ADV200 - Flying Shear for Roll Forming machines Application

ADV200 - Flying Shear for Roll Forming machines Application English

Instruction manual

Rev

. 1.3

– 1

6-6-

2020

1S

3E64

EN

Flying Shear for Roll Forming machines – Instruction manual Pag. 2 / 28

------------------------------------------------------------------------------------------------------------------------------ Thank you for choosing this Gefran product. We will be glad to receive any possible information which could help us improve this manual. The e-mail address is the following: [email protected]. Before using the product, read the safety instruction section carefully. Keep the manual in a safe place and available to engineering and installation personnel during the product functioning period. Gefran Drives and Motion S.r.l. has the right to modify products, data and dimensions without notice. The data can only be used for the product description and they can not be understood as legally stated properties. All rights reserved.

Revision index Date Author Changes

0.0 4-2-2019 BNM-BRI New edition

0.1 8-5-2019 BNM Application V 1.x.1: add PARs 11612 and 11010, mod description PAR 11000, update Table 7: word mapping.

1.0 9-12-2019 BNM Application 2.X.0; ROLL FORMING FS menu in RFFLSH; Chapter 3: speed profile mod. and addition of machine state ; Chapter 4: Addition of operating logic for high and low blade sensors, new section 4.2 Plant Configuration, mod section 4.3 Function Configuration and commissioning, new section 4.4 Function configuration; Chapter 5, description of the menus mod: 26.02 App Service, 26.03 Enable, 26.04 Fast Stop, 26.05 Jog, 26.09 Auto (+ addition of par 11726 Min Cut Time and 11728 Auto Wait long cut), 26.12 Alarm (+ mod par 11902 Safe Sync Stop and addition of par 11914 Auto set alarm mask and 11916 Alarm stop mask), 26.13 Virtual (+ mod name par 11000 Virtual Line start and 11010 Virtual Line src. New menu 26.07 Limit switch. Chapter 6 mod table mapping word alarms.

1.1 15-1-2020 BNM-BRI Add par 11808; modified sequence and parameters numbering of menu 26.12 Alarm.

1.2 19-02-2020 BNM Application 3.x.0; Ch. 3 General description: speed profile sequence changed; Table 2: Command mapping word changed; Ch. 4.2: machine data table and cutting characteristics changed; new section 4.4.5 Stop metric wheel reading added; menu 26.07 Limit switch: important note added; menu 26.09 Auto: new PAR 11614 added; menu 26.10 Trolley: new PAR 11730 and 11732 added; menu 26.11 Line: new PAR 11810 added.

1.3 16-6-2020 BNM Unit measure = s, PARS: 11206 Fast Stop dec, 11306 Jog acc, 11308 Jog dec, 11414 Home acc, 11416 Home dec; Removed PAR 11606 Sync Kp; mod description PAR 11608 Imm cut spd, Unit measure = m/s on PAR 11612 Max Line Spd.


CONTENTS

1 Introduction ............................................................................................................................................... 4

1.1 Information about this manual ............................................................................................................. 4 1.2 Drive Firmware / Application version Cross compatibility ................................................................... 4 1.3 Symbols used in the manual ............................................................................................................... 4

2 Installing the application ......................................................................................................................... 5

2.1 Application key .................................................................................................................................... 6

3 General description .................................................................................................................................. 8

4 Sizing and commissioning .................................................................................................................... 10

4.1 ADV200 Wiring .................................................................................................................................. 10 4.2 System configuration ......................................................................................................................... 11 4.3 Commissioning .................................................................................................................................. 14

4.3.1 Check hardware limit switch ...................................................................................................... 14 4.3.2 Direction checking ...................................................................................................................... 14 4.3.3 Zero cycle positioning ................................................................................................................ 14 4.3.4 Carriage length development ..................................................................................................... 15 4.3.5 Metric Wheel Advancement ....................................................................................................... 15

4.4 Function configuration ....................................................................................................................... 15 4.4.1 Maximum line speed calculation ................................................................................................ 15 4.4.2 Cutting time ................................................................................................................................ 15 4.4.3 Support time ............................................................................................................................... 16 4.4.4 Saving the material length ......................................................................................................... 16 4.4.5 Stop metric wheel reading ......................................................................................................... 16

5 Description of functions and parameter list ........................................................................................ 17

26.01 Application .......................................................................................................................................... 17 26.02 App Service ........................................................................................................................................ 19 26.03 Enable ................................................................................................................................................ 19 26.04 Fast Stop ............................................................................................................................................ 19 26.05 Jog ..................................................................................................................................................... 20 26.06 Homing ............................................................................................................................................... 20 26.07 Limit switch ......................................................................................................................................... 21 26.08 Move .................................................................................................................................................. 22 26.09 Auto .................................................................................................................................................... 22 26.10 Trolley ................................................................................................................................................ 23 26.11 Line .................................................................................................................................................... 25 26.12 Alarm .................................................................................................................................................. 25 26.13 Virtual ................................................................................................................................................. 26 26.14 About .................................................................................................................................................. 27

6 Application alarms ................................................................................................................................. 28


1 Introduction

1.1 Information about this manual This document describes the Flying Shear for Roll Forming machines software, supplementing what is described in the ADV200 drive manual (for asynchronous and synchronous motors) and the optional boards for encoder acquisition and input expansion.

1.2 Drive Firmware / Application version Cross compatibility

Flying Shear for Roll Forming machines Application ADV200 Firmware

3.x.0 7.7.18 and higher

1.3 Symbols used in the manual

Indicates a procedure, condition, or statement that, if not strictly observed, could result in personal injury or death.

Indicates a procedure, condition, or statement that, if not strictly observed, could result in damage to or destruction of equipment.

The following operations require the machine in motion. Unforeseen machine movement is always possible. Take this into account and take the necessary precautions.

Indicates that the presence of electrostatic discharge could damage the appliance. When handling the boards, always wear a grounded bracelet.

Indicates a procedure, condition, or statement that should be strictly followed in order to optimize these applications.

Note !

Indicates an essential or important procedure, condition, or statement.


2 Installing the application The Flying Shear for Roll Forming machines application must be installed on the ADV200(/S) drive to be used. The operations to be performed are listed below. • Run the rfflsh_x_x_47_x_setup.exe application to set up the installation on a PC. • Open the GF_eXpress configurator (catalogue version > 2.42) • Connect the PC to the drive using the serial cable. • On the GF_eXpress, select the ADV200 inverter (for asynchronous motors) and ADV200S inverter (for

synchronous motors). • Once communication with the drive has been established, select the Download Firmware item on the

command bar. Then the window depicted below will appear. In that window, select the Flying Shear for Roll Forming machines application (A1 to load the application on memory sector 1, A2 to load the application on memory sector 2). During this operation, do not turn off the drive.

• Once the firmware has been loaded, the application has to be enabled on the drive: - Select the “expert” mode using the Access Mode parameter (PAR 554, - DRIVE CONFIG menu). - Select the application: Application 1 if the rfflsh_..._A1 application was loaded

Application 2 if the rfflsh_..._A2 application was loaded

o Save and reset the drive. At the start, the drive will show the message, “ADV200 rfflsh V…” on the display to confirm that the drive has been loaded.

• Perform a default load of the application parameters (App load def, PAR 11524) and then save.

Restart GF_eXpress. This will automatically recognize the application version and select the appropriate parameters. Then, configuration can begin.

.


2.1 Application key This application must be registered. Register by entering a code supplied by Gefran. Enter the code as follows: • Connect to the drive using the GF_eXpress configurator or read the parameter indicated in the next point

using the keypad.

• Write down the Serial Number indicated in Regulation S/N (PAR 12106, RFFLSH \ About menu).

• Contact Gefran support and provide the serial number you just read to obtain the application unlock

key.

• Enter the unlock code in the Application key parameter field (PAR 572, CONFIG DRIVE menu).


• Save and reset the drive. At the start, the drive will no longer show the “Key Expiring” message on the display, confirming that the drive has been unlocked.


3 General description The blade or cutting assembly is fixed onto a carriage that can move forwards and backwards, piloted by the application. The application measures the length of the material to be cut by a metric wheel binding onto the material. For each position of the material from zero up to the cutting length and according to other mechanical parameters, the application produces the carriage position and therefore the blade position. The speed profile is the relationship between the material speed and the carriage speed, see figure 1. The speed profile consists of: • At the line’s start up, the trolley moves to the end of the line, supporting the head of the material. • Once the end of the line has been reached, a standby period can be set, during which the material runs

under the trolley. • The first phase, when the trolley returns, is for positioning. The position is set based on the line speed,

the cutting time and any safety gaps. • The second phase is called acceleration forward. During this phase, the trolley reaches the speed of the

material. • The third phase is synchronization. The carriage proceeds synchronized with the material to reduce as

much as possible any positional error between the carriage and the material. • The fourth phase is the cut which, always moving in synch with the application gives the cut command. • The last phase is deceleration where the trolley slows down until it stops at the end of the line, resuming

the cam from the second point.

Note: 1) Each phase provides for a defined shift using an electric cam, with its position set according to the

different parameters. The space used for each phase is calculated according to the maximum speed allowed for the material.

2) The space used by the carriage and maximum speed vary depending on the set cutting length.

Figure 1: Speed profile


When the drive is enabled or if a zero search has been performed, a test is performed. Otherwise the drive will go into the “Not Ready” state, where it is only possible to execute a “Jog” movement or to perform a zero search. Once a zero search has been completed, the drive returns to the “Standstill” state. From this state, automatic cutting can be activated if there are no alarms, or a zero search or jog movements can be performed again. If there is an alarm, the drive will go into the “FastStop” state; it is possible to exit that state by disabling the drive.

Figure 2: State machine


4 Sizing and commissioning

4.1 ADV200 Wiring The following figure shows the typical wiring diagram for asynchronous and synchronous motors:

Figure 3: Typical connection diagram

The drive hardware enable input must be connected to digital input 7. The high and low blade inputs are used to indicate blade position. These are connected to sensors on the blade as shown in the figure:

Figure 4: High and low blade sensor operating logic

The default output that controls the cut is the output listed in the table:


DIGITAL OUTPUT FUNCTION NOTE

13 DO3 Cut cmd Pad 2

The metric wheel encoder selection is essential for the system to function properly. The choice depends on the geometry of the metric wheel and of the carriage. The encoder resolution used on the metric wheel must be greater than or equal to the encoder resolution of the carriage motor. In other words, the ratio between the advancement of the carriage and the carriage motor ppr encoders must be similar to the ratio between the advancement of the metric wheel and the metric wheel ppr encoders. The number of the required pprs on the metric wheel encoder can be calculated as follows:

𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑊𝑊ℎ𝑀𝑀𝑀𝑀𝑒𝑒 𝐸𝐸𝐸𝐸𝑀𝑀𝐸𝐸𝐸𝐸𝑀𝑀𝑀𝑀 𝑝𝑝𝑝𝑝𝑀𝑀 =𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑊𝑊ℎ𝑀𝑀𝑀𝑀𝑒𝑒 𝐴𝐴𝐸𝐸𝐴𝐴𝐴𝐴𝐸𝐸𝑀𝑀𝑀𝑀𝑚𝑚𝑀𝑀𝐸𝐸𝑀𝑀 [𝑚𝑚𝑚𝑚]

𝐶𝐶𝐴𝐴𝑀𝑀𝑀𝑀𝑀𝑀𝐴𝐴𝐶𝐶𝑀𝑀 𝐴𝐴𝐸𝐸𝐴𝐴𝐴𝐴𝐸𝐸𝑀𝑀𝑀𝑀𝑚𝑚𝑀𝑀𝐸𝐸𝑀𝑀 𝑝𝑝𝑀𝑀𝑀𝑀 𝑀𝑀𝐸𝐸𝑀𝑀𝐸𝐸𝑀𝑀 𝑅𝑅𝐸𝐸𝑀𝑀𝐴𝐴𝑀𝑀𝑀𝑀𝐸𝐸𝐸𝐸 [𝑚𝑚𝑚𝑚]∗ 𝑀𝑀𝐸𝐸𝑀𝑀𝐸𝐸𝑀𝑀 𝐸𝐸𝐸𝐸𝑀𝑀𝐸𝐸𝐸𝐸𝑀𝑀𝑀𝑀 𝑝𝑝𝑝𝑝𝑀𝑀

Suppose we have a cutting system with these specifications:

• The carriage advances 36 mm per motor revolution. • The encoder on the carriage motor has 1024 ppr. • The advancement of the metric wheel on the material is 314 mm.

In this case, an encoder with 8192 ppr is suitable.

4.2 System configuration Perform the Load default (PAR 11100) to allow correct configuration of the drive system parameters and the fieldbus exchange parameters. Following tables shows the configurations loaded.

PARAMETER SETTING PAR MENU PARAMETER 552 DRIVE CONFIG Regulation mode Flux vector CL 556 DRIVE CONFIG Control mode select Speed 752 RAMPS Ramp out zero src One 650 REFERENCES Dig speed ref 2 Dig spd ref1 1000 COMMANDS Commands remote sel Digital 1010 COMMANDS Commands safe start On 1018 COMMANDS Digital Enable src Pad 1 1020 COMMANDS Digital Start src Pad 1 1022 COMMANDS Fast Stop src Off 1314 DIGITAL OUTPUT Digital Output 3 src Pad 2 4452 WORD DECOMP Word decomp src Dig word decomp 4500 ALARM CONFIG Fault reset src Null

Table 1: Parameters loaded using Load Default


PARAMETER SETTING PAR COMMUNICATION

MENU PARAMETER

4010 FIELDBUS CONFIG Fieldbus M->S enable Enable

4020 FIELDBUS M->S Fieldbus M->S1 PAR 11800 Required cut size [m] 4022 FIELDBUS M->S Fieldbus M->S1 sys Par 32 4030 FIELDBUS M->S Fieldbus M->S2 PAR 4450 Dig word decomp 4032 FIELDBUS M->S Fieldbus M->S2 sys Count 16 4040 FIELDBUS M->S Fieldbus M->S3 PAR 11002 Virtual line speed [m/s] 4042 FIELDBUS M->S Fieldbus M->S3 sys Par 32 4050 FIELDBUS M->S Fieldbus M->S4 PAR 11702 Trolley motor mechanical K 4052 FIELDBUS M->S Fieldbus M->S4 sys Par 32 4060 FIELDBUS M->S Fieldbus M->S5 PAR 11804 Line mechanical K 4062 FIELDBUS M->S Fieldbus M->S5 sys Par 32 4070 FIELDBUS M->S Fieldbus M->S6 PAR 0 4072 FIELDBUS M->S Fieldbus M->S6 sys Fill 32 4080 FIELDBUS M->S Fieldbus M->S7 PAR 11012 Maximum return speed 4082 FIELDBUS M->S Fieldbus M->S7 sys Par 32 4090 FIELDBUS M->S Fieldbus M->S8 PAR 11716 Cut time [s] 4092 FIELDBUS M->S Fieldbus M->S8 sys Par 32

4180 FIELDBUS S->M Fieldbus S->M1 PAR 3708 Command status word

[See PAR 12054] 4182 FIELDBUS S->M Fieldbus S->M1 sys Par32 4190 FIELDBUS S->M Fieldbus S->M2 PAR 12052 Alarm status word 4192 FIELDBUS S->M Fieldbus S->M2 sys Par32 4200 FIELDBUS S->M Fieldbus S->M3 PAR 12046 Line speed monitor [s] 4202 FIELDBUS S->M Fieldbus S->M3 sys Par32 4210 FIELDBUS S->M Fieldbus S->M4 PAR 12056 Position error monitor [m] 4212 FIELDBUS S->M Fieldbus S->M4 sys par32 4220 FIELDBUS S->M Fieldbus S->M5 PAR 12038 Shear position [m] 4222 FIELDBUS S->M Fieldbus S->M5 sys Par32 4230 FIELDBUS S->M Fieldbus S->M6 PAR 12030 Cut time monitor [s] 4232 FIELDBUS S->M Fieldbus S->M6 sys Par32 4240 FIELDBUS S->M Fieldbus S->M67PAR 12044 Maximum line speed [m/s] 4242 FIELDBUS S->M Fieldbus S->M7 sys Par32 4250 FIELDBUS S->M Fieldbus S->M8 PAR 12040 Length of last bar cut [m] 4252 FIELDBUS S->M Fieldbus S->M8 sys Par32

Table 1a: Fieldbus configuration

Command mapping word The word sent by the PLC containing the commands is written in the Dig word decomp parameter (PAR 4450), the table shows the default configuration.

WORD DECOMP BIT NUMBER

WORD DECOMP [HEX] DESCRIPTION

0 0x0001 Enable 1 0x0002 Fast Stop 2 0x0004 Jog - 3 0x0008 Jog + 4 0x0010 Auto 5 0x0020 Homing 6 0x0040 Home sens 7 0x0080 Imm cut 8 0x0100 Blade close 9 0x0200 Blade open

10 0x0400 Virtual line Start / Stop 11 0x0800 Virtual line Enable 12 0x1000 Not used 13 0x2000 Virtual blade


WORD DECOMP BIT NUMBER

WORD DECOMP [HEX] DESCRIPTION

14 0x4000 Not used 15 0x8000 Not used

Table 2: Command mapping word

Command status word mapping (PAR 12054):

DIGITAL OUTPUT BIT NUMBER

DIGITAL OUTPUT [HEX] DESCRIPTION

0 0x0001 Enable 1 0x0002 Fast Stop 2 0x0004 Jog + 3 0x0008 Jog - 4 0x0010 Home sens 5 0x0020 Home OK 6 0x0040 Auto 7 0x0080 Cut cmd 8 0x0100 Blade close 9 0x0200 Blade open

10 0x0400 Spot cut 11 0x0800 Virtual line 12 0x1000 Virtual blade 13 0x2000 Cam status = 15 (synchronism phase with the line) 14 0x4000 Hw limit switch 15 0x8000 Not used

Table 3: Alarm word command status mapping Enter machine data: • Mechanical ratios to define trolley movements: The coefficient to be entered corresponds to the trolley movement per 1 motor revolution.

PARAMETER FUNCTION DESCRIPTION PAR 11700 Trolley Select the trolley encoder PAR 11702 Trolley Trolley movement in metres per 1 motor revolution PAR 11704 Trolley Travel available for the trolley PAR 11710 Trolley Setting maximum forward acc/dec, toward material output PAR 11712 Trolley Setting maximum acc/dec during return phase PAR 11802 Line Select the line encoder PAR 11804 Line Line advancement per 1 metric wheel revolution

• Set the hardware limit switches:

PARAMETER FUNCTION DESCRIPTION PAR 11018 Limit Switch Hardware limit switch input PAR 11020 Limit Switch Type of limit switch: NO or NC PAR 11022 Limit Switch Deceleration set to trip limit switch

• Set ramps and speed references:

PARAMETER FUNCTION DESCRIPTION PAR 11304 Jog Speed reference for jog movement PAR 11306 Jog Acceleration for Jog movement PAR 11308 Jog Deceleration for Jog movement PAR 11410 Homing Speed reference for zero-sensor search. PAR 11412 Homing Speed reference for zero-sensor disengagement. PAR 11414 Homing Acceleration for homing movement PAR 11416 Homing Deceleration for homing movement PAR 11304 Move to Speed reference for positioning before automatic cutting


• Set cutting specifications: Changing these parameters changes the calculation of the maximum line speed displayed by the Max line spd mon parameter (PAR 12044).

PARAMETER FUNCTION DESCRIPTION PAR 11604 Auto Synchronism time PAR 11612 Auto Maximum line speed PAR 11016 Trolley Stopping distance at end of cut PAR 11704 Trolley Maximum trolley travel PAR 11706 Trolley Cutting time PAR 11710 Trolley Cutting time margin PAR 11712 Trolley Max acceleration for trolley movements PAR 11714 Trolley Max deceleration for trolley movements PAR 11718 Trolley Set up material at the end of the line PAR 11732 Trolley Minimum trolley movement acceleration/deceleration PAR 11730 Trolley Jerk on acceleration and deceleration phases PAR 11800 Line Cut length

4.3 Commissioning Enable the metric wheel simulator using the Virtual Line start parameter (PAR 11000). We now continue by checking the data inserted and machine movements. If the PLC has not yet been configured or connected, it is possible to set the Enable, Jog, Fast Stop and Auto commands on the digital inputs, to test the machine movements.

The following operations require the machine in motion. Unforeseen machine movement is always possible. Take this into account and take the necessary precautions.

The operation described must be initially carried out with the motor disconnected from the machine. Once the functions have been tested, the operations can be repeated with the motor connected to the machine.

4.3.1 Check hardware limit switch

Enable the drive and check that the drive state is “Standstill” (PAR 12000). Trip the hardware limit switches to check that the drive goes to Fast Stop (PAR 12000) and remains in this state until the enable is removed.

4.3.2 Direction checking

Jog forwards and Jog backwards. Check for movement in the correct direction. With Jog forward the carriage advances in a positive direction and the Pos trolley mon (PAR 12038) increases. Otherwise, reverse the motor phases and encoder channels A+ and A-.

4.3.3 Zero cycle positioning

Zero searching is to be checked out: - Enable the drive. - Enable the Homing command. The status of State mon (PAR 12000) must become Homing. The

carriage must move towards the zero position. Otherwise, remove Auto command and invert Home dir (PAR 11400).

- Once the zero sensor has been engaged, the motor reverses its direction of travel to disengage the sensor and move to the zero point

- The correct execution of the homing command is indicated by the Home found mon monitor (PAR 12014).


4.3.4 Carriage length development

The Jog command is used. After the zero cycle position measurement is active. Mark the position on the carriage and register the Pos trolley mon (PAR 12038) position. The carriage moves with JogPos or JogNeg depending on the direction desired. Measure the distance travelled confronting the distance to the difference of the two Pos trolley mon positions. Adjust the Trolley Kmec (PAR 11702) value if any errors occur.

4.3.5 Metric Wheel Advancement

Check the correctness of the direction using the metric wheel. If the direction is incorrect use the metric wheel encoder. Otherwise, reverse the motor phases and the A and A-denied encoder channels.

4.4 Function configuration

4.4.1 Maximum line speed calculation

The application is able to calculate the maximum line speed possible with the system data entered and make it available to the user; the parameters used to process the maximum speed are:

• Stopping space (PAR 11016) • Required cut length (PAR 11800) • Cut time (PAR 11706) • Synchronism time (PAR 11604) • Maximum stroke (PAR 11704) • Trolley acceleration (PAR 11712)

The calculation procedure is repeated every time one of these parameters is changed and every time the trolley finishes a cut in automatic mode.

4.4.2 Cutting time

The cutting time is acquired by the drive and managed by a specific function; if the high and low blade sensors are connected, the exact cutting time can be measured by readjusting the cam to the value acquired at each cycle to adapt the cutting time to any blade wear.

High-blade sensor

presence

Low-blade sensor

presence Cut time Note

First cut cut time + margin cut time PAR 11706+ PAR 11710

From the second cut no no cut time + margin cut time PAR 11706+ PAR 11710

From the second cut ok no cut time mon + margin cut time PAR 12030 + PAR 11710

Cut time mon = High-low-high transition time of the high blade sensor

From the second cut ok ok cut time mon + margin cut time PAR 12030 + PAR 11710

Cut time mon = High-low transition time of the high-blade sensor and high-low transition time of low-blade sensor

The cutting time used to define the cam will still and in any case be higher than the Min Cut Time (PAR 11726); if a cutting time lower than the Min Cut Time is acquired, the value acquired will be discarded and the Min Cut Time will be used.


If the blade simulator is used, the cutting time will still be the same as the Virtual Cut Time parameter (PAR 11008).

4.4.3 Support time

The support space Wait pace end line (PAR 11716), is the amount of material that the trolley must wait to exit the shear before starting a new cycle, once the cut has been completed. This function has the purpose of supporting the material head on the trolley to avoiding jamming. For very long cuts that require an excessively low trolley return speed, the Auto Wait long cut parameter (PAR 11728) can be used to ensure that: If the required cutting length is greater than this parameter, the trolley will automatically set a waiting time equal to:

Waiting time = cut request – auto wait long cut + wait space end line PAR 11800 - PAR 11728 + PAR 11716

4.4.4 Saving the material length

Saving the material length allows the quantity of material in the shear to be saved in a variable in the drive memory even when the drive is switched off and without launching a command to save the parameters. Using the Line save pos parameter (PAR 11806), the saving operation can be set:

Line Save pos (PAR 11806) Description Null Function deactivated

Always The line can be switched off at any stage of the shear by removing the “automatic

cut” command and then disabling the drive.

Return The line can only be switched off during the shear return phase by removing the “automatic cut” command and then disabling the drive.

When the drive is switched on again, do the zero search procedure and then, without heading the material, enable “automatic cutting”, so that the trolley will go to the head of the material, resuming the cycle from where it was stopped.

Do not move the material when the drive is switched off because the new position will not be read by the drive and the shear will not be repositioned correctly.

4.4.5 Stop metric wheel reading

Using a command to stop the metric wheel reading makes it possible to achieve a longer cut than required, variable according to the length of time the MW line skip command (PAR 11810) is kept active. When this control is activated, the trolley stops because the material advancement is no longer read; once the control is released, the trolley picks up from the cam point where it had stopped.


5 Description of functions and parameter list

26.01 Application The menu will display the version of the application installed on the drive.

MENU PAR Description UM Type Def Min Max ACCESS 26.01.01 12000 State mon * ENUM * * * R Application status monitor:

0 Init 1 Disable 2 Standstill 3 Fast Stop 4 Jog + 5 Jog - 6 Homing 7 Auto 8 Move To 9 Heading

26.01.02 12002 Enable mon * BOOL * * * R Monitors the drive enabling command.

26.01.03 12004 Fast Stop mon * BOOL * * * R Monitors the fast stop command.

26.01.04 12006 Jog- mon * BOOL * * * R Monitors the negative Jog command.

26.01.05 12008 Jog+ mon * BOOL * * * R Monitors the positive Jog command.

26.01.06 12010 Homing mon * BOOL * * * R Monitors the zero search (homing) command.

26.01.07 12012 Home sens mon * BOOL * * * R Monitors the zero position sensor.

26.01.08 12014 Home found mon * BOOL * * * R Monitors the zero position search status.

26.01.09 12016 Auto mon * BOOL * * * R Automated cut command monitor.

26.01.10 12018 Blade down mon * BOOL * * * R Monitors the blade in low position signal (in the end of cut position).

26.01.11 12020 Blade up mon * BOOL * * * R Monitors the blade in high position signal (in the rest position).

26.01.12 12022 Imm cut mon * BOOL * * * R Instantaneous cut manual command monitor.

26.01.13 12024 Virtual line mon * BOOL * * * R Line simulator activation monitor.

26.01.14 12026 Virtual blade mon * BOOL * * * R


MENU PAR Description UM Type Def Min Max ACCESS Blade simulator activation monitor.

26.01.15 12028 Reset line mon * BOOL * * * R Material count reset monitor.

26.01.16 12030 Cut time mon s FLOAT * * * R Cut time monitor, measured as the time elapsed between the command being sent

and the blade release. The monitor is updated after a cut in “automatic cut” mode, or after an immediate cut.

26.01.17 12032 Trolley spd ref mon rpm FLOAT * * * R Speed reference monitor.

26.01.18 12034 Trolley acc ref mon s FLOAT * * * R Acceleration time monitor.

26.01.19 12036 Trolley dec ref mon s FLOAT * * * R Deceleration time monitor.

26.01.20 12038 Pos trolley mon m FLOAT * * * R Trolley position monitor.

26.01.21 12040 Bar Length mon m FLOAT * * * R Monitor the length of the last cut tube.

26.01.22 12042 Pos line mon m FLOAT * * * R Monitor of the material not yet cut that passed under the shear.

26.01.23 12044 Max line spd mon m/s FLOAT * * * R Maximum permitted line speed monitor.

26.01.24 12046 Line spd mon m/s FLOAT * * *000 R Line speed monitor.

26.01.25 12048 Auto state mon * ENUM * * * R Automated cut status monitor:

0 Init 1-2-3 Dec fwd Shear deceleration at the end of the line. 4 Wait fwd Standby at the end of the line. 5-6-7 Acc rev Shear acceleration towards the tracking start point for cut. 8 Rev spd Constant shear speed to the tracking start point for cut. 9-10-11 Dec rev Shear deceleration to stop at the tracking start point for cut. 12 Wait rev Shear standby at the tracking start point for cut. 13-14 Acc fwd Shear acceleration at tracking start point for cut. 15-16 Sync Synchronization and cut phase.

26.01.26 12050 Cut req mon * FLOAT * * * R Required cut length monitor.

26.01.27 12052 Word alarms mon * DINT * * * R Alarm status word monitor.

(See Table 6 and Section 6 for more information)

26.01.28 12054 Word cmds mon * DINT * * * R Command status word monitor.

(See Table 2 and Section 4.3 for more information)


MENU PAR Description UM Type Def Min Max ACCESS 26.01.29 12056 Pos err m FLOAT * * * R Position error monitor, misalignment between the actual shear position and the

reference generated by the drive.

26.02 App Service

This menu allows the default parameters to be loaded and the speed reference destinations generated by the application to be set and the destination of the word containing the command status.

MENU PAR Description UM Type Def Min Max ACCESS 26.02.01 11100 Load default * BOOL Off * * R/W Load default application, reload only the default application values and configure

some system parameters to run the application (see Table 1 chapter 4.3 for more information).

26.02.02 11102 Speed ref dest * ENUM Speed ref 1

* * R/W

Speed reference destination generated by the application .

26.02.03 11104 Cmds mon dest * ENUM Pad 5 * * R/W Destination of the status word containing the commands generated by the application

(see Table 3 chapter 4.3 for more information).

26.03 Enable

This function allows the source of the enabling command software to be set and the possible destination of the command monitor. To enable the drive, it is always necessary to command the hardware enable (connected to terminal 7 of the control board).

MENU PAR Description UM Type Def Min Max ACCESS 26.03.01 11200 Enable src * ENUM Decp

bit0 * * R/W

Drive enable command source.

26.03.02 11202 Enable dest * ENUM Pad 1 * * R/W Drive enable command monitor destination.

26.04 Fast Stop

The menu allows the source of the fast stop command and its deceleration ramp to be set. This function must be activated using the alarms mask (see chapter 6 for more information) to generate a ramp stop on command, in whatever state the shear is in; otherwise there will only be a signal that the fast stop command has been received without stopping the trolley.

The alarm is reset by removing the Fast Stop command and disabling the drive.

MENU PAR Description UM Type Def Min Max ACCESS

26.04.01 11204 Fast Stop src * ENUM Decp bit1

* * R/W

Source of the command to enable fast stop.


26.04.02 11206 Fast Stop dec s FLOAT 0.5 0.01 10.0 R/W Stop ramp for emergency stop.

26.05 Jog

This menu allows the jog command source, the acceleration and deceleration ramps, and the speed reference to be set. This function, active only in manual mode (automatic cutting not active), allows the trolley to be moved manually along its available travel.

The carriage can be moved in jog mode beyond the software limit switches, while reaching the hardware limit switches will generate a “ramp stop”.

MENU PAR Description UM Type Def Min Max ACCESS 26.05.01 11300 Jog+ src * ENUM Decp

bit3 * * R/W

Source of the jog to positive command.

26.05.02 11302 Jog- src * ENUM Decp bit2

* * R/W

Source of the jog to negative command.

26.05.03 11304 Jog speed m/s FLOAT 0.2 * * R/W Speed reference for jog command.

26.05.04 11306 Jog acc s FLOAT 1.0 0.01 10.0 R/W Acceleration ramp for jog command.

26.05.05 11308 Jog dec s FLOAT 1.0 0.01 10.0 R/W Deceleration ramp for jog command.

26.06 Homing

This menu allows the source of the homing command, the zero-ramps sensor and the speed references to be set. This function is activated through the “home src” command; the trolley moves with the “home speed” reference speed and the ramp is set in the direction indicated by the “home dir” parameter; once the zero sensor is reached, depending on how the “home sens edge” parameter is set, the trolley will immediately reverse direction by disengaging the (Rising) sensor or will continue in the same direction, stopping only once the (Falling) sensor has been disengaged. Once the zero search procedure has been successfully completed, this will be indicated in the “home found” bit in the state word (PAR 12054) and at the destination indicated in the Home found dest parameter (PAR 11418).

MENU PAR Description UM Type Def Min Max ACCESS 26.06.01 11400 Home dir * ENUM Positi

ve * * R/W

Parameter that detects the first direction of the zero-position search when the POS 0 Search command is activated (DIGITAL INPUTs menu).

0 Positive The motor turns clockwise.


MENU PAR Description UM Type Def Min Max ACCESS 1 Negative The motor turns counter clockwise.

26.06.02 11402 Home src * ENUM Decp bit5

* * R/W

Source of the zero-search command.

26.06.03 11404 Home sens src * ENUM Decp bit6

* * R/W

Source of the zero sensor.

26.06.04 11406 Home sens edge * ENUM Rising * * R/W Parameter that sets the activation edge of the zero sensor.

0 Rising The zero sensor is active on the rising edge. 1 Falling The zero sensor is active on the falling edge.

26.06.05 11408 Home enc index * ENUM Off * * R/W Parameter that enables/disables index search (rotation pulse, zero mark) of the

position encoder during zero search.

26.06.06 11410 Home speed m/s FLOAT 0.1 * * R/W Speed reference for zero-sensor search.

26.06.07 11412 Home fine speed m/s FLOAT 0.05 * * R/W Speed reference adopted during the search for the absolute zero position.

This reference is applied when the zero sensor is activated and/or in encoder index search phase.

26.06.08 11414 Home acc s FLOAT 1.0 0.01 10.0 R/W Acceleration ramp for Homing command.

26.06.09 11416 Home dec s FLOAT 1.0 0.01 10.0 R/W Deceleration ramp for Homing command.

26.06.10 11418 Home found dest * ENUM Null * * R/W Destination of the zero-search status monitor.

26.07 Limit switch

This menu allows the source of the limit switch sensors, its type and the deceleration ramp to be set. This function allows the trolley to be stopped in the event that it exceeds the limits of the available travel, regardless of its state.

If the limit switch is tripped it will be necessary to disable the drive, mask the limit switch intervention with a suitable external circuit and then, using the jog command, bring the trolley back to its original position.


26.07.01 11018 Limit Switch src * ENUM Null * * R/W Source of the hw limit switches located at the limits of the trolley travel.

26.07.02 11020 Limit Switch type * ENUM NC * * R/W Type of limit switch used.



26.07.03 11022 Limit Switch dec m/s2 FLOAT 0.5 0.01 10 R/W Deceleration ramp to stop the machine after the limit switches have been tripped.

Changing the Limit Switch src parameter (PAR 11018) automatically assigns the system parameter ExtFlt src (PAR 4502, ALARM CONFIG menu) to the same source.

26.08 Move

This function allows the parameters for repositioning the shear at the zero point or at the head of the material to be set, when the Drive is switched on, if the save function for the material present in the machine (PAR 11806) has been activated.

MENU PAR Description UM Type Def Min Max ACCESS 26.08.01 11500 Move Kp m/m/s FLOAT 0.22 * * R/W Proportional gain setting of the position ring

26.08.02 11504 Move spd rpm FLOAT 50 * * R/W Speed reference used for positioning.

26.09 Auto

This menu allows the cut automation parameters to be set.

The automatic cutting function is conditioned:

• When the zero-point search is performed, otherwise the machine will remain in the “Not Ready” state.

• The material is headed using “immediate cut”, since when the drive is switched on the length of the material already present in the shear is not known. If the material length save function is used, heading is not required (see chapter 4.5 for more information).

Once the function has been activated using the “Auto src” parameter, a series of operations are then carried out 1. A Move is made to the zero position. 2. The maximum line speed is calculated (Max Line Spd, PAR 11612). 3. (From the outside). The line starts up. 4. The trolley, moving in synchronisation with the line, moves to the end position, supporting the head of the

material. 5. The maximum line speed is calculated (Max Line Spd, PAR 11612). 6. Standby time can be set. 7. The trolley moves to the position determined by the algorithm to make the cut correctly. 8. Cut point standby. 9. The trolley accelerates to synchronize with the speed of the material. 10. Trolley speed stabilization time with the line speed. (Sync time and Sync Kp). 11. Execution of the cut. 12. When the cut is finished, it resumes from point 3. The operation status is shown in Auto state mon (PAR 12048).


By commanding an immediate cut by Imm cut src parameter (PAR 11602) the application will start the execution of a cut regardless the dimension reached, shifting the trolley at the maximum speed allowed and making the shortest possible cut.

MENU PAR Description UM Type Def Min Max ACCESS 26.09.01 11600 Auto src * ENUM Decp

bit4 * * R/W

Cut automation command source.

26.09.02 11602 Imm cut src * ENUM Decp bit7

* * R/W

Immediate manual cut command source.

26.09.03 11604 Sync time s FLOAT 0.2 * * R/W Trolley speed stabilization time during the synchronization phase.

26.09.04 11608 Imm cut spd m/s FLOAT -0.8 * * R/W If the speed of the current line is lower than the maximum line speed set, during the

return phase of the immediate cut the speed reference given to the trolley will be the greater between the current line speed or this speed reference.

26.09.05 11612 Max Line Spd m/s FLOAT 4.0 * * R/W Setting the maximum line speed. The calculated line speed will be limited to this

parameter.

26.09.06 11614 Max pos err * FLOAT 0.1 0 1 R/W Setting the maximum correction allowed by the position controller.

26.10 Trolley

This function allows the parameters that manage the trolley and the immediate manual cut to be set.

MENU PAR Description UM Type Def Min Max ACCESS 26.10.01 11012 Max spd bck m/s FLOAT 0.5 * * R/W Maximum speed the trolley can return from the end of the line to the beginning to

perform a cut.

26.10.02 11014 P gain pos m/m/s FLOAT 1 * * R/W Proportional gain of position ring.

26.10.03 11016 Trolley stop space m FLOAT 0.07 * * R/W The space used by the shear to stop once the cut has been completed. This space

is added to the Trolley Limit pos (PAR 11704) to set the maximum stroke of the shear.

26.10.04 11700 Trolley Enc sel * ENUM Encoder1

* * R/W

Encoder source mounted on the motor for shear movement.

26.10.05 11702 Trolley Kmec * FLOAT 0.065 * * R/W Mechanical coefficient to define the metric advancement per motor shaft revolution.

26.10.06 11704 Trolley Limit pos m FLOAT 1 * * R/W Trolley movement limit, with respect to the zero-point defined by Homing. This

parameter defines the useful stroke for the trolley.

26.10.07 11706 Cut time s FLOAT 0.6 * * R/W


MENU PAR Description UM Type Def Min Max ACCESS Cut time.

26.10.08 11708 Margin cut time s FLOAT 0.1 * * R/W Safety margin for the cut time (the total cut time will be given by the sum Cut time +

Margin cut time).

26.10.09 11710 Trolley acc m/s2 FLOAT 2 * * R/W Acceleration ramp for trolley movement.

26.10.10 11712 Trolley dec m/s2 FLOAT 3 * * R/W Deceleration ramp for trolley movement.

26.10.11 11714 Trolley Overacc m/s2 FLOAT 1.1 1.1 10 R/W Possibility of defining an over-acceleration that can be used when the trolley returns.

26.10.12 11716 Wait time end line m FLOAT 0 * * R/W The amount of material that runs out of the machine to support the header, once the

cut has been made, with the shear in standby.

26.10.13 11718 Blade Close src * ENUM Decp bit8

* * R/W

Source of the low blade sensor, i.e. in the end of cut position.

26.10.14 11720 Sens Blade Open * BOOL Off * * R/W Enabling the high blade sensor.

26.10.15 11722 Blade Open src * ENUM Decp

bit9 * * R/W

Source of the high blade sensor, i.e. in the rest position.

26.10.16 11724 Cut Cmd dest * ENUM Pad 2 * * R/W Cut command destination.

26.10.17 11726 Min Cut Time s FLOAT 0 * * R/W Minimum cut time. Between this parameter and the cutting time previously

measured during the cut, the cam calculation algorithm acquires whichever is higher as the cutting time.

26.10.18 11728 Auto Wait long cut m FLOAT 0 * * R/W In the case of very long cuts, the waiting space is automatically calculated using the

formula: 𝑇𝑇𝐸𝐸𝑀𝑀𝐴𝐴𝑒𝑒 𝑤𝑤𝐴𝐴𝑀𝑀𝑀𝑀 𝑠𝑠𝑝𝑝𝐴𝐴𝑀𝑀𝑀𝑀 = 𝐶𝐶𝐶𝐶𝑀𝑀 𝑀𝑀𝑀𝑀𝑟𝑟𝐶𝐶𝑀𝑀𝑠𝑠𝑀𝑀 − 𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨 𝒘𝒘𝒘𝒘𝒘𝒘𝑨𝑨 𝒍𝒍𝑨𝑨𝒍𝒍𝒍𝒍 𝒄𝒄𝑨𝑨𝑨𝑨+ 𝑊𝑊𝐴𝐴𝑀𝑀𝑀𝑀 𝑠𝑠𝑝𝑝𝐴𝐴𝑀𝑀𝑀𝑀 𝑀𝑀𝐸𝐸𝐸𝐸 𝑒𝑒𝑀𝑀𝐸𝐸𝑀𝑀

26.10.19 11730 Trolley jerk * INT 100 100 10000 R/W Jerk on the acceleration and deceleration ramps. Increasing this value decreases

the S-effect on the ramps.

26.10.20 11732 Trolley min acc m/s2 FLOAT 0 * * R/W Minimum acceleration applicable to cam acceleration and deceleration ramps.


26.11 Line

This function allows the parameters that manage the line to be set.

MENU PAR Description UM Type Def Min Max ACCESS 26.11.01 11800 Cut request m FLOAT 6 0.1 30 R/W Required cut size.

26.11.02 11802 Line enc sel * ENUM Enco

der2 * * R/W

Encoder source mounted on the metric wheel to measure the material at the shear input.

26.11.03 11804 Line Kmec * FLOAT 0.05 * * R/W Mechanical coefficient to define the metric advancement per metric wheel revolution.

26.11.04 11806 Line save pos * ENUM Null * * R/W Selection of the mode for saving the length of the material present in the machine

after switching it off.

0 Null Function not active 1 Always The measurement is saved in each phase of shear movement. 2 Return The measurement is only saved during the return phase (from the

end to the start of the line). This allows more precise repositioning the next time the drive is started up again.

26.11.05 11808 Line Kmec tune % FLOAT 0.0 -1.0 1.0 R/W Fine calibration of the mechanical coefficient of the metric wheel, the percentage

indicated is added to or subtracted from the mechanical coefficient (PAR 11804), this parameter can also be changed when the flying shear is enabled.

26.11.06 11810 MW line skip * ENUM Null * * R/W Input selection to stop metric wheel reading.

26.12 Alarm

The menu allows the alarms to be set and the intervention of the application alarms to be managed. This function allows the application alarms to be managed.

MENU PAR Description UM Type Def Min Max ACCESS 26.12.01 11900 Dly blade cut s FLOAT * * R/W Maximum permissible delay between the command and the execution of the cut.

26.12.02 11902 Trolley pos max m FLOAT 2 * * R/W Maximum permissible trolley position. If this is exceeded the alarm is tripped by the

appropriate bit of the word alarms.

26.12.03 11904 Trolley pos min m FLOAT -0.1 * * R/W Minimum permissible trolley position. If this is exceeded the alarm is tripped by the

appropriate bit of the word alarms.

26.12.04 11906 Max diff sync m FLOAT 0.5 * * R/W Maximum misalignment allowed between the actual shear position and the drive-

generated reference. If this is exceeded the alarm is tripped by the appropriate bit of the word alarms.

26.12.05 11908 Alarm dest * ENUM Pad6 * * R/W Alarm status word destination.


MENU PAR Description UM Type Def Min Max ACCESS 26.12.06 11910 Auto set alarm mask * ENUM FastS

top * * R/W

Automatic setting of the mask for the generation of blocking alarms that stop the trolley.

0 None Hardware limit switch Drive system alarms

1 FastStop Fast stop command Hardware limit switch Drive system alarms

2 FastStop SW_LS

Fast stop command Software limit switch Hardware limit switch Drive system alarms

3 Custom Customizable mask (using the Alarm stop mask parameter, PAR 11914) Hardware limit switch Drive system alarms

26.12.07 11912 Alarm stop mask * INT 18 * * R/W Customizable mask for the generation of blocking alarms that stop the trolley.

Parameter valid if Auto set alarm mask (PAR 11912) is set to “custom”.

26.12.09 11916 Safe Sync Stop m FLOAT 0 * * R/W Space from the end of the line within which, once the cut has been made, the blade

must return to its rest position.

26.13 Virtual

This menu allows the times and references for the line simulator and the blade simulator to be enabled and set. The line simulator function, useful for commissioning, allows the presence of material to be simulated by setting the speed that allows the trolley to move with the cam in the absence of material. The blade simulator function allows the movement of the high/low blade sensors and the cutting time to be simulated.

MENU PAR Description UM Type Def Min Max ACCESS 26.13.01 11000 Virtual Line start * ENUM Decp

bit12 * * R/W

Start / stop of the virtual metric wheel. Parameter active only by enabling the virtual line (PAR 11010).

26.13.02 11002 Virtual Line spd * FLOAT 0.2 * * R/W Simulator line speed.

26.13.03 11004 Virtual Line acc m/s2 FLOAT 2 * * R/W Line acceleration simulator.

26.13.04 11006 Virtual blade src * ENUM Decp

bit11 * * R/W

Enable blade command simulator.

26.13.05 11008 Virtual Cut time s FLOAT 0.6 * * R/W Simulated blade cut time.

26.13.06 11010 Virtual Line src * ENUM Decp

bit10 * * R/W

Source of the command to enable the virtual line.


26.14 About

The menu will display the version of the application installed on the drive.

MENU PAR Description UM Type Def Min Max ACCESS 26.14.01 12100 App version * FLOAT * * * R Application version.

26.14.02 12102 Build date * FLOAT * * * R Date when the application was compiled.

26.14.03 12104 MDPlc version * FLOAT * * * R MDPlc version used to compile the application.

26.14.04 12106 Regulation S/N * DWORD * * * R Serial Number of the control board.

Use to activate the application.


6 Application alarms The application carries out a series of checks on itself while it is functioning. The information is stored in the Word alarm mon (PAR 12052) parameter. The table shows the application-specific alarms: APPLICATION

ALARM CAUSE

BIT NUMBER

APPLICATION ALARM CAUSE

[HEX]

APPLICATION ALARM CAUSE [dec]

DESCRIPTION ACTION

0 0x0001 1 Cut Consistency check between cut commands and blade position.

Signalled

Stop during ramp

1 0x0002 2 Auto Alarm during the automated cycle.

2 0x0004 4 Cut length Cutting does not meet the required tolerances.

3 0x0008 8 Pos min Trolley exceeds minimum position.

4 0x0010 16 Pos max Trolley exceeds maximum position.

5 0x0020 32 Sync Trolley movement not synchronised with the line.

6 0x0040 64 Fast Stop Fast Stop commands active.

7 0x0080 128 Pos line The length of the material (in progress) inside the machine is excessive and will not allow the cut.

8 0x0100 256 Calc VLM The calculation of the maximum line speed generated an error.

9 0x0200 512 Not used

10 0x0400 1024 Spd Overlimit

The maximum speed that the carriage must reach to make the cut exceeds the limits set by Speed Ref Top Lim and Speed Ref Bottom Lim (PAR 670, PAR 672).

Signalled

Stop

during ramp 11 0x0800 2048 Spd Over

VLM The line speed exceeds the calculated maximum line speed.

12 0x01000 4096 Limit switch Tripping the hardware limit switches Stop during ramp

13 0x02000 8192 Drive alarm Tripping a drive system alarm

14 0x04000 16384 Not used

15 0x08000 32768 Not used

Table 4: Command mapping word

Activation of an alarm set as “Ramp stop” causes the motor to stop quickly and the trolley to stop. Continuously monitor the alarm states through your PLC to synchronize the drive stop with the line stop (to prevent a possible collision between blade and the material if there is a cut in progress).

Documents

ADV200 - Flying Shear for Roll Forming machines Application