Motion ControlFeaturing Distributed and Centralized Motion Control Solutions

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Motion Control

“Consider It Solved” with a servo motion solution that fi ts your experience and application needs. Are you experienced with decentralized multi-axis drive solutions and maybe you want to integrate logic and motion? Then the Unidrive SP product line is the solution for you. Do you want a simple but powerful decentralized axis and a half solution? Then the “Motion Made Easy” product line, featuring the new compact Epsilon EP, is the solution for you! Are you more familiar with centralized multi-axis position control via analog or digital servo

drive connection? Then the Motion Coordinator is the solution for you. You can be certain that any solution you pick will have a matched servo drive and motor to ensure the best performance and reliability. You can also be certain that your solution will be backed by one of the largest companies in the world.

“Motion Made Easy”TM systems for precise control of axis and axis-and-a-half applications

“Motion Made Easy”TM servo systems have been the choice of machine builders for over 20 years, since Emerson Control Techniques introduced the fi rst fully-integrated servo system with “fi ll-in-the-blank” programming software.

Today’s “Motion Made Easy”TM systems, MDS, EN Series, and Epsilon EP systems, are still up and running in minutes and hours instead of days and weeks because the drives can handle inertia mismatches of greater than 10-to-1 right out of the box. More importantly, free Windows-based PowerTools software continues to improve, making synchronized motion, multiple profi les, camming, and other motion functions even easier to implement.

The new Epsilon EP line of drives offer compactness, simplicity, scalability, and very competitive pricing. The Epsilon EP-P Programming version is a highly capable multi-tasking single axis control

with onboard Ethernet and the ability to synchronize with another axis via a second encoder/analog sync connection.

Distributed Multi-Axis Controlwith Unidrive SP

The Unidrive SP “Solution Platform” is the most versatile motion control platform with the broadest available power range. The base drive is capable of connecting a broad selection of motors including vector, brushless servo and linear motors. The modular expansion slots and optional SM solution modules, such as SM-SERCOS, make the Unidrive SP compatible with almost every motion controller or PLC on the market. The addition of the multitasking SM-Applications coprocessor module, programmed using SyPTPro, transforms the Unidrive SP into a decentralized multi-axis control with integrated motion and logic. Furthermore, complete machine control and synchronization can be realized by adding CTNet I/O, CTNet HMI and CTSync drive to drive synchronization.

SyPTPro is an IEC-61131-3 compliant ladder logic software that incorporates the new OpenPLC standard for motion function blocks.

When equipped with an SM-EZMotion module the Unidrive SP possesses the “Motion Made Easy”TM benefi ts of PowerTools software for a simple, and sophisticated axis or axis-and-a-half motion control system.

Motion Control

Motion control solutions to fi t your applicationDistributed Multi-Axis Control with Unidrive SPpage 168

Distributed 1 1/2 Axis Controlwith “Motion Made Easy”™page 88

Centralized Motion Controlwith Motion Coordinatorpage 196

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Centralized Motion Control

with Motion Coordinator

Realize centralized control and decentralized functionality using Control Techniques Motion Coordinator motion controllers with Unidrive SP, Epsilon EP, EN or MDS servo drives. The Motion Coordinator series of centralized controllers offer almost unlimited scalability, modularity, and fl exibility. Scalability is offered through the choice of two different base controllers, four different servo drives, and over 10 daughter board options. Furthermore, all Motion Coordinators are programmed with the free MotionPerfect2 software. Modularity is offered by selecting only the daughter board options needed for a specifi c motion application. Finally, fl exibility is offered by the controllers ability to perform interpolated, point to point, camming, electronic gearing and even CNC motion.

MotionPerfect2 software provides all the functions necessary to write simple and fast programs for the most rigorous and precise motion applications.

Positioning with Vector Motors

Using vector positioning control, employing servo control on a closed loop vector motor, is ideal for applications susceptible to load disturbances,

having high inertia loads, or with high horsepower requirements. While not physically compact, savings are realized because the cost of a vector motor with encoder is much less than that of a brushless servo motor, and this solution often eliminates the need for a gearbox.

Many of the applications that can benefi t from vector positioning control will fi nd the Unidrive SP equipped with an SM-EZMotion module the perfect choice for those wanting their system programmed, setup and run-ning in hours, rather than days or weeks.

Continuous Torque

Servo drive/lb-in

Unidrive SP in servo mode:

1 20 40 750 3,600 4,5001,450200130

with Brushless Servomotor with AC Vector motor

100

Epsilon EP115V/230VEN-Series

115V/230VMDS

230V/460V

Unidrive

230V

460V

575V690V

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Motion Control

Motion Control Product Matrix

Drive Family

Epsilon EPp. 96

ENp. 122

Motors ControlledServomotors, Linear Motors, Linear Actuators, Gearmotors

Servomotors, Linear Motors, Linear Actuators, Gearmotors

Control Modes

Analog Velocity, Analog Torque, Position Tracker™, Digital Velocity Preset, Summation of A/D Velocity, and Pulse/Pulse, Pulse/Direction, and Pulse/Quadrature Indexing and Programmable Analog Position Versions

Analog Velocity, Analog Torque,Digital Velocity Preset,Summation of A/D Velocity, andPulse/Pulse, Pulse/Direction, and Pulse/Quadrature

Continuous Torque Up to 100 lb-in Up to 132 lb-in

AC Voltage 50/60Hz

90 to 264VAC 1Ø 90 to 264VAC 1Ø and 3Ø

Motor Feedback Incremental Encoders Incremental Encoders

Input/Output

Input OutputDigital* 16 8Analog 1 2

Pulse Single-Ended 1Pulse Dif. 1 1

*Programmable

Input OutputDigital* 5 3Analog 1 2

Pulse Single-Ended 1Pulse Dif. 1 1

*Programmable

Input/Output options N/A Extended I/O via FM Modules

Communication

MODBUS RTU, MODBUS TCP/IP PROFIBUS DP, DeviceNet, Ethernet, and Ethernet-IPModel Dependant

MODBUS RTUFM-modules for

PROFIBUS DP, DeviceNet, Ethernet, and Ethernet-IP

Confi guration & Programming

PowerTools Pro PowerTools FMPowerTools Pro

ApplicationCo-processor

N/AFM-modules for

IndexingProgrammable Positioning

Approvals UL, CUL, RoHS Option, CE UL, CUL, CE

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Drive Family

MDSp. 138

Unidrive SPp. 167

Motors ControlledServomotors, Linear Motors, Linear Actuators, Gearmotors

Servomotors, Linear Motors, Linear Actuators, Gearmotors, Vector motors

Control Modes

Analog Velocity, Analog Torque,Digital Velocity Preset,Summation of A/D Velocity, andPulse/Pulse, Pulse/Direction, and Pulse/Quadrature

Analog Velocity, Analog Torque, Digital Velocity Preset, Summation of A/D Velocity, and with Second Encoder: Pulse/Pulse, Pulse/Direction, and Pulse/Quadrature

Continuous Torque Up to 748 lb-inUp to 750 lb-in (brushless)Up to 4,500 lb-in (vector)

AC Voltage 50/60Hz ± 10%

187 to 528VAC 3Ø200-240V ±10% 1Ø200-240V ±10% 3Ø380-480V ±10% 3Ø

Motor Feedback Incremental Encoders

Universal Encoder Port supports14 feedback devices (including ABS, ENC)

Optional Solution Modules forResolver, Second encoder, andUniversal encoder support withsimulated encoder output

Input/Output

Input OutputDigital* 5 3Analog 1 2

Pulse Single-Ended 1Pulse Dif. 1 1

*Programmable

Input OutputDigital* 4 3Analog 3 2

Relay 1Pulse Dif. with 2nd Encoder

*Programmable

Input/Output options Extended I/O via FM Modules

Remote and SM-modules forExtended I/O Real-Time Clock I/ODouble-Insulated I/O120V I/O

Communication

MODBUS RTUFM-modules for

PROFIBUS DP, DeviceNet, Ethernet, and Ethernet-IP

MODBUS RTUOptional SM-Modules for

PROFIBUS DP, DeviceNet, CAN,CANopen, INTERBUS-S, CTSync, CTNet, Ether-net, and SERCOS

Confi guration & Programming

PowerTools FMPowerTools Pro

CTSoft, SyPTLIte, SyPTPro (IEC-61131-3) software PowerTools Pro for SM-EZMotion

ApplicationCo-processor

FM-modules forIndexingProgrammable Positioning

SM-modules forScalable PLC functionalitySM-EZMotion Servo Control

Approvals UL, CUL, CE UL, CUL, CE, C-Tick, ISO14001, ISO9001:2000

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“Motion Made Easy”™for Motion ControlEpsilon EP, EN, MDS Drive Platforms – Distributed 1 1/2 Axis Servo Systems

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In addition to the dedicated servo platforms the Unidrive SP with the SM-EZMotion module is capable of “Motion Made Easy”™ programming and functionality and can power vector motors in positioning applications.

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“Motion Made Easy”™for Motion ControlIntroducing “Motion Made Easy”™

THE EASY MOTION STRATEGY

Control Techniques “Motion Made Easy” is more than just motion products. It is a complete strategy focused around providing a motion control system that is easy to Select, Setup, Program, and Service.

Easy selection is achieved through the scalable choice of Epsilon EP, EN, MDS, or the powerful Unidrive SP servo drives. Control Techniques makes motor and drive selection easier by providing motor and drive matched speed torque curves. Furthermore, cable and accessories selection is easy as all necessary components are provided in easy to read graphical diagrams.

Selecting motion capabilities is easy with the modular selection of Epsilon EP, which comes in base, indexing, or programming or the scalable FM modules for the EN and MDS servo drive families. Furthermore, the SM-EZMotion module fully integrates the Unidrive SP into the “Motion Made Easy” product family.

Selection is made easy with free CTSize software. Setup and Programming is made easy with the free, drag and drop, PowerTools software which programs the entire “Motion Made Easy” product family.

MATCHING CONTROLS TO APPLICATIONS

A properly matched servo drive and motor could run hundreds of different applications. What differentiates these applications is the type of control needed to insure the correct operation and performance.

The “Motion Made Easy” family of control modules allows you to specify the amount and type of control you need for your application. From simple speed control to complex synchronized motion control, you can choose a module with the features you need to get the high performance you expect from a Control Techniques drive.

Functions FM-2EP-I

FM-3 FM-4EP-P

SM-EZ

Analog Output 3 3 3 3

Custom Motors 3 3 3 3

Homing 3 3 3 3

Index Chaining 3 3 3 3

Indexing 3 3 3 3

Jogging 3 3 3 3

Linear Motors 3 3 3 3

Modbus Communications 3 3 3 3

Motor Brake Control 3 3 3 3

NVM Parameter Storage 3 3 3 3

Rotary Rollover 3 3 3 3

Software Watch Window 3 3 3 3

Torque Level Flags 3 3 3 3

Torque Limit 3 3 3 3

User Units 3 3 3 3

Compound Indexing 3 3 3 3

Gearing 3 3 3 3

Software Oscilloscope 3 3 3 3

Auto-tune 3 3 3 3

Analog Input Control 3 3 3

“Auto” Position Capture 3 3 3

DeviceNet Option 3 3 3 3

Ethernet Option 3 3 3

Feedhold 3 3 3

Feedrate Override 3 3 3

LCD Keypad/Display 3 3 3

PLS (Global and Index) 3 3 3

Profi bus Option 3 3 3

S-Curve Ramps 3 3 3

Secure Download 3 3 3

Synchronized Motion 3 3 3

Timed Index 3 3 3

User Programs 3 3 3

User Variables 3 3 3

Multiple Profi le Summation 3 3

Position Capture Object 3 3

Program Multi-tasking 3 3

Queuing 3 3

Dual Loop Mode 3

Absolute Encoder Feedback 3

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Virtual Wiring allows the User to map any input function to any output function.

Index Initiate

Index Select 0

Index Select 1

Index Select 2

Index Select 3

Registration Sensor 1

Registration Sensor 2

Run Next Index

Home Initiate

Home Sensor

Defi ne Home

Stop

Jog +

Jog –

Jog Fast

Travel Limit +

Travel Limit –

Torque Limit Enable

Brake Control

Brake Release

Reset

Alternate Mode Enable

End of Index Motion

End of Index

End of Index Count

End of Chaining Count

Registration Limit Distance Hit

End of Home

Absolute Position Valid

Home Limit Distance Hit

At Velocity

In + Motion

In – Motion

Drive OK

Fault

Travel Limit +

Travel Limit –

Foldback Active

Shunt Active (EN only)

Torque Limit Active

Brake

Power Stage Enabled

Torque Level 1 Active

Torque Level 2 Active

Torque at Max Velocity

Index In Position*

Power Module System Ready*

Drive Module Current Limt*

*MDS only

Input Functions Output Functions

EASY JOG SETUP

Select from two jogs, each with their own Velocity, Acceleration, and Deceleration. Select from Realtime or Synchronized (referenced to master encoder) timebase. Initiate Jogs from a user program, an Assignment (I/O Control), or a fieldbus.

FLEXIBLE YET SIMPLE HOMING ROUTINES

The advanced “Motion Made Easy” solutions include flexible yet easy homing routines. Define the reference type for the home function, selecting from Encoder Marker, Sensor, or Sensor then Encoder Marker. A completely dynamic home allows full programmability enabling users to define the Home Velocity, Acceleration, and Deceleration, as well as Home Offset (distance traveled after reference) and End of Home Position. Initiate from a user program, an Assignment, or from a fieldbus.

PowerTools Pro screen with unexpanded Hierarchy View on left.

EASY PROGRAMMING WITH POWERTOOLS

The free PowerTools software is designed to get “Motion Made Easy” base, indexing, and programming drives running in minutes, not hours. Easily confi gure basic drive and motor information via simple drag and drop windows. Select drive operating modes and setup preset velocities via the setup windows.

“Motion Made Easy” functionality includes simple jogging, homing, to more advanced indexing and motion programming.

EASY I/O SETUPAssigning functionality to I/O is a snap using the drag and drop I/O assignments window.

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FLEXIBLE AND SIMPLE UNITS SETUP

All motion is configured in user units which the user selects based on real machine parameters. Select inches, millimeters, degrees, or whatever your application calls for. Simply scale your units into units of revolutions once, and the rest is done for you.

MULTIPLE MOTION TYPES The Epsilon EP-P, FM-3, FM-4, and SM-EZMotion offer several different types of motion each with a flexible and simple setup.

Each motion is capable of having a realtime or encoder generated timebase and all are accessible via programs, I/O, PowerTools online screen, as well as Modbus, DeviceNet, Profibus, and Ethernet.

EASY MOTOR SELECTION AND TUNING

Select motor data for Control Techniques supported motors or use the motor auto tuning routine for third party motors.

SIMPLE TO COMPLEX INDEXING

A core component of “Motion Made Easy” is Indexing for simple to complex motion profiles. Indexing capabilities are available in the Epsilon EP-I, EP-P, and all FM modules. Easily setup a simple point to point index move or a more complex compounded move with registration triggered motion. Select from a variety of Index types, including Incremental, Absolute, Registration, Rotary +, Rotary -, and Timed Indexes. Define the timebase for each index individually (Realtime or Synchronized). Each Index contains its own Index PLS providing incremental limit switches outside of existing Global PLS’s.

PowerTools graphical interface makes it easy to select the type of index and enter settings. Easily enter index distance, velocity, acceleration and deceleration parameters. The resulting index motion profile is viewable via the graphical display.

Indexing takes on a new level with the registration and chaining capabilities. The added capabilities means it takes minutes and not hours to program complex motion applications. Applications which include on the fly master and slave synchronization such as a flow wrapper, labeling, flying shear, or any rotary cut-off type machines.

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GEARING

Perform electronic line shafting applications using the EP-P, FM-3, FM-4, or SM-EZMotion by defining a ratio between master and follower axes. Once a ratio is defined, follower axis motion is linked to master axis motion at a specified ratio while the gearing function is active. Master can change velocity and direction and follower maintains geared relationship.

POSITION CAPTURE OBJECT

Many high-speed applications require the ability to accurately capture a position at a specified moment in time, so that a motion profile can be initialized. Enter the Position Capture object. The capture component is fully controlled by the user and when activated it captures and stores (within 1 to 2 µsec): Time, Command Position, Feedback Position, and Master Feedback Position.

The Rotary Knife application uses an Epsilon EP-P to implement the Position Capture Object and Multiple Profile Summation. High speed position capture (1 to 2 µsec) allows the EP-P to catch sensor inputs with extreme accuracy.

Program Flow

If / Then / EndIf

Else

For Count / Next

Do While / Loop

Wait For

Wait For Time

Call Program

End

Formula

Label:

GoTo:

Motion

Dwell For Time

Dwell For MasterDist

Index.Initiate

Index.CompoundInitiate

Home.Initiate

Jog.Stop

Jog.PlusInitiate

Jog.MinusInitiate

Program.ProgramStop

Program.Initiate

Gear.Stop

Gear.Initiate

Motion Modifiers

Using Last

Programming Instructions

PROGRAMMING

Drag and Drop commands and parameters make programming the Epsilon EP-P, SM-EZMotion, FM-3, and FM-4 very intuitive. Commands are based on simple BASIC operations.

The multi-tasking microprocessors allow for multiple programs and programs can be assigned different tasks. This allows for prioritization of code and also for better program organization.

Easy to understand motion instructions make programming motion straight forward.

Programs are easy to set up, use our quick programming tools to drag and drop any command or parameter.

Rotary Knife

Epsilon EP-P

Sensor

CutterSealer

NT Motor

SCS-XEncoder

Wrapper Feed(Bottom)

Wrapper Feed(Top)

PLC withDeviceNetMasterCard

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QUEUING

Queuing is used when the ability to store data in a temporary memory location is needed. Up to eight Queues are available with the Epsilon EP-P, SM-EZMotion, and FM-4. Queues are generally found in applications where a sensor is located several product lengths ahead of the actual drive motion. The controller stores the captured position with an offset and accesses it using a built-in compare function.

High Speed Labeling

MASTER ENCODER SYNCHRONIZATION

Easily configure a single axis of simple or complex motion and have it coordinated with another axis of motion. The additional master encoder axis input makes applications, such as even distribution from a random infeed a snap.

MULTIPLE PROFILE SUMMATION

Motor motion or “Axis” motion may be generated from either of two Profiles: Profile.0 and Profile.1. Each of these Profiles can run any type of motion (Index, Jog, Gear, etc) at any time or both of the Profiles can generate motion simultaneously.

Random Infeed – Smartbelt

The Epsilon EP-P is used to speed up or slow down the motor. The product is dropped exactly in the desired position.

EN Serieswith FM-4

Sensor

Master AxisEncoder

NT Motor

CTVueOperatorInterface

PLC withProfibus

NT Motor

Labels

ProductSensor

MasterEncoder Peel Bar

PLC with Modbus TCP/IP

High Speed Labeler

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“One Source” for Motion ControlControl Techniques offers its motion control customers industry standard, specialized options and accessories from select leading companies to complement the wide breadth of products we manufacture. This allows our customers to obtain the very best solution from only “One Source” providing piece of mind in their selecting the very best motion solutions available in the industry.

Gearing OptionsCompact Gear Motors Precision or Value, Planetary Gears (inline or right angle)High Torque Worm Gears

Mechanical Cam / Servo Indexers (Rotary)Zero backlashHigh RepeatabilityVersatile mounting

High Performance Actuators (Linear)FastPowerfulPrecisionLong life

Servo Motor OptionsExplosion ProofFood GradeGear MotorsFeedback Options (resolver, sin/cos absolute en-coder)Customized fi nish, connectors, mountingWide range of IP RatingsHigh Flex Cables