system.

Figure 39 - Converter and Shunt Tab

Table 34 - Converter and Shunt Tab Properties (refer to Figure 39

Parameters Description

Shunt Selection and Component Listing

(label 1 in Figure 39)

Calculation Utilizations

Utilization (label 2 in Figure 39

)

In this section you select a shunt for each axis, and a capacitor module for the system.

Click Calculate Utilizations to analyze the behavior of the bus, and to calculate the drive and shunt utilizations.

The drive continuous and peak current utilizations and the shunt continuous current utilization histograms are displayed in this area. Click the drive module catalog number to view the drive specifications.

)

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.4.1.3. Analysis Tab

Click the Analysis tab to conduct detailed analysis of the drive module activity in terms of bus volts and system current, along with the capability of simulating changes to the system parameters. The analysis activities are described as follows:

• The red line is the bus voltage trip point.

• The green line is the DC bus voltage.

• The grey line is the bus current.

Figure 40 - Analysis Tab

Table 35 - Analysis Tab Properties (refer to Figure 40

Parameters Description

Simulation Parameters (refer to Figure 40)

Zoom window (refer to Figure 40)

54 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Adjust these parameters to obser ve how changes to the parameters impact the bus voltage and current.

Time From/ Voltage From

Time Slice

Check these boxes to adjust the X- and Y-axis values for the plot.

The Time Slice variable sets the time interval for the analysis display. Because the shunt switching action is modeled during selection, this value needs to be very short to obtain an accurate shunt selec tion (0.1 ms, for example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive.

The time is equal to the longest axis cycle. In the case of a very long length of time, we suggest that a longer time slice be used for early checks, but a time slice of less than 0.1 ms should be used for the final selection.

)

Welcome to Motion Analyzer Software Chapter 1

If the time is increased, the time slice error message often appears.

This time slice message often appears if one of the motion cycles is a cam, which often has very short time segments. In this case, click No to ignore the message.

1.2.2.4.4.1.4. Energy Tab

Click the Energy tab to display the main power supply parameters including Input Current, System Power, Shunt Power, and Energy Savings Estimates.

Figure 41 - Energy Tab

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.4.1.5. Configure Power Supply BOM Tab

Click the Configure Power Supply BOM tab to complete the bill of materials (BOM) for the power supply after fully sizing the application. In this tab, you select options for the power rail, shunt module, filters, circuit breakers, and fuses.

Figure 42 - Configure Power Supply BOM Tab

1.2.2.4.4.2. AC Sharing Only

Use the AC Sharing Only configuration to group axes to share input AC supply only, with no DC bus sharing.

Figure 43 - Power Configuration Tab for AC Sharing Only Mode

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Table 36 - Power Supply/Accessories (refer to Figure 43)

Parameters Description

Power Data Tab View regeneration and motoring data for each axis.

Conver ter and Shunt Tab

Analysis Tab

Energy Tab View input current values and energy savings estimates for each axis.

Config ure Power Sup ply BOM Tab

Select the shunt and capacitor for your system.

Analyze the drive module activity in terms of bus voltage and system current. With this tab, you can also simulate changes to the system parameters.

Configure the bill of materials (BOM) for the power supply after fully sizing the application.

1.2.2.4.4.2.1. Power Data Tab

Use the Power Data tab to view regeneration and motoring data for each axis.

Figure 44 - Power Data Tab

Table 37 - Power Data Tab Properties (refer to Figure 44

Parameters Description

Axis histograms

The axis histograms show a multi-axis representation of axis currents including peak motoring, average motoring, peak regenerating, and average regenerating.

)

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Chapter 1 Welcome to Motion Analyzer Software

1.2.2.4.4.2.2. Shunt Tab

Select the shunt and capacitor module for your system.

Figure 45 - Shunt Tab

Table 38 - Shunt Tab Properties (refer to Figure 45

Parameters Description

Shunt selection (refer to Figure 45

Continuous Current utilization bar (refer to Figure 45

)

Click Search to configure external shunts if an existing internal shunt for a given drive is outside its rating. If you need more than one external shunt, click search to select multiple shunt modules. You can also select a compatible shunt manually.

)

58 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

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1.2.2.4.4.2.3. Analysis Tab

Click the Analysis tab to display plots of drive module activity in terms of the DC bus voltage and DC bus current. The analysis activities are described as follows:

• The red line is the bus voltage trip point.

• The green line is the DC bus voltage.

• The grey line is the bus current.

Figure 46 - Analysis Tab

Table 39 - Analysis Tab Properties (refer to Figure 46

Parameters Description

Shunt On The voltage level where the shunt enables.

Shunt Off The voltage level where the shunt turns off.

Simulation Parameters (refer to Figure 46)

Zoom window (refer to Figure 46

(1) Click Apply to implement these changes.

(1)

Tri p

Resistance The shunt resistance level in ohms.

Power

Capacitance Changing the capacitance value changes the DC bus capacitance.

Time From/ Voltage From

)

Time Sli ce

The voltage level where the drive trips on an overvoltage fault by changing the trip volts.

Changing the power value modifies how much energy the shunt resistor can dissipate continuously.

Check these boxes to adjust the X- and Y-axis values for the plot. Click Plot to implement these changes.

However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is equal to the longest axis cycle.

)

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Chapter 1 Welcome to Motion Analyzer Software

If the time is increased, the time slice error message often appears.

This time slice message often appears if one of the motion cycles is a cam, which often has very short time segments. In this case, click No to ignore the message.

1.2.2.4.4.2.4. Energy Tab

Click the Energy tab to display the main power supply parameters including input current, cost of system energ y, and cost of shunt energy.

Figure 47 - Energy Tab

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1.2.2.4.4.2.5. Configure Power Supply BOM Tab

Figure 48 - Configure Power Supply BOM Tab

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1.2.3. Preferences Tab

The Preferences tab contains three sections.

Figure 49 - Preferences Tab Options

Table 40 - Preferences Tab Descriptions

Options Description

The product databases may be modified to restrict selections to those items marked by you. This may be used, for example, by a distributor to select from a range of popular stock items. Drives, Motors, and Gearboxes may all be marked.

Creates a database of custom motors with your own specifications that can be sized and analyzed.

Updates the Motion Analyzer database on your personal computer to the latest database available from the Motion Analyzer server.

Enter details about the end-user. Entries appear on printouts.

)

Lets privileged users select the electronic keys to provide additional features and functions.

Lets you set default units for all data entry. Choice includes a user Custom set.

Lets you set the operating conditions used to calculate Life calculations of Bearing Life, Bal l Screw Life, Roller Screw Life, and Strip Seal Life in Motion Analyzer software.

Database (label 1 in

Figure 49 )

Settings (label 2 in

Figure 49 )

Options (label 3 in

Figure 49

My Preferred Database (refer to Figure 50)

User Defined Database (refer to Figure 51)

Check for Updates

User Inform ation (refer to Figure 52

Key Status

Units of Measure (refer to Figure 53)

)

Operating Conditions (refer to Figure 54)

Notes Launches system notes for the application.

Figure 50 - Preferred Data Dialog Box

62 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Figure 51 - User Defined Motors Dialog Box

Figure 52 - Options - User Information Dialog Box

Welcome to Motion Analyzer Software Chapter 1

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Chapter 1 Welcome to Motion Analyzer Software

Figure 53 - Options - Units of Measure Dialog Box

Figure 54 - Options - Operating Conditions Dialog Box

64 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

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1.2.4. Export – Import Tab

The Export - Import tab contains two sections.

Figure 55 - Export - Import Tab Options

Table 41 - Export - Import Tab Descriptions

Options Description

Project Data to Word Exports the application data to a Microsoft Word document.

Launches the export wizard to let you export the profile data of the selected axis. Refer to More Options Profile Editor Mode on page 142.

Exports motion system information to RSLogix™ 5000 software to use it in the next step of your design process.

Imports the axis data from another axis either of current application or from any other Motion Analyzer application.

Imports the Profile data for selected axis. Impor ted Profile Data must have been previously exported by Motion Analyzer software.

Export (label 1 in Figure 55

Import (label 2 in Figure 55)

Profile Data

BOM to Word Exports Bill of Material to Microsoft Word document.

)

BOM to Excel Exports Bill of Material to Microsoft Excel file.

Export To RSLogix 5000

Axis Data

Profile Data

1.2.4.1. Export to RSLogix 5000 Wizard

Once you have selected a motor and drive in Motion Analyzer software, you can export motion system information to RSLogix 5000 software and use it in the next step of your design process. You can generate an RSLogix 5000 file (.L5X), version 18.00, 19.00, 20.00, or 21.00. Applications can be exported to RSLogix 5000 software as new .L5X files or as updates to existing .L5X files.

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1.2.4.1.1. Export Options - Create a New .L5X File

1. From the Export-Import menu, click Export To RSLogix 5000.

The Output Format Selection dialog box opens.

2. Select Create a New L5X and from the pull-down menu and choose the RSLogix 5000 software version you intend to use.

3. Click Next.

The Axis Mapping dialog box opens.

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1.2.4.1.1.1. Axis Mapping

Information about .L5X file that Motion Analyzer generates is displayed at the top of the screen as read only information.

Table 42 - Axis Mapping Properties

Attribute Description

Controller Name

Controller Type

Chassis Type

Motion Analyzer software assigns a default name for the controller. You can edit this once the file has been loaded.

Motion Analyzer software creates a file with a default controller type. You can edit this once the file has been loaded.

Motion Analyzer software creates a file with a default Logix chassis. You may change your chassis type once the file has been loaded.

The name you define for each axis in Motion Analyzer software is used to create a RSLogix 5000 axis tag. Underscore characters replace spaces in the name defined in Motion Analyzer software. To change these names you must exit the Export to RSLogix 5000 wizard and change the names by right-clicking each axis in the Motion Analyzer explorer tree.

All axes in your Motion Analyzer (.mba) file appear in the table. If they will export without trouble, a green status check is displayed.

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Table 43 - Axis Mapping Symbols

Attribute Description

Axes will export without errors.

Axes with warning icon only partially export to RSLogix 5000 software. A note at the bottom of the screen indicates what is wrong.

Not recommended icon. A note at the bottom of the screen indicates what is wrong.

If problems occur with selected catalog numbers, a warning icon and a note at the bottom of the dialog box appears.

Figure 56 - Axis with Warning Icon

If export isn’t possible, a note at the bottom of the dialog box indicates what the problem is. This axis is not exported to RSLogix 5000 software.

Figure 57 - Axis with Not Recommended Icon

If the number of axes a sercos module can support is exceeded, a new sercos module is added into the pull-down menu in the third column. This is selectable for the rest of the axes. This new module is also exported to the .L5X file.

4. Click Next.

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IMPORTANT

The Target Location dialog box opens.

1.2.4.1.1.2. Save and Import the L5X File

1. Click Browse to select a target location and save the .L5X file.

2. Click Finish.

Do not use spaces or special characters in the name, or RSLogix 5000 software will not open the file.

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3. Open RSLogix 5000 software.

4. Browse to your .L5X file and open it.

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5. Browse to the location where you would like to store your .acd file.

6. Click Import.

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Your motion system information imports from Motion Analyzer software. Exceptions include warnings noted on the Axis Mapping dialog box.

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1.2.4.1.2. Export Options - Update an Existing L5X File

1. From the Export-Import menu, click Export To RSLogix 5000.

The Output Format Selection dialog box opens.

2. Select Update an Existing L5X and click browse to find the file you wish to update.

3. Click Next.

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The Axis Mapping dialog box opens.

4. Make changes as needed to the existing file.

5. Click Next.

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The Target Location dialog box opens.

Welcome to Motion Analyzer Software Chapter 1

Table 44 - Export Output Target Properties

Attribute Description

Save Select Save to replace the old L5X file with the updated file.

Save As Select Save As to create an updated L5X file in a new location and/or with a new name.

6. Open the file in RSLogix 5000 software as described earlier and notice that the motion system information from your Motion Analyzer software file has been included.

7. Click Finish.

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1.2.5. Bill of Materials (BOM) Tab

The Bill of Materials (BOM) tab contains two sections.

Figure 58 - Bill of Materials (BOM) Tab Options

Table 45 - Bill of Materials (BOM) Tab Descriptions

Options Description

This is a combo item and contains the axis names of all the axes in the Drives Group that have a solution. It lets you navigate to the Configure Axis BOM tab of Axis view where you can configure the BOM for the axis chosen.

This is a combo item for single-axis drive family and a button item for multi-axis drive family. For single-axis drive family, it contains the axis names of all the axes in Drives Group that have a solution. It lets you navigate to Configu re Power Supply B OM tab of the Power Supply & Accessories view where you can configure the Power Supply BOM for the system.

Navigate to the Software & Accessories tab of System BOM view on

page 38.

Navigate to the Additional Parts tab of System BOM view on page 39.

Navigate to the BOM tab of System BOM view on page 37.

Confi gure (label 1 in Figure 58)

Export (label 2 in Figure 58

Axis

System Module

Software and Accessories Tab

Additional Parts Tab

Configuration Summary Tab

BOM to Word Exports Bill of Material to Microsoft Word document.

)

BOM to Excel Exports Bill of Material to Microsoft Excel file.

1.2.6. Help Tab

The Help tab contains one section.

Figure 59 - Help Tab Options

Table 46 - Help Tab Descriptions (refer to Figure 59

Options Description

Motion Analyzer Help Launches Motion Analyzer help.

Activate Motion Analyzer

Send Feedback Provides contact information for Motion Analyzer software support.

Release Notes Launches the Release Notes for the installed Motion Analyzer software revision.

About Motion Analyzer

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Launches the Motion Analyzer Activation wizard. You can Purchase License or Activate their Motion Analyzer installation (refer to Figure 60

Launches the About Motion Analyzer dialog box that displays details of the installed copy of Motion Analyzer software (refer to Figure 61

)

Figure 60 - Motion Analyzer Activation Wizard

Welcome to Motion Analyzer Software Chapter 1

Figure 61 - About Motion Analyzer

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1.3. Explorer View

The Explorer view provides a Windows Explorer style graphical user interface for accessing components in your Motion Analyzer software application.

For multi-axis drive systems, the axes are added under the Power Rail node in the Explorer hierarchy view.

Figure 62 - Typical Multi-axis Drive Explorer View

For single-axis drive systems, the axes are added under the Project node in the Explorer hierarchy view.

Figure 63 - Typical Single-axis Drive Explorer View

For drive families that allow stand alone as well as power sharing group (Kinetix 5500 drives), a mix of drive group and stand alone axes can be added under the Project Node.

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Figure 64 - Typical AC/DC Power Sharing System (Kinetix 5500) Explorer View

Options Description

The project node contains two types of groups. The Power Rail/Drive Group (of the selected product family) and an unallocated group.

Power Rail No de

Drives Group Node

Axis Module Node

Project Node

Axis Module Node

IPIM Module Node

IDM Unit Node

Empty Slot Node

Table 47 - Explorer View Structure (refer to Figure 62

Applies to multi-axis drive families. Shown is the power rail icon, drive family na me, and power rail catalog number. The default name for this node is Drives Group 1, however, it is renamed when a solution for any axis under this group is defined.

For single-axis family, the default name is Drives Group 1. For multi-axes family, the default name is Power Rail 1. Also, for multi-axis family, after the drive family is defined, the power rail displays many empty slots until each slot is allocated a module.

Applies to drive families that allow AC and DC power sharing (Kinetix 5500). Shown is the drive group icon and drive name.

Axis node consists of two levels. First level displays the slot number of the power rail (available only for multi-axis families), axis name, drive catalog number, and the solution status of the axis. Second level displays the motor catalog number for the selected solution. Additionally, if there is a warning in the axis, then a warning triangle is also displayed beside the solution status.

When the solution is not yet selected, then only the axis node is displayed and instead of drive catalog number, Incomplete is displayed.

This node displays the slot number that the IPIM module is assigned to on the power rail along with the name of the IPIM module, catalog number of the selected IPIM module, and the IPIM module status.

IDM unit node is similar to axis module node except that the IDM unit node consists of only a single node representing the axis solution.

Applies to multi-axis drive families. It is visible after a multi-axis drive family is selected.

)

Unallocated Axis Node

Status Symbols

The Unallocated Axes Node is where axes independent of other axes can be created. An unallocated axis can be allocated to a Drive Group using the allocate button located in the Home Tab

Additionally, if the power supply solution is present, then the status of the selected power supply solution is also displayed, as described below.

Indicates that the selected power supply solution and all children support the application requirement.

Indicates that the selected power supply solution or any one of the children marginally support the application requirement.

Indicates that the selected power supply solution or any one of the children is not recommended for the application. Additionally, this icon is also displayed when the IAM module for the power rail has not been sized.

on the menu bar or by dragging and dropping the axis.

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Notes:

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Top ic Pa ge

Identify Your Load 82

Linear Loads 83

Rotary Loads 86

Rotary Complex Loads 87

Application Template Loads 96

From SolidWorks 120

Define Your Profile 139

Less Options Profile Editor Mode 140

More Options Profile Editor Mode 142

Specify Your Linear Load Mechanism 178

Belt Drive 180

Lead Screw 181

Chain and Sprocket 182

Rack and Pinion 183

Linear Motor 184

Electric Cylinders 186

Linear Stages 187

Linear Thrusters 189

Specify Your Transmission 191

Compute Using Inertia and Ratio 193

Compute Using Pitch Circle Diameter 194

Compute Using Number of Teeth 195

Choose Your Motor Series 196

Choose Your Electric Cylinder Series 199

Choose Your Drive Family 201

Chapter 2

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2.1. Identify Your Load

A load is a device that transfers the actuator output to the desired end effectors. Loads do not affect the motion type.

Figure 65 - Load Type Tab

Table 48 - Load Type Options

Load Type Description Page

Linear Loads Load moves in a straight line. 83

Rotary Loads Load rotates and the system has no translation to linear motion. 86

Rotary Complex Loads

Application Template Loads

From Soli dWorks

Rotary motion can be translated to linear motion, and vise versa. Iner tia, friction, and/or torque values for the system change with time.

Simplify data entry dramatically where the application is appropriate. The Application Templates include Press Roll Feed (Constant Time or Angle), Carriage Cut Off, Cutter Knife Drive, Advanced Templates, and Power Speed.

Used to obtain load data to aid in sizing your application for the appropriate motors, drives, and accessories.

120

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2.1.1. Linear Loads

For a Linear application, the load moves in a straight line.

Figure 66 - Linear Load Type

Sizing Your System Chapter 2

Table 49 - Linear Load Parameters

Parameter Description

Load Mass Mass of the linear load.

Applied Force

Coeff of Friction

Inclination

Any external force (+/-) acting on the load. Positive force acts to oppose positive movement; down the inclination surface if inclination is non-zero. The arrow on the graphic indicates the force direction.

Coefficient of friction (μ). It is a unitless value, which is used to calculate the force of friction. It is largely dependent on the nature of the surfaces in contact with each other. Typical values for the coefficient of friction can be found in engineering tables. This value, along with the load mass (for example, Load weight + Table/Slide/Carriage weight), determines the amount of motor force or torque necessary to move a slide or table, for example.

Angle of inclination from the horizontal. The limits for this value are 0 and 90°. In the horizontal case (0° inclination), the Table Mass, Belt/Chain Mass, and/or Slide Mass are not affected by gravity, whereas in the vertical case (90° inclination), only the table mass is affected by gravity. Values for Table Mass, Belt/Chain Mass, and/or Slide Mass may be entered on the Mechanism tab (a future step in the workflow) if a Belt Drive, Lead Screw, Chain and Sprocket, or Rack and Pinion are selected.

If the Inclination angle is between 0 and -90°, you must enter the angle as a positive number and invert the motion profile. For example, enter a 45° angle value on the Load tab and a negative velocity in More Options Profile Editor Mode this will result in an under- calculation of the regenerative energy.

on page 142. Failure to do

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Chapter 2 Sizing Your System

Counterbalance Mass

Mass Counterbalance

Force Counterbalance

Counte rbalance Cyli nder

Air Pressure

Force

Weig ht

Drive Belt

Load Ma ss

Load Mass

Motor

2.1.1.1. Advanced Considerations - Counterbalances

In a counterbalanced system, unbalanced mass should be entered as Table Mass and balanced mass as Belt/Chain Mass. Values for Table Mass, Belt/Chain Mass, and/or Slide Mass may be entered on the Mechanism tab (a future step in the workflow) if a Belt Drive, Lead Screw, Chain and Sprocket, or Rack and Pinion are selected.

There are two main types of counterbalance.

Table 50 - Counterbalance Types

Type Description

Mass Counterbalance

Force Counterbalance

Figure 67 - Counterbalance Types

A 100% counterbalance doubles the load mass entered on the Load tab. Friction is usually negligible and the net force is zero. Accelerations are normally limited to less than gravity

(9.81 m/s

) to maintain the suspension tension.

A 100% counterbalance means there is zero net force, but usually adds significant friction, especially hydraulic types. For example, pneumatic, hydraulic, or spring. The increase in load mass is usually negligible.

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2.1.1.1.1. Mass Counterbalance

• Vertical load with a 100% mass counterbalance

Set the Inclination field to zero and enter a load mass two times greater than the load into the Load Mass field.

• Vertical load with less than 100% mass counterbalance.

Set the Inclination field to zero and enter the load mass plus the counterbalance mass into the Load Mass field. Add an external positive force equal to the following into the Applied Force field:

F = (M

load

- M

counterbalance

where a = acceleration due to gravity = 9.81 m/s

) a

2.1.1.1.2. Force Counterbalance

For a vertical load with a 100% force counterbalance, you have two choices:

• Set the Inclination field to zero and enter the load mass into the Load Mass field.

• Set the Inclination field to 90°, and enter the load mass into the Load Mass field. Add an external negative force equal to the load weight into the Applied Force field.

For a vertical load with less than 100% force counterbalance, set the Inclination field to 90° and put the load mass into the Load Mass field. Add an external negative force equal to the counterbalance force into the Applied Force field.

Be sure to add some allowance for friction. Hydraulic type counterbalances are notorious for high friction, which is usually speed-dependent. Because a mass counterbalance cannot easily handle this directly, take the friction force at the maximum speed, convert the friction force to torque at the drive shaft and add this torque to the Losses field in the Actuator tab.

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2.1.2. Rotary Loads

For a rotary application, the load rotates and the system has no translation to linear motion.

Figure 68 - Rotary Load Type

Table 51 - Rotary Load Parameters

Parameter Description

Primary Inertia

Friction This is the force resisting the relative motion of two surfaces against each other.

(1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily

available.

(1)

This is the inertia of any balanced load about the axis of rotation. For example, if the main mass is a circular table which is driven about its own axis of symmetry, then primary inertia is equal to the table inertia.

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2.1.3. Rotary Complex Loads

A complex rotary load is non-linear, which means that the load position is not directly proportional to the input shaft position as it is with standard actuator types. A simple example is a crank, where the load velocity is sinusoidal with a constant shaft speed. The Crank and Four Bar Linkage templates are available for these applications.

The main challenge with non-linear mechanisms is that the inertia value varies with shaft angle. This means that even at constant shaft speed, a torque that varies with the rate of change of inertia is required to maintain that speed. The same is true of an unbalanced load in which external forces, such as gravity, induce torque values that depend only on shaft angle, not velocity or acceleration.

The Rotary Complex load separates the dynamic inertia values from the motion profile so that, having calculated inertia for a range of shaft positions, the motion profile can be varied without having to re-calculate inertia at each shaft position.

Figure 69 - Rotary Complex Load Type

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Table 52 - Complex Load Data Options

Option Description

Complex Load Data (label 1 in Figure 69

(1)

Motion (label 2 in Figure 69)

Graph tab (label 3 in Figure 69

User Defined

)

Templates

Repeating

Limited Range

# Data point number; this number is arbitrary.

Position Driving shaft angle with refe rence to the sta rting angle.

Inertia Load inertia for the given shaft angle.

Applied Torque Torque applied at the given position.

Friction Torque Torque loss due to friction.

Description Available for you to enter optional notes.

The Graph tab of the display window shows the inertia, applied torque, and friction torque values as a function of shaft position based on the data entered in the table on the left (label 2

)

in Figure 69 ).

Impo rt loa d data f rom an ex terna l file i nto the Complex L oad Data table o n

page 90.

Use the Unbalanced Load and Crank temp lates to calculate load data and enter it in the Complex Load Data table on page 90.

With this option, the first and last points should be identical so that the motion profile can be repeated (for example, zero and 360 °). Motion Analyzer software assumes that rotation may continue indefinitely in either direction.

With this option, the first and last points indicate the maximum and minimum positions permitted.

(1) The complex load data (position, inertia, and torque, for example) is entered manually, imported, or calculated in the available

Rotary Complex Templates.

It is important to start with the mechanism in the appropriate position. Click

Start Condition

on the toolbar at the top of the More Options Profile Editor

Mode dialog box to input the motion profile start condition.

Figure 70 - Graph Tab

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In this Crank application, the green applied torque curve shows a sharp peak around 180° when a high force is encountered near the end of the linear stroke.

Figure 71 - Crank Application Example

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IMPORTANT

2.1.3.1. User Defined

For the User Defined data entry option, calculations are typically made with a spreadsheet. Once the data is arranged in columns to match the Complex Load Data table, you can copy the data to the clipboard and paste it into the table. The columns are tab delimited, which is the default format for Microsoft Excel software. Alternatively, you can create and import a text file.

Before pasting data make sure that the column units match those of the data.

2.1.3.2. Templates

The Rotary Complex templates can be used to calculate Complex Load Data for Unbalanced Load and Crank application types.

Figure 72 - Rotary Complex Loads

There are two Rotary Complex templates available to assist in calculating data for the Complex Load Data table (label 2 in Figure 72

Table 53 - Template Options (label 1 in Figure 72)

Template Description Page

Unbalanced Load Tem p l at e

Crank Template

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Sizing Your System Chapter 2

2.1.3.2.1. Unbalanced Load Template

This template lets you enter parameters for an unbalanced load application.

Figure 73 - Unbalanced Load Template

Motion Analyzer software assumes that the axis of rotation is parallel to the ground if no axis angle is entered and that unbalanced masses create a gravity related torque. Secondary Inertia, Secondary Mass and Axis Separation parameters are required to take into account gravity induced torque values.

Figure 74 - Axis of Rotation Parallel to Ground with No Axis Angle Defined

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If the gravity torque (Secondary Mass * 9.81 m/s2 * Axis separation2) is known to be small as compared to the acceleration torque or motor nominal torque, then it may not be necessary to include the unbalanced mass effects.

ATT EN TI ON : If the angle of movement in any profile segment is such that the gravity torque changes significantly during that segment (a common occurrence) then break the segment into smaller portions.

Table 54 - Unbalanced Load Parameters (refer to Figure 73)

Parameter Description

Primary Inertia

Losses The losses consist of the torque lost in the system due to friction.

Secondary Inertia

Secondary Mass The unbalanced mass.

Axis Separation The distance between the secondary mass’ center of gravity and the axis of rotation.

Axis Angle

(1)

The inertia of any balanced load about its own axis of rotation. For example, if the main mass is a circular table which is driven about its own axis of symmetr y, then Primary Inertia is equal to the table inertia.

The moment of inertia of the unbalanced mass about its own center of gravity.

The starting angle of rotation. Zero indicates that at the start of the motion profile, the center of gravity lies vertically below the center of rotation. This is the position of the load if it is allowed to swing freely. Positive rotation is clockwise.

(1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily

available.

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IMPORTANT

TIP

2.1.3.2.2. Crank Template

The Crank template is used to calculate the load profile for a given application, based on either input shaft velocity or linear load velocity.

This template should only be used for constant inertia. Do not set secondary mass or secondary inertia when using this template.

Figure 75 - Crank Template

Figure 76 - Animated Display (for reference)

Parameter entry descriptions are displayed when the cursor is held over an entry field for several seconds.

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Table 55 - Crank Template Parameters

Parameter Description

For reference to make sure that entered data is accurate and particularly that the ori entation of the crank is correct. The animation rotates the crank so that the system can be better visualized. The X/Y plane is horizontal.

Vertical Slider (Left)

Horizontal Slider (Top)

Animated Display (label 1 in Figure 75)

Template Options (inside red box in Figure 75

)

Mechanical Data (label 2 in Figure 75

Export to Complex Load (label 3 in Figure 75

Horizontal Slider (Scale) Sets the display scale.

Horizontal Slider (Speed) Sets the animation speed.

Black Arrow Represents the ex ternal force and th e arrow length is proportional to the applied force.

2D/3D Toggles between two and three-dimensional representations of the crank.

Thick Lines Check this box if you would like the graphical displays to be shown with a thicker line.

Animate Click to run the simulated crank image through the specified motion profile.

Stop Click to stop the animation.

Calculate Click to calculate the external torque and reflected inertia values.

Crank Radius The distance between crank shaft and crank pin.

Crank Inertia

(1)

Connecting Rod Length

Connecting Rod Mass The total mass of the connecting rod.

Conrod C of G from Crankpin The distance between the crank pin and the connecting rod center of gravity.

Conrod Inertia about C of G

Linear (Load) Mass The mass of the load attached to the connecting rod at the gudgeon pin.

Linear (Load) Offset The distance from the linear motion center line to the crankshaft axis.

Force Start Position The distance between gudgeon (wrist) pin and crank shaft center when force is applied.

Force End Position The distance between the gudgeon (wrist) pin and crank shaft center when force stops.

)

Force at En d

(3)

Force v Angle Box When this box is checked, the force varies according to shaft angle rather than linear position.

Draw Click this button to show the geometry at the start angle/position.

Logix Cam

Crankshaft Inclination

Crank Plane Inclination

Start Angle The starting angle for the Crank load profile.

End Angle The ending angle for the Crank load profile.

)

Points The number of points you would like to divide the load profile into.

Sets the crankshaft inclination. Set this parameter before starting the animation. The 0y button sets the angle to 90°. The current angle is displayed in the Mechanical Data window.

Sets the linear slide inclination. The 0z button sets the angle to 0°. The current angle is displayed in the Mechanical Data window. The true angle to the horizontal is dependent on both slider positions since it is a compound angle.

The inertia of the crank alone, when the connecting rod is disconnected.

(2)

The distance from the crank pin center to the gudgeon (wrist) pin center.

(1)

The inertia of the connecting rod about its own center of gravity.

The magnitude of the force at the ending point.

Click this button to transfer the geometrical data to the clipboard for pasting into the RSLogix 5000 Cam Editor. The master axis is a virtual axis and the slave axis is the crank axis. A trapezoidal move of the virtual axis produces a trapezoidal load profile at the gudgeon pin. The master data must increase positively so only that part of the cam that satisfies this requirement is exported.

This displayed value is the angle of the crank shaft with respect to the XY (horizontal) plane. 90° indicates vertical and gravity has no effect.

This displayed value is the angle with respect to the horizontal plane along which the linear mass moves. Zero degrees indicates horizontal and gravity has no effect.

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Table 55 - Crank Template Parameters (continued)

Parameter Description

Peak Inertia The calculated maximum reflected inertia at the crankshaft.

Results (label 4 in Figure 75

Peak Ext. + Grav. Torque

)

Apply Click to apply the load profile data and close the window.

Cancel Click to close the window without applying any data.

Chart Display (label 5 in Figure 75

(1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available. (2) Setting this length to zero configures the mechanism as a Scotch Yoke, where the linear load follows a simple harmonic motion. (3) If the Force at Start is different from the Force at End, the force varies between these two limits according to gudgeon pin position or crank angle. If the values are equal, a constant force is applied.

The Chart Display displays the crank velocity, the inertia that is reflected to the crankshaft, and the crank torque due to external influences such as gravity

)

and applied force. These are the parameters which will be applied.

The Peak External Force + Gravity Torque is the calculated peak torque, generated from the external linear force and gravity.

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2.1.4. Application Template Loads

The application templates let you enter pre-configured mechanism application data.

Figure 77 - Application Template Load Type

Table 56 - Application Template Options

Template Type Description Page

Press Roll Feed (constant time/constant angle)

Carriage Cut Off

Cutter Knife Drive

Advanced Templates

Power/Speed Templates

This application is typically cutting strip material into pre-set lengths with a ‘Press Shear’ (heavy-duty knife). The material must be stationary when the cut is made and the cut takes place over a fixed amount of time or a fixed angle of the driving crank whose speed is varied to match the cut rate.

This application is typically cutting strip material into pre-set lengths with a ‘Flying Shear’ (heavy-duty knife on a moving carriage). The shear must be stationary relative to the material (for example, moving at li ne speed) when the cut is made and the cut takes a fixed time.

This application is typically cutting strip material into pre-set lengths with a ‘Rotary Knife’ (heavy-duty knife blades mounted on a pair of rotating drums). The blades must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes place over a fixed drum angle.

These templates let you enter data for complex mechanisms. Advanced Templates include the Inertia Calculator, Crank, Winder/Unwinder, and Four Bar Linkage.

These templates let you enter torque and speed values that are used to calculate the power requirement for the application.

100

102

104

118

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2.1.4.1. Press Roll Feed (constant time/constant angle)

This application is typically cutting strip material such as steel into pre-set lengths by means of a press shear (heavy-duty knife). The material must be stationary when the cut is made and the cut takes place over a fixed amount of time or a fixed angle of the driving crank whose speed is varied to match the cut rate.

Strip material is unwound from a reel at constant surface speed and fed via separately driven leveler rolls into one end of a looping pit (a free-hanging loop of material providing storage). On the other side of the loop, a pair of feeder rolls grips the material and moves it forward the required cut length and then stops. After the cut is complete, the material is moved again. The average velocity of the nip/feeder rolls must be equal to the constant velocity of the unwinder and leveler rolls.

Figure 78 - Press Roll Feed - Constant Time

Figure 79 - Press Roll Feed - Constant Angle

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Parameter Description

Moving Material Mass The mass of the material in the loop and on the flat before the Nip/Feed rolls.

Bias Force The force required to overcome the force of gravity on the loop.

Drive Roll Diameter The diameter of the roll in direct contact with the strip, driven from the motor. Load (label 1 in Figure 78

Total Roll Inertia

Figure 7 9)

Cut (Waiting) Time

Cut (Waiting) Angle

Max Average Line Speed

Critical Preferences

(1)

(label 2 in Figure 78 or

Figure 7 9)

Cuts/ min

System Properties (label 3 in Figure 78

Figure 7 9)

Settling Time

Cosine Compensat ion

Linear Select this option for standard linear acceleration and deceleration ramps.

Motion Type Properties (label 4 in Figure 78

S-Curve

Figure 7 9)

Triangular Move

Table 57 - Press Roll Feed Parameters

(3)

(2)

The total inertia of the strip material at the drive shaft.

The time during which the material must be stationar y in an accurate position. This value is only required for Press Roll Feed Constant Time applications (refer to the red boxes in images above).

The crank angle during which the material must be stationary in an accurate position. This value is only required for Press Roll Feed - Constant Angle applications (refer to the red boxes in images above).

Select this option for data entry when the maximum design speed of the constant-speed sections of the line is known. This speed does not refer to the peak velocity of the feeder section, which is determined by Motion Analyzer software.

Min. Cut length at Max line speed

When you select the option to enter data based on Max Average Line Speed, this data is required. This is the critical condition on which the sizing process is performed. To cut shorter lengths than this critical length, the line speed must be reduced.

Select this option for data entry when the number of cuts made by the system per minute is known.

Max. Cut length at Cuts/ min

When you select the option to enter data based on Cuts/min, this data is required. This is the critical condition on which the sizing process is performed. To cut longer lengths than this critical length, the line speed must be reduced.

This is the time required for the system to achieve the required position accuracy before the cut commences. The finer the required accuracy, the longer the settling time value. This time is typically 20 to 75 ms for an A servo system.

This option is only required for Press Cutter Knife Drive applications. The Cosine Compensation is used to make sure that while the press cutter knife is in contact with the material being cut, the horizontal component of the knife’s velocity matches the material speed.

Select this option for ‘S’ shaped acceleration and deceleration ramps that are used to produce smoother motion. You need to enter the percent jerk value for this option.

Select this option for a triangular load profile. This option is only required for Press Roll Feed - Constant Angle applications (see red box in Figure 79

(1) At very long cut lengths, the limiting factor, determined by the design speed of the leveler rolls and unwinder, is the maximum line speed. As cut length is reduced, the servo has to index more and more

rapidly until the peak or RMS (root mean squared) torqu e limit is rea ched. To cut shorter lengths than this critical length, the line speed must be reduced. Sizing is based on this critical length, maximum

line speed and cut time, which are typically specified. (2) Use the Inertia Calculator Template (3) You can enter this data manually or use the Loop Calculator

on page 105 to calculate the inertia value for your application, if the value is not readily available.

on page 99, to determine the value.

98 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Sizing Your System Chapter 2

Click in Figure 78 or Figure 79 to determine the Moving Mass and Bias Force parameters by using the Loop Calculator.

Figure 80 - Loop Calculator

Table 58 - Loop Calculator Parameters

Parameter Description

Density

Material (label 1 in Figure 80)

Loop (label 2 in Figure 80

Computed Parameters (label 3 in Figure 80

Thickness Strip material thickness.

Width Strip material width.

Flat Length Strip material flat length as defined in the Press Roll Feed Diagram.

Loop Length Strip material loop length as defined in the Press Roll Feed Diagram.

)

Loop Depth Strip material max loop depth as defined in the Press Roll Feed Diagram.

Moving Mass When you click Compute, the Loop Calculator displays the Moving Mass

)

Bias Force

Choose strip material from the pull-down menu or enter the density value manually.

and Bias Force values based on the values you entered for the parameters above. These values are entered in the Application Template when you click OK.

Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012 99

Chapter 2 Sizing Your System

2.1.4.2. Carriage Cut Off

This application is typically cutting strip material such as steel into pre-set lengths by means of a Flying Shear (heavy-duty knife mounted on a moving carriage). The shear must be stationary relative to the material (for example, moving at line speed) when the cut is made and the cut takes a fixed time.

Strip material is unwound from a reel at constant surface speed and fed via separately driven leveler rolls. After the cut is complete, the shear is stopped then moved back to its start position. It must accelerate to match the line speed at the correct position to cut the required length of material.

Figure 81 - Carriage Cut Off Template

100 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Rockwell Automation Motion Analyzer User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Summary of Changes

New and Updated Information

Preface

About This Publication

Who Should Use This Manual

Conventions Used in This Manual

System Requirements

Additional Resources

1.1. Before You Begin Sizing

1.1.1. Database Updater Program

1.1.2. Welcome to Motion Analyzer

1.2. Menu Bar and Quick Access Toolbar

1.2.1. File Tab

1.2.2. Home Tab

1.2.2.1. Graphical View

1.2.2.1.1. Power Rail View

1.2.2.1.2. Power Interface Module View

1.2.2.2. Group View

1.2.2.2.1. Power Rail Image

1.2.2.2.2. Axis Summary Image

1.2.2.3. Multiple Profile View

1.2.2.3.1. Top Band

1.2.2.3.2. Graph View

1.2.2.4. Power Supply/Accessories View

1.2.2.4.1. Power Supply/Accessories - Multi-axis Drive Systems

1.2.2.4.1.1. Power Data Tab

1.2.2.4.1.2. IAM and Shunt Tab

1.2.2.4.1.3. IAM Control Power Tab

1.2.2.4.1.4. Analysis Tab

1.2.2.4.1.5. Energy Tab

1.2.2.4.1.6. Configure Power Supply BOM Tab

1.2.2.4.1.7. System Bill of Materials (BOM) View

1.2.2.4.2. Power Supply/Accessories - Integrated Drive-Motor (IDM) Systems

1.2.2.4.2.1. Power Data Tab

1.2.2.4.2.2. IPIM Module Selection Tab

1.2.2.4.2.3. Cable Length Tab

1.2.2.4.2.4. Control Power Tab

1.2.2.4.2.5. Configure IPIM Module BOM Tab

1.2.2.4.3. Power Supply/Accessories - Single-axis Drive Systems

1.2.2.4.3.1. Power Data Tab

1.2.2.4.3.2. Shunt Tab

1.2.2.4.3.3. Analysis Tab

1.2.2.4.3.4. Energy Tab

1.2.2.4.3.5. Configure Power Supply BOM Tab

1.2.2.4.4. Power Supply/Accessories – AC/DC Power Sharing Systems (Kinetix 5500 drives)

1.2.2.4.4.1. DC Sharing

1.2.2.4.4.2. AC Sharing Only

1.2.3. Preferences Tab

1.2.4. Export – Import Tab

1.2.4.1. Export to RSLogix 5000 Wizard

1.2.4.1.1. Export Options - Create a New .L5X File

1.2.4.1.1.1. Axis Mapping

1.2.4.1.1.2. Save and Import the L5X File

1.2.4.1.2. Export Options - Update an Existing L5X File

1.2.5. Bill of Materials (BOM) Tab

1.2.6. Help Tab

1.3. Explorer View

2.1. Identify Your Load

2.1.1. Linear Loads

2.1.1.1. Advanced Considerations - Counterbalances

2.1.1.1.1. Mass Counterbalance

2.1.1.1.2. Force Counterbalance

2.1.2. Rotary Loads

2.1.3. Rotary Complex Loads

2.1.3.1. User Defined

2.1.3.2. Templates

2.1.3.2.1. Unbalanced Load Template

2.1.3.2.2. Crank Template

2.1.4. Application Template Loads

2.1.4.1. Press Roll Feed (constant time/constant angle)

2.1.4.2. Carriage Cut Off