Yaskawa MP940-MW+ User Manual

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Subject: MotionWorks+ Simple Template Program

Product: MP-940, MotionWorks+ v2.83 or later

Engineer: Michael J. Miller

Who should read this document?

Anyone is who is attempting to program an MP-940 Machine Controller, using MotionWorks+
programming environment. This document illustrates a standardized template program to be used
while programming the MP-940 with MotionWorks+. The template includes three main programs:

1) Supervisor

2) Manual

3) Automatic

In addition, eight subroutines are called from two of the main programs. The subroutines include:

1) Jog Forward

2) Jog Reverse

3) Homing

4) Indexing with Programmable Limit Switch (PLS)

5) Gearing

6) Camming

7) Torque

8) Latch with PLS

The program described in this document is meant to be used a starting point for virtually all MP-940
with MotionWorks+ applications. Make use of the subroutines that are appropriate for the application
and discard the subroutines that are not.

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Table of Contents

Summary............................................................................................................................4

Programs ............................................................................................................................4

Program Definition ........................................................................................................4

Program Guidelines .......................................................................................................5

1: Supervisor ..................................................................................................................6

Start-up.......................................................................................................................7

Fault Detection...........................................................................................................8

Disable Handler .........................................................................................................8

Fault Recovery...........................................................................................................9

2: Manual .....................................................................................................................10

3: Automatic.................................................................................................................11

Subroutines ......................................................................................................................12

02 Jog +........................................................................................................................12

03 Jog –........................................................................................................................12

04 Home.......................................................................................................................13

05 Move .......................................................................................................................13

Programmable Limit Switch (PLS) .........................................................................14

Timer........................................................................................................................14

06 Gear.........................................................................................................................15

Engaging/Disengaging.............................................................................................15

Running....................................................................................................................16

07 Cam.........................................................................................................................16

Engaging ..................................................................................................................16

Disengaging .............................................................................................................16

08 Torque.....................................................................................................................17

09 Latch .......................................................................................................................17

Latch Target Block ..................................................................................................18

Configuration ...................................................................................................................18

System Parameters.......................................................................................................19

System Properties ........................................................................................................20

SGDH.......................................................................................................................21

MP940......................................................................................................................22

COM1 ......................................................................................................................23

COM2 ......................................................................................................................24

Network....................................................................................................................25

External Encoder......................................................................................................26

Data..................................................................................................................................26

Constants......................................................................................................................27

Network........................................................................................................................28

Tables...........................................................................................................................29

Variables ......................................................................................................................30

I / O ..............................................................................................................................31

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Local Input functionality .........................................................................................32

Local Output functionality.......................................................................................33

System Variables .........................................................................................................34

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Summary

This document outlines the details of a template example program for an MP-940/SGDH
system. In particular, it was designed with the Yaskawa demonstration (YEA Part # DEMO4700)
unit in mind; however, it can be modified to suit virtually any application, and is commonly used
as a starting point when programming the MP940 using MotionWorks Plus.

There are three main programs: Supervisor, Manual, & Automatic. The Supervisor
program is the only of the three that is auto-starting. Once it starts and some conditions are
satisfied, it starts both Manual & Automatic program. In addition, there are seven subroutines: 02
Jog+, 03 Jog-, 04 Home, 05 Move, 06 Gear, 07 Cam, 08 Torque, and 09 Latch.

While the Manual & Automatic programs may be running, various conditions must be met
for them to start a sub-routine. All of these programs, as well as the configuration for the system
will be discussed. This will be completed in the order that a program in MotionWorks+ is laid out,
according to the Project Explorer window.

Programs

The Programs folder contains the following:
Supervisor, Manual, and Automatic programs.

Program Definition

Using MotionWorks+ up to eight main programs or tasks are possible. A program can
run in either the High or Low speed Scan. The action or blocks in the program will update at the
selected scan rate.

Auto start is also a possibility for each program. This template program has one program
that is auto starting (Supervisor). Once that program has started and various conditions have
been satisfied, it will start the other programs. If the supervisor detects a fault, error, or other
event it will stop the other programs. This programming methodology creates a solid
infrastructure to build from so that each individual program does not have to monitor for errors,
there is one program the does that and coordinates appropriately.

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Lastly, a task can be Active or not. A deactivated program may be some code for feature
that is not available in a particular machine. Keep in mind; deactivated programs still count
towards the maximum of eight total tasks.

Program Guidelines

As a guideline it is recommended that each “program” contain a maximum of 64 total
blocks including all subroutine blocks called from within the program (not including start and stop
blocks). [Version 2.83 of MotionWorks+ includes an update to the compiler that lifts this
restriction, but it is still a good programming practice] In this example, the Supervisor program
utilizes 34 blocks; the Manual program utilizes 35 blocks; the Automatic program utilizes 44
blocks. In addition, it is also recommended that execution of motion effecting blocks, only be
active in one program at a time. For this reason, the Manual and Automatic routines are
interlocked such that they can only operate exclusively.

Blocks that affect motion include the following:

Move Axis
Jog
Stop
Home
CAM
Change Dynamics
Define Position
Gear
Latch Target
Scale CAM
Servo Enable
Torque
Slave Offset

The Supervisor routine utilizes the Servo ON, Stop, and Change Dynamics block, but is closely
monitoring the other programs to ensure that there is no overlapping. Some precautions must
still be followed with the use of Motion Effecting blocks.

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1: Supervisor

The Supervisor is quite daunting at first glance, however, once broken down it is not that
difficult to follow. It can be separated into four distinct sections: Start-up, Fault Detection, Disable
Handler, and Fault Recovery.

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Start-up

The start-up section encompasses
block 3-6, 10, and 31. It is responsible for
startup. Block 31 is executed only once
(upon power up) and can be useful for
setting user variables, or outputs that need
to be reinitialized at power up, but may be
variables themselves. Block 3 has the
condition “False” in and provides a point to
loop back the end of the flow chart, and
ensures that all blocks have connections.
The balance of the blocks regulates a
normal start up.

Block 4 must see the rising edge of
Local_Input1, this assures that input was
activated to enable system, rather than just
left on all of time. Block 5 enables the servo.
Local_Output1 and (user variable)
[SystemOk] is set in Block 6. The [System
Ok] variable is used by the two other main
programs a signal that it is Ok to execute.
The last block (10) starts the other main programs (Manual and Automatic). Lastly
Local_Output4 is set if the system had been previously homed. Only a power cycle will clear the
[Homed] bit indication.

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Fault Detection

After the start-up section has been completed successfully, the next section, and the
section that the program will be in most is the Fault Detection / Disable loop. All of the If Event
(including a special If Fault) blocks are designed to detect various faults and errors in the system.
When an error is detected, the next block that is executed is a Set Variable block that sets an
internal flag to trap the type of error that occurred and may also capture some pertinent data.
Lastly, Set Variable block (27) is executed, which sets an internal fault flag and clears the
SystemOk flag, then execution continues to disable handler. If the user simply turns off of the
enable input (Local_Input1), execution continues to disable handler. One thing to keep in mind is
that block 21 does not detect ServoPack warning conditions. ServoPack warning conditions
include any A.9x (where x = 0 – F) alarm code display on SGDH display. The programmer may
want to include additional code to detect these conditions and notify the operator. For example
A.91 is a torque overload warning, indicating that continued operation of the machine at this rate
will result in an A.71 or A.72 torque overload alarm.

Disable Handler

When a fault or a normal disable is detected, this section of code executed. The first
block (29) stores the commanded and actual position (these may be useful in a recovery routine).
Next, the other main programs are halted; the servo is commanded to go to zero speed (25), then
stop (26), and lastly the Servo Off block (8) is executed.

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If a fault has occurred block (28) will direct execution to the fault recovery section,
otherwise block (9) is executed. Block (9) clears all of the outputs that may have inadvertently
left on. The Disable handler and the fault recovery routine both make use of Block (20). It is
simply a timer that ensures everything has settled down before attempting a restart. After block
(20) execution continues back to block (3).

Fault Recovery

Once it has been
determined that a fault
occurred and the appropriate
blocks have executed, the
program ends up in the fault
recovery section. Block (16)
sets an output to indicate that
a fault has occurred (in the
case of the demo box, it
actually sets all eight outputs).
Input block (17) waits to see
the rising edge transition of
SGDH input SI-4
(coincidently, the Servo Alarm
Reset input when the
ServoPack is used alone).
Reset fault block (18) is a
special block that will reset
any ServoPack alarm that does not require a power cycle to reset. Lastly, Set Variable blocks 19
and 38 clear the alarm output and take care of clearing all of the internal error bits. Block (20)
was discussed above in the Disable Handler section. Conveniently, the blocks in the fault
detection section latch the fault type so the operator can tell what type of fault occurred prior to
resetting it. For example if the user variable ‘ErrorCPU’ = 1, then user will know that a MP-940
CPU error occurred. The error code is trapped in another user variable, ‘ErrorCPUCodeTrap.’
Be sure to check these prior to activating the alarm reset, as the bit indications are cleared during
an alarm reset sequence.

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2: Manual

Functions typically performed while in a “manual” mode are included in the manual main
program. While this program is executing it is waiting for the user to activate an input to select a
subroutine program. As long as no input is selected the program scans the blocks in order of 3,
4, 5, 6, 9, and 11 then back to 3.

Two key features in this program are important to mention. First, if event block (3)
detects if (user variable) [SystemOk] is true. As long as this condition is true the program will
stay running (recall SystemOk is controlled by the supervisor program). Second, input block (4)
ensures that (Manual Mode) [!Local_Input2] has been selected. This is a critical interlock that
guarantees that more than one main program is not attempting motion at the same time. This
can be especially unsettling if one program is running the servo in camming mode and another
program is attempting to jog.

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3: Automatic

]

Functions typically performed while in an “automatic” mode are included in the automatic
main program. While this program is executing it is waiting for the user to activate an input to
select a subroutine program. As long as no input is selected, and not in manual mode, the
program scans the blocks in order of 3, 4, 5, 8, 11, 14 then back to 3.

Two key features in this program are important to mention. First, if event block (3)
detects if (user variable) [SystemOk] is true. As long as this condition is true the program will
stay running (recall SystemOk is controlled by the supervisor program). Second, if event block
(4) ensure that (Auto Mode) [Local_Input2] has been selected (in other words if the machine is
not in manual mode, it is in automatic mode) & (homing sequence has been completed) [Homed]
= true. This is a critical interlock that guarantees that more than one main program is not
attempting motion at the same time. This can be especially unsettling if one program is running
the servo in camming mode and another program is attempting to jog.

If a user puts the machine in automatic mode, attempts to execute an automatic
subroutine, nothing will happen, as execution is held at block 4.

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