Technical Manual
Linear Flying Shear Application Solution Package
for MPiec Controllers
Doc#: TM.MPIEC.02 Copyright Yaskawa America Incorporated 2014 January 20, 2014
Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
Contents
Application Overview: ................................................................................................................ 3
Application Highlights: ............................................................................................................... 3
Implementation: ......................................................................................................................... 4
1. Configuring the Master and Slave Axes ........................................................................... 4
2. Adding User Libraries ....................................................................................................... 4
3. Generating Cam Profiles .................................................................................................. 5
3 a) Generating Cam Profiles using LinearShearCamGen ............................................. 5
3 b) Generating custom cam profiles .............................................................................. 8
4. Setting the CamMasterCycle ............................................................................................ 9
5. Linear Flying Shear Motion ............................................................................................ 11
5 a) Constant cut length without registration ................................................................. 13
5 b) Applications requiring product registration ............................................................. 14
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
Application Overview:
The Linear Flying Shear Application Solution Package (ASP) offers an easy way to implement linear flying shear
applications. This ASP applies to other applications such as bottle filling because the motion required is identical.
This solution package was designed for machines that process products spaced at fixed intervals and machines
that must make dynamic corrections based on product registration marks. The Linear Flying Shear ASP project
can be used as a template on which the user can complete the application, or the ASP can be added as a user
library into an existing project. The Linear Flying Shear ASP focuses only on the core motion features required
to operate a flying shear and does not include other functionality such as servo enable, homing, manual modes,
alarm handling, etc. The user is responsible for incorporating other basic logic functionality required for the
complete application.
The main steps involved in completing a linear flying shear application are:
1) Configure the axes in Hardware Configuration.
2) Import all required user libraries.
3) Create cam profiles. (Two choices)
a) Use the ‘LinearShearCamGen’ function block in the ASP (for the speed matching axis). Create a
custom cam profile for a secondary axis if present.
OR
b) Create custom cam profiles for the speed matching axis and secondary axis.
4) Home the speed matching axis and secondary axis. Set the CamMasterCycle for all slave axes.
5) Use the ‘LinearFlyingShear’ function block with or without the Registration input.
Application Highlights:
1. Designed for Linear Flying Shear applications with or without product registration.
2. Designed to accommodate a secondary slave axis in addition to the speed matching axis.
3. Uses smooth cam motion to reduce jerk.
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
Implementation:
1. Configuring the Master and Slave Axes
Configure the master and slave axes in the Hardware Configuration. Configure the master and slave
‘load type’ as linear.
2. Adding User Libraries
If the Linear Flying Shear ASP is being used as a template, no additional user libraries need to be added.
If the Linear Flying Shear ASP is applied as a user library:
1. Delete all Yaskawa Data Type files from the main project.
2. Add the Y_Motion firmware library to the main project.
Add the following toolboxes to the main project in the order in which they appear. The minimum versions
are given in Figure 1 below:
1. DataTypes_Toolbox_v200
2. Math_Toolbox_v202
3. Yaskawa_Toolbox_v204
4. PLCopen_Toolbox_v206
5. Cam_Toolbox_v205
6. Add the Linear Flying Shear ASP project as a User library in the main project.
Figure 1: User libraries added to Linear Flying Shear project
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
3. Generating Cam Profiles
The user has two options for creating cam tables:
1) Use the LinearShearCamGen function block for the speed matching axis. The function block creates
cam profiles with Tangent Matching segments. If a secondary slave axis exists, create a custom
profile using Y_CamFileSelect, CamGenerator, and Y_CamStructSelect.
2) Create custom cam profiles for the speed matching axis and the secondary axis using
Y_CamFileSelect, CamGenerator, and Y_CamStructSelect. Custom profiles may be necessary for
applications with unique mechanisms where the user desires to create unique cam profiles for the
application.
3 a) Generating Cam Profiles using LinearShearCamGen
Add LinearShearCamGen to a POU running in a slow / low priority task (1000 ms task update).
Figure 2: LinearShearCamGen function block
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Parameter
Data type
Description
Default
Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
VAR_INPUT
U* Execute BOOL Upon the rising edge, all other function block inputs
are read and the function is initiated. To modify
an input, change the value and re-trigger the
Execute input.
U PartLength LREAL Length of the part to be processed. If randomly
spaced parts are to be processed, enter a nominal
distance between registration marks.
U MasterSyncPosition LREAL The position of the master in the cam table where
both axes must be moving at the same speed.
U SlaveSyncPosition LREAL The position of the slave axis in the cam table
where both axes must be moving at the same
speed.
U SyncDistance LREAL The distance travelled by the slave axis while in
sync with the master. Note that the total travel
distance will be greater due to the acceleration
and deceleration phase.
U MaxStroke LREAL The maximum allowable stroke length for the
linear slave axis. If the calculated stroke required
is greater than MaxStroke, an Error will be
generated.
VAR_OUTPUT
F* Done BOOL Set high when the commanded action has been
completed successfully. If another block takes
control before the action is completed, the Done
output will not be set. This output is reset when
execute goes low.
F Busy BOOL Set high upon the rising edge of the 'Execute' input,
and reset if Done, or Error is true.
F Error BOOL Set high if error has occurred during the execution
of the function block. This output is cleared when
'Execute' goes low
F ErrorID UINT If error is true, this output provides the Error ID.
This output is reset when 'Execute' goes low
F CamTableID UINT CamTable ID for the speed matching slave axis
* U: Input to be provided by user
FALSE
LREAL#0.0
LREAL#0.0
LREAL#0.0
LREAL#0.0
LREAL#0.0
* F: Parameter generated by the function block
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
A cam profile that illustrates various inputs for the LinearShearCamGen function block is shown in figure 3.
Figure 3: Sample cam profile for a linear shear application
If the application uses a secondary axis for punching/slitting/cutting while the linear axis is synchronized
with the master, and a cam is required for the secondary operation, use the following function blocks to
create a cam profile yourself.
1) Y_CamFileSelect (If the cam will be loaded in the controller memory as a .csv file)
2) CamGenerator (If the cam profile will be created in the IEC application program.)
3) Y_CamStructSelect (If the cam profile was created in the IEC application program.)
ErrorID Meaning
10190 PartLength must be greater than zero.
10191 The SyncDistance input must be greater than zero.
10192 The MasterSyncPosition must be greater than zero.
10193 The PartLength must be greater than the SyncDistance.
10194 The calculated stroke length is greater than the allowable ‘MaxStroke’. Increase MaxStroke or reduce the
All other ErrorIDs are listed under help for CamGenerator (Cam_Toolbox), CamTableManager (Cam_Toolbox),
SyncDistance.
Y_CamStructSelect (PLCopenPlus_v_2_2a).
(Refer to the Toolbox manual at: www.yaskawa.com/iectb)
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: Linear Flying Shear Application Solution Package for MPiec Controllers
If the application requires custom profiles and the LinearShearCamGen function block is not used
because of mechanism constraints, use the following function blocks:
If the application uses a secondary
with the master, and a cam profile
function blocks mentioned above.
secondary axis (if servo is being used as a cam slave)
function block discussed in section
A sample profile for the secondary axis is shown in figure 4b.
: Sample cam profile for
: Sample cam profile for
#: TM.MPIEC.02
axis for punching/slitting/cutting while the primary axis is
for the secondary servo as well,
Cam table IDs for the primary speed matching axis and the
be obtained for using the LinearFlyingShea
shear axis is shown in
linear flying shear applications
secondary axis in linear flying shear applications
Subject: Technical Manual
Title
3 b) Generating custom cam profiles
1) Y_CamFileSelect
2) CamGenerator
3) Y_CamStructSelect
synchronized
figure 4a.
Product: MPiec Controllers Doc
slave
is required
must
5. A sample profile for the speed matching
use the
r
Figure 4a
the speed matching axis in
Figure 4b
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
4. Setting the CamMasterCycle
Linear flying shear applications that require product registration must make adjustments to the cam cycle
to synchronize with the first part before motion starts. To initialize the CamMasterCycle, execute the
SetCamMasterCycle function block after the desired running CamTableIDs have been generated and the
servos are enabled. If the machine includes a secondary slave axis, set the cam master cycle for that
axis using another instance of the SetCamMasterCycle function block.
Figure 5: Setting the CamMasterCycle
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Parameter
Data type
Description
Default
Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
VAR_IN_OUT
B Master AXIS_REF Logical axis reference. This value can be located on the Configuration
tab in the Hardware Configuration (logical axis number)
B Slave AXIS_REF Logical axis reference. This value can be located on the Configuration
tab in the Hardware Configuration (logical axis number)
VAR_INPUT
B Execute BOOL Upon the rising edge, all other function block inputs are read and the
function is initiated. To modify an input, change the value and
re-trigger the Execute input
B CamTableID UINT A reference to the cam memory in the motion engine UINT#0
VAR_OUTPUT
B Done BOOL Set high when the commanded action has been completed
successfully. If another block takes control before the action is
completed, the Done output will not be set. This output is reset when
Execute goes low.
B Busy BOOL Set high upon the rising edge of the 'Execute' input, and reset if Done,
or Error is true.
B Error BOOL Set high if error has occurred during the execution of the function
block. This output is cleared when 'Execute' goes low
E ErrorID UINT If Error is true, this output provides the Error ID. This output is reset
when 'Execute' goes low
FALSE
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
5. Linear Flying Shear Motion
Two types of linear shear applications are supported:
a) Constant product size without registration.
b) Variable product size with registration.
Figure 6: LinearFlyingShear function block
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Parameter
Data type
Description
Default
added to the product buffer.
Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
VAR_IN_OUT
U* Master AXIS_REF Logical axis reference. This value can be located on the
Configuration tab in the Hardware Configuration (logical axis
number)
U Slave1 AXIS_REF Logical axis reference. This value can be located on the
Configuration tab in the Hardware Configuration (logical axis
number). Refers to the speed matching linear axis in the
linear shear system.
U Slave2 AXIS_REF Logical axis reference. This value can be located on the
Configuration tab in the Hardware Configuration (logical axis
number). Refers to the secondary axis in the linear shear
system. If a secondary servo is not used, use UINT#0 for this
AXIS_REF.
U RegistrationData ProductBufferStruct Structure containing all information for the circular buffer to
operate. The user inputs in this structure will be used in
managing the product buffer that keeps track of registration
marks.
U ControlData CamSyncStruct Structure containing all information that enables the
LinearFlyingShear function to correct the slave axis motion for
varying product sizes and to determine when the slave axis
should disengage from the master if no products are being
registered
VAR_INPUT
U Enable BOOL The function will continue to execute while Enable is held
high.
U ClearBuffer BOOL While high, new products are not
The products that are already in the buffer will get processed
by the function block.
U Slave1CamTableID UINT Cam Table ID corresponding to the speed matching linear
axis.
U Slave2CamTableID UINT If being used in the system, Cam Table ID corresponding to
the secondary servo.
U Registration BOOL Selects if registration based corrections are required. If
TRUE, adjustments will be performed to synchronize with the
registration marks on the master axis.
VAR_OUTPUT
F* InSync BOOL Indicates that the outputs of the function block are valid and
the salves are following the master. It does not indicate if the
slave are matching speed with the master.
F Busy BOOL Set high upon the rising edge of the 'Execute' or 'Enable'
input, and reset if Done, CommandAborted, or Error is true.
F CommandAborted BOOL Set high if motion is aborted by another motion command or
MC_Stop. This output is cleared with the same behavior as
the Done output.
F Error BOOL Set high if error has occurred during the execution of the
function block. This output is cleared when 'Execute' goes
low.
F ErrorID UINT If error is true, this output provides the Error ID. This output
is reset when 'Execute' goes low.
F BufferLevel INT Number of products detected by the sensor which have not
been processed by the machine.
F ItemsProcessed UDINT Provides a count of the number of products processed since
this function was enabled.
* U: Input to be provided by user. * F: Parameter generated by the function block
FALSE
FALSE
UINT#0
UINT#0
FALSE
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
ErrorID Meaning
All ErrorIDs are listed under help for CamShiftControl (Cam_Toolbox), CamControl (Cam_Toolbox), Y_CamIn
5 a) Constant cut length without registration
Use the LinearFlyingShear function block with the ‘Registration’ input set to FALSE. If only one slave is
used, connect UINT#0 to Slave2 and Slave2CamTableID. Connect variables for RegistrationData and
ControlData. These variables must be declared but need not have valid data. (These structures are not
used for applications that do not use registration).
(PLCopenPlus_v_2_2a), Y_CamOut (PLCopenPlus_v_2_2a), ProductBuffer (PLCopen_Toolbox)
(Refer to the Toolbox manual at: www.yaskawa.com/iectb)
Figure 7: Linear Flying Shear function block
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
5 b) Applications requiring product registration
Use the LinearFlyingShear function block with the ‘Registration’ input set to TRUE.
1. Define a variable for RegistrationData (datatype: ProductBufferStruct) and initialize the following elements of
the structure:
• BufferSize
• LockoutDistance
• SensorDistance
• ProductAwayDistance
• Sensor.Bit
Figure 8: LinearFlyingShear with registration
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
Figure 9: Definition of RegistrationData input
A graphical representation of the various elements of the RegistrationData input are shown in figure 10 below.
Figure 10: RegistrationData elements
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
2. Define a variable for ControlData. Populate the structure elements with:
• Mode
• DecisionPosition
• EndSyncPosition
• StartSyncPosition
Figure 11: ControlData input structure
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Subject: Technical Manual Product: MPiec Controllers Doc#: TM.MPIEC.02
Title: Linear Flying Shear Application Solution Package for MPiec Controllers
Figure 12 illustrates the various elements that form the ControlData structure.
Figure 12: ControlData elements
3. Ensure that all slave axes are homed. The LinearFlyingShear function block assumes that the slave axes are
at their home positions when the function block is enabled. If the slave axes are not at their home positions,
the slave axes may run into mechanical limits depending on the stroke length of the designed cam.
4. Enable the LinearFlyingShear block.
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