Robo Cylinder Automation Examples Manual (Part 1) This publication was written to assist you in better understanding this part of your IA system. If you require further assistance,

Intelligent Actuator, Inc.

Robo Cylinder Automation Examples Manual (Part 1)

2

This publication was written to assist you in better understanding this part of your IA system. If you require further assistance, pleasecontact IA Technical Support. For Central and East Coast Time Zones, please call our Itasca, IL office at 1-800-944-0333 or FAX 630-467-9912. For Mountain and Pacific Time Zones, please call our Torrance, CA office at 1-800-736-1712 or FAX 310-891-0815;Monday thru Friday from 8:30AM to 5:00PM.

© Aug 2002 Intelligent Actuator, Inc. All rights reserved.No portion of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic,mechanical, recording, or otherwise, without the prior written permission of Intelligent Actuator, Inc.

DisclaimerThe information and technical data contained herein are subject to change without notice. Intelligent Actuator, Inc. assumes noresponsibility for any errors or omissions regarding the accuracy of the information contained in this publication.

Intelligent Actuator, Inc.

U.S. Headquarters2690 W. 237th StTorrance, CA 90505310-891-6015 / 310-891-0815 FAX

Central Region Office1261 Hamilton ParkwayItasca, IL 60143630-467-9900/ 630-467-9912 FAX

Eastern Region Office7 South Main St. Suite FMarlboro, NJ 07746732-683-9101 / 732-682-9103 FAX

www.intelligentactuator.com

Publication No: IAI-077

3

Table of Contents

Application Example 1 (Sorting items flowing on the cable track) · · · · · · · · · · · · · · · · · · · · ·4~11 Outline, the differences and benefits · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·4Movement flow (entire illustration) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·5System diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·6Control specifications, signal terminal diagram of the I/O · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·7The Robo Cylinder setting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·8Movement flow chart (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·9PLC ladder diagram (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·10

Application Example 2 (Liquid inserting work to multiple various shaped containers) · · ·12~19 Outline, the differences and benefits · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·12Movement flow (entire illustration) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·13System diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·14Control specifications, signal terminal diagram of the I/O · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·15The Robo Cylinder setting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·16Movement flow chart (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·17PLC ladder diagram (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·18

Application Example 3 (Drum roll device for wire material) · · · · · · · · · · · · · · · · · · · · · · · · ·20~27 Outline, the differences and benefits · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·20Movement flow (entire illustration) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·21System diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·22Control specifications, signal terminal diagram of the I/O · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·23The Robo Cylinder setting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·24Movement flow chart (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·25PLC ladder diagram (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·26

Application Example 4 (Stacking wrapped boxes flowing on a cable track) · · · · · · · · · · · ·28~35Outline, the differences and benefits · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·28Movement flow (entire illustration) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·29System diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·30Control specifications, signal terminal diagram of the I/O · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·31The Robo Cylinder setting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·32Movement flow chart (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·33PLC ladder diagram (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·34

Application Example 5 (Press-fit a lid onto a plastic container) · · · · · · · · · · · · · · · · · · · · · ·36~43 Outline, the differences and benefits · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·36Movement flow (entire illustration) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·37System diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·38Control specifications, signal terminal diagram of the I/O · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·39The Robo Cylinder setting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·40Movement flow chart (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·41PLC ladder diagram (for reference) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·42

4

Existing specifications:An air cylinder is used to push items traveling on a conveyor onto a different line.

Existing problems:The air cylinder causes damage when the rod tip plate impacts the item at high speed. Therefore,cycle time cannot be reduced because speed is restricted.

Machine Changes:Line diverter was modified from air cylinder to the Robo Cylinder.

Appropriate Robo Cylinder:RCS-SA5 Slider High Speed Type 400 stroke (Model type: RCS-SA5I-20-H-400)

Benefits:1) By decreasing the acceleration during start to 0.05G and setting speed to 800mm/sec, not only

is damage to the item from impact avoided, but also the item is quickly transferred to a separate conveyor reducing cycle time.

Speed Maximum 800mm/sec (Minimum setting of 1mm/sec)

Payload Horizontal: Maximum 4kgVertical: Maximum 1kg

Stroke Stroke 50~500mm (50mm increments)

Application Example 1:Device Function: To sort items traveling on a conveyorMovement: Line diverter

Speed · Acceleration Setting Function:Characteristics:

· The Robo Cylinder allows the speed allows the speed and acceleration to be set for each position with a numeric value. Speed is set in 1mm/sec increments (minimum input is 1mm/sec), and the acceleration is set in 0.01G increments (minimum input acceleration is 0.01G).

· By adjusting the velocity and acceleration on the fly, movement of the item is possible withoutcausing damage from the impact.

RCS-SA5Slider High Speed TypeSpecifications Range

5

1

23

4

9

RCSSA5-2001

645105645105

424010424010

9

RCSSA5-2001

645105645105

424010424010

9

RCSRB75-2001

645105645105

424010424010

9

RCSRB75-2001

645105645105

424010424010

9

RCSRB75-2001

645105645105

424010424010

Movement Flow:

1) Boxes are traveling across the conveyor.2) The bar code scanner reads the bar code of the box and determines whether or not sorting is

needed.3) When sorting is needed, the box reaches the set position, and the slider moves forward sliding

the box onto the opposite conveyor. 4 ) In case sorting is not needed, continues passing.

6

RCSController

I/O

Power Unit

Power

Power

Electrical Panel

PLCEmergencyStop Circuit

Work 1Work 1 Work 2 Work 1

M

Operation

End

Passing

RCSActuator

Passing Detection Sensor

Bar Code Reader

Conveyor DriveMotor

Operation Panel

RCS start movement

Work recognitiondue to power code reader

Passingdetection

2

N1

Y

RCS movementcomplete

N

Y

System startvia operation panel

Slider

System Diagram

< General Operation Flow Chart >

7

Control Specifications:1) Under normal circumstances, Servo ON Signal and Hold Signal are turned ON.2) When Robo Cylinder receives Operation Ready Signal from the Conveyor Control Sequence,

move to Position0*.3) Once the Sorting Signal is received from the Conveyor Control Sequence, move to position 1*. 4) When the Conveyor Control Sequence receives the Movement Complete Signal from the

Robo Cylinder, return the Robo Cylinder back to Position 0*. 5) Then, repeat steps, 3 and 4.6) If the Positioning Complete Signal does not turn ON within 2 seconds after the Robo Cylinder

Start Signal turns ON, the alarm will turn ON. 7) In case the Alarm Signal from the Alarm Signal turns OFF, the alarm LED will turn ON.

* Position 0 and 1 refer to No. 0 and 1 of the position data which is located within the controller.For further details, please refer to the section, “PC Display Screen,” located on the next page.

Note:1. The Hold Signal (normally ON) stops the Robo Cylinder’s movement due to the hold of the conveyor. To stop the

actuator, turn OFF the Hold Signal. To continue movement in progress, turn the Hold Signal back ON. To cancel the movement in progress, turn the Hold Signal back ON. To cancel the movement in progress, toggle the Reset Signal ON before turning back ON the Hold Signal.

2. The Operation Ready Signal and Sorting Signal from the Conveyor Control Signal will turn OFF once the RCScontrol sequence recognizes these Signals.

3. If the RCS is in alarm or emergency stop, the Conveyor Controller will not give a System Ready or Move Signal toany device on the controller.

4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel.5. This control is specifically for the Robo Cylinder controller.

PLC

Conveyor Control Sequence RCS Control Sequence

RCS Controller

Operation Preparation Start

Command Position 1

Hold

Reset

Servo ON

Complete Position 1

Positioning Complete

Homing Complete

Alarm

Moving

Emergency Stop

RDY

STR

ALRST

AL1

AL2

CSTR

PC1

*iLK

*ALM

*EMG

CN

RES

SON

PM1

PFiN

ZFiN

Sorting Signal

Alarm Reset

Alarm 1(Over time)

Alarm 2(RCS Alarm)

I/O Signal

8

Robo Cylinder Setting:

The operation for the Robo Cylinder is extremely simple. To move, all Robo Cylinder requires is toteach a position to an assigned number.

There are two method to teach positions:1. Numeric input (coordinate value)2. Input the coordinate value of the desired position by manually moving the slider or by machine

operation (JOG function).

Use either the PC Software or Teach Pendant to input the position data into the controller. The PCSoftware and Teach Pendant share the same content for teaching the basic columns (refer to the“PC Display Screen diagram shown at the bottom of the page).

Positioning between two points (in case of direct numeric input (coordinate value):

Set Position 0 at the motor side end (coordinate value 0) and Position 1 at the non-motor end(coordinate value 400), and execute a movement reciprocating between the two points.

1. Input the value “0” into the Position for No. 0. 2. Speed, the column next to Position of the PC display screen, will be the speed to move to

Position 0, so input your desired speed. Here, we input 800mm/sec. In the Speed Column, nextto the Position Column in the PC display screen, input the desired speed at which to move to Position 0. For this case, enter 800mm/sec.

3. Input the value “400” into the Speed Column for Position No. 1.4. Input the value “800” into the Speed column for Position No.1.

The above steps completes position data input.The other columns are required for other functions. Input is not necessary for this application.

Below is the Point Edit Screen located within the controller.

Position Data

9

Alarm detection

End

End

Servo ON Signal ON

Move to Position 0

Move to Position 1

Move to position 0 Time set

RCS ControllerAbnormal detection reset

RCS Controller Abnormal detection error

Over time

Over time reset

(Homing)

Stand by positionStand by

Sortingmovement

Operation prepareshoming

Hold Signal ON

OperationReady Signal

ON

Sorting SignalON

Operationend

Position 0positioningcomplete

Position 1positioning complete

N

Start Signal ON N

N

Y

Y

Y

Y

Y

Set Position 0, and turn StartSignal ON. In the initial commandafter power UP, execute home.

Wait for Operation Ready Signal from Conveyor Control Sequence.

Normally ON.

N

N

N


Y

N N

PositioningComplete Signal

ON

Time up

Y

Y

Y

NAlarm Signal

Y

NAlarm reset

Y

N

Wait for Sorting Signal from Conveyor Control Sequence.

Set position 1 and turn ONStart Signal.

Wait for Alarm ResetSignal from dispensercontrol sequence.

[Slide Flow Chart]

[Alarm Detection Flow Chart]

Movement Flow Chart (for reference)

Pusher

10

Servo ON

Hold

Complete Position Strobe Signal

Complete Position 0

Complete Position 1

Homing Start Pulse

Homing Start Pulse Support

Position 0 Positioning Start Support

Position 0 Start Confirm

Position 0 Positioning Complete

Position 1 Positioning Start Pulse

Positioning 1 Positioning Start Pulse Support

SON

Timer 1

R01

R02

R03

R04

R05

R06

*iLK

0.1sec

PFiN

Timer 1PM1

PM1

RDY R04

R03

R04

R03

RDY

ZFiN

R02 R12

R05

R06

Start WaitTimer 2

0.1sec

R05

PFiN

STR R09

R05 CN

R06

R07CSTR

Position 1 Start ConfirmR11

R10 CN

R11

R12CSTR

R07

R09

R08

R06

R07

R08R01

Position 1 Positioning Start SupportR10

R01

R10

R11R08

Positioning 1 Positioning CompleteR12

R11

R12

R05

R14

R02

R08

R09

STR

Position 0 SetR13

R05

R13

R10

R13 Position 1 SetR14

R10

Command Position 1PC1

Start SignalCSTR

R14

R14

R10

Positioning Over Time Timer 3

2sec

R15

R16

R05

Position 0 Positioning Over Time Detection SupportR15

R05

R15

R07

Position 1 Positioning Over Time Detection SupportR16

R10

R16

R12

PLC Diagram

Timer 1

Timer 2

The following is a basic circuit to control the Robo Cylinder. Therefore, it does not connect with the circuit that controls the entire machine. In addition, this circuit was not designed for a particular PLC manufacturer and instead, describes a Robo Cylinder controller circuit from a general circuit. When designing your circuit, please remember the aforementioned. Reference

11

Alarm 1 (Overtime)

Alarm 2 (RCS Alarm)

AL1

AL2

AL1

Timer 3

ALRST

AL2 ALRST

*ALM

Reference

12

Application Example 2:Device Function: To insert liquid into multiple types of containers that requires

speed changeMovement: Liquid Dispensing

Speed Change Function:

Characteristics: In the midst of moving to a desired position (assumed as P1), the Robo Cylinder allows the user tosend a signal to change to another position (assumed as P2). The Robo Cylinder cancels the moveto P1 and then continues onto P2 from the point where the signal was received.

Using the above function with P1 speed set to 100, P2 speed to 200, and designated position setthe same for the both points, speed will increase from 100 to 2000 without stopping.

Existing Specifications:When a major distance is set between the dispensing nozzle and the surface of the liquid in the container, the liquid will bubble. In order to prevent the bubbles, the dispensing nozzle must rise atthe same rate as the liquid in the container. The rate of the liquid rising increases when the crosssection of the container becomes smaller.

Existing Problems: Cam component adjustment is required for the dispensing nozzle to match the speed changes of therising liquid in the container slowing down cycle time.

Content Changes:By using the Robo Cylinder Rod Type, the speed setting for the nozzle is easily executed even with multiple types of containers.

Applicable Robo Cylinder:RCS-RA 55 High Speed Rod SlimType with 250 stroke (model type:RCS-RA55I-60-GN-H-250-B)

RCS-RA55Rod Slim High Speed TypeSpecifications Range

Benefits:1. Speed can be adjusted in 1mm/sec increments making efficient speed adjustment.2. Nozzle speed is easier to set when no adjustment of hardware is required.

Speed Maximum 800mm/sec (Minimum speed possible 1mm/sec)

Payload Horizontal: Maximum 12kg (*in case with guide)Vertical: Maximum 2kg

Stroke 50~300mm (50mm increments)

13

Movement Flow1. When the container flows on the conveyor and stops underneath the insert nozzle, the rod lowers

to the liquid insert start point.2. The rod (dispensing nozzle) rises at the same constant speed as the liquid in the container. 3. The speed of the rod (dispensing nozzle) will increase at the position where the container’s

cross-section becomes smaller. 4. After dispensing the liquid, the rod (dispensing nozzle) will move up to the stand-by position.

1

2

3

4

14

M

RCSController

I/O

Power Unit

Power

Power

Electrical Control Box

PLCEmergency StopCircuit

Operation

End

Conveyor stop

RCS start Nozzle lowers Conveyor start

RCS Actuator

Passing Detection Sensor

Dispenser

ConveyorDriverMotor

Work detectionsensor ON

N

Y

Nozzle loweringcomplete

N

Y

Time UpN

Y

Nozzle risingcomplete

N

YStop detection

N

Y


Dispenser ONliquid insert start

RCS startNozzle rises

Dispenser OFFliquid insert end

RCS startNozzle rises (high speed)

Nozzle rises (low speed)Timer ON

Operation Panel

System Diagram

[General Operation Flow Chart]

15

Control Specifications:1) Under normal circumstances, Servo ON Signal and Hold Signal are turned ON.2) When Robo Cylinder receives Operation Ready Signal from the Conveyor Control Sequence

move to Position 0* (stand-by position). 3) Move to Position 1* (liquid dispense start position) when the container is positioned by the

conveyor underneath the nozzle signaling the insert start command from the dispenser control sequence.

4) From the Positioning Signal of Position 1, the dispenser control sequence starts the liquid flowas the Robo Cylinder moves to Position 2*.

5) Upon move start to Position 2*, after 3 seconds (at the position where the cross section of the container becomes smaller), change the move position to Position 3*.

6) Upon completing the move to Position 3*, move to Position 0. 7) Repeat above steps, 3) ~ 6). 8) The alarm will turn ON if the Robo Cylinder takes over 5 seconds to return from Position 3* to

Position 0.9) When the Alarm Output (normally ON) turns OFF, the alarm LED will turn ON.

* Position 0 through 3 refer to No. 0 through 3 of the position data located within the controller.For further details, please refer to the section, “PC Display Screen,” located on the next page.

Note:1. The Hold SIgnal (normally ON) stops the Robo Cylinder’s movement due to a clog in the liquid dispenser. To stop the

actuator, turn OFF the Hold Signal. To continue movement in progress, turn the Hold Signal back ON. To cancel the movement in progress, turn the Reset Signal ON before turning back ON the Hold Signal.

2. The Operation Ready Signal and Insert Nozzle Start Signal from the Dispenser Control Sequence turn OFF afterconfirming the RCS RCS Controller recognized the Signals.

3. If the RCS is in alarm or emergency stop, the Dispenser Controller will not give a System Ready or Move Signal to any device on the controller.

4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel. 5. This program is specifically for the Robo Cylinder Controller.

PLC

Dispenser ControlSequence RCS Control Sequence

RCS Controller

Operation Ready Start

Command Position 1

Command Position 2

Hold

Reset

Servo On

Complete Position 1

Complete Position 2


Homing Complete

Alarm

Moving

Emergency Stop

RDY

STR

ALRST

AL1

AL2

CSTR

PC1

PC2

*iLK

*ALM

*EMG

CN

RES

SON

PM1

PM2

PFiN

ZFiN

Insert start

Alarm reset

Alarm 1(Overtime)

Alarm 2(RCS alarm)

I/O Signal Terminal Diagram

16


To change the speed without stopping during movement, send a separate position command. Forinstance, Position A is set to 300mm/sec, a move command is sent to Position B, which is ahead ofPosition A. Position B is set to 500mm/sec. Speed will increase from 300 to 500.

Speed Changes:When the speed is a direct numeric input, teach the position coordinate value by using the JOGfunction.

Position 0 is the stand-by station.Position 1 is the liquid dispensing start point.Position 2 is the passing point.Position 3 is the liquid dispensing end point.

1. After selecting No. 0, use the JOG (forward · backward) button to adjust the suitable position for the stand-by point. Once the position is determined, push the Teach Pointbutton to incorporate the current coordinate value into No. 0 Position.

2. Directly input 500 into the Speed of No. 0.3. Similar to step 1 after selecting No. 1, move the actuator with the JOG function and teach

the Liquid Dispensing Start Point. 4. Directly input 500 into Speed of No. 1.5. Apply the above step 1 to the Position of No. 2.6. Directly input 300 into the Speed of No. 2.7. Apply the above step 1 to the Position of No. 3.8. Directly input 500 into the Speed of No. 3.

From the above steps, position data input is completed.

· PC Display Screen:Below is the Point Edit Screen which located within the controller.

Position Data

Jog Button Teach Point Button

17

Liquid insert position control

Alarm detection

End

End

Servo Signal ON

Move to Position 0

Insert the reset

Move to Position 0

Move to Position 1

Move to Position 3

Insert nozzle complete

Move to Position 0

Moving time timer

Timer set

RCS Controller Abnormal detection


Overtime

Overtime reset

Stand-by position

(Homing)

Stand-by

InsertMovement

Operation ReadyHoming

Hold Signal ON

OperationReady Signal ON

Insert Nozzlecommand


Position 1PortioningComplete

N

Insert Start command

N

N

Y

Y

Y

Y

Time up

Y

Sets Position 0, and turn ONStart Signal.

Set position o and turn ON the Start Signal.

Set Portion 2and turn ON the Start Signal.

Set Position 3and turn ON the Start Signal.

Move at thespeed assignedin Position 2.

Move at thespeed assigned in Position 3.

Wait for Operation Ready Signal from dispenser control sequence.

Normally ON.

N

N

Position 3Positioning Complete

Y

N


Y

N

N

Operation End

Y

N

N

Insertcomplete

Time up

Y

Y

Y

NAlarm Signal

Y

NAlarm reset

Y

N

Wait for insert Nozzle command from dispensercontrol sequence.

The dispensercontrol sequenceturns ON due tothe positioningcomplete and begins insert.

[Liquid Dispensing Position Control]

[Alarm detection flow chart]

Movement Flow Chart (for reference)

Execute homing for the initialcommand after power UP.

18

Servo ON

Hold


Complete Position 0

Complete Position 1

Homing start pulse

Homing start pulse support

Position 0 start confirm

Position 0 positioning complete

Position 1 positioning start pulse

Position 1 positioning start pulse support

SON

Timer 1

R01

R02

R05

R06

R08

* iLK

0.1sec

PFiN

Timer 1PM1

PM1

RDY R06

R05

R06

PM2

PM2

PM2

PM2

RDY

Position 3 start waitTimer 2

3sec

R16

Position 0 positioning start supportR07

R05 ZFiN

R04 R19

R07

R08PFiN

STR R11

R07 CN

R08

R09CSTR

Position 1 start confirmR13

R12 CN

R13

R14CSTR


R15 CN

R16

R17

R18

CSTR

Position start confirmR18

R17 CN

R18

R19CSTR

R09

R11

R10

R08

R09

R10R01

Position 1 positioning start support R12

R01

R12

R13R10


R02

R15

R16R14

·Position 3 positioning completeR19

R18

R19

R07R04

Position 1 positioning completeR14

R13

R14

R15R02

R10

R11

STR

Position 3 start supportR17

R17

Timer 1

Complete Position 2

Complete Position 3

R03

R04

Timer 1PM1

PM1Timer 1

Timer 2

Reference

· PLC Ladder DiagramThe following is a basic circuit to control the Robo Cylinder. Therefore, it does not connect with the circuit that controls the entire machine. In addition, this circuit was not designed for a particular PLC manufacturer and instead, describes a Robo Cylinder controller circuit from a general circuit. When designing your circuit, please remember the aforementioned.

19

Command position 1PC1

R21

R23


R22

R23

Overtime detection supportR24

OK

R24

Position o setR20

R07

R20

R21 R22 R23R12 R15 R17

Position 1 setR21

R12

R21

R20 R22 R23R07 R15 R17

Position 2 setR22

R15

R22

R20 R21 R23R07 R12 R17

Position 3 setR23

R17

R23

R20 R21 R22R07

R25

R09

Start confirmR25

R24

R25

AL1

R09R15

ALRST

R12 R15

Start signalCSTR

Timer 2

Alarm 1 (Overtime)AL1

Timer 3

AL2 ALRST

*ALM Alarm 2 (RCS alarm)AL2

Star waitTimer 2

0.1sec

R07

Insert movement overtimeTimer 3

5sec

R24

R12

R15

R17

Reference

20

Application Example 3:Device Function: Wire feeder to roll on drum Movement: Position the wire material that is being drum rolled

Multiple Positions (Pitch) Function:

Characteristics: The incremental move function of the Robo Cylinder is a relative movement. The numeric value inthe position data* is incremented from the current position.

The procedure for the incremental movement is the same as a normal movement. By assigning theposition data* number and toggle the start signal input, the Robo Cylinder moves to the coordinatevalue. However, with the increment setting, the actuator increment [+] or [-] for only the amount inthe position data.

Existing Specifications:

Existing Problems: In cases where accuracy is not required, the current synchronized machine increased cost and pro-duction time; therefore, an easier and more affordable device is needed.

Machine Changes:Mount the wire on the Robo Cylinder Slider Type and move only in the needed area.

Appropriate Robo Cylinder:RCS-SA5 Slider High Speed Type 300 stroke (model type: RCS-SA51-20-H-300)

RCS-SA5Slider High Speed TypeSpecifications Range

Benefits:

1. Utilizing the Robo Cylinder’s pitch function, the price of rolling machine was reduced.

2. Programming of the machine became less complicated because the only a signal to thecontroller is required.

3. Machine change to different size of drums or wire thickness is now smoother. Only the increment amount needs to be changed in the Robo Cylinder controller.

* Position data is the position data that is input into the controller. For details,please refer to the “PC Display Screen” located on Page 21 of this manual.

Speed Maximum 800mm/sec (minimum setting of 1mm/sec)



21

Movement Flow1. By toggling the operation ready switch, the slider will move to the start position.2. By toggling the start switch, the drum begins rolling the wire and the actuator constantly

increments 10mm. 3. When the wire reaches the edge of the drum, the actuator increments at the same rate in the

opposite direction.4. Once the wire is completely wound, the Robo Cylinder stops.

1

2

2

3

4

22

M

ENC

[+]

[-]

RCSController

I/O

Power unit

Power

Power

Electric Panel

PLCEmergency stopcircuit

Operation

End

Drum rolling start

RCS ActuatorDrum driver motor

Drum rolling detection encoder

Start positionmove complete

N

Y

Rollingangle search

N

Y

Y

[+] pitchtransfer count

count up

N

[-] pitchtransfer count up

N

Y

Drumrolling counter up

N

Y

System start viaoperation panel

RCS startMove to start position

RCS start[+] pitch transfer

RCS start[-] pitch transfer

RCS startMove to stand-by position

Operationpanel

System Diagram


23

Control Specifications:1) Under normal circumstances, Servo ON Signal and Hold Signal are turned ON.2) When the Robo Cylinder controller receives Operation Ready Signal from the Drum Rolling

Controller, move to position 0*.3) When Robo Cylinder controller receives start position command from the Drum Rolling

Controller, move to Position 1.4) The incremental Signal from the Drum Rolling Controller pulses 1 time per roll at the same

rotating angle. 5. When the first row of wire is complete on then roll, from the control sequence, the reverse pitch

transfer command outputs. 6. Repeat steps 4) and 5) for the amount set into the Control Sequence. After receiving Roll

Complete Signal, move to Position 0 and wait for new drum. 7. The time out alarm will turn ON if the increment move does not complete in 1 second or if the

move to Position 0* does not complete within 5 seconds after roll complete signal.g8. The alarm LED indicator will turn ON when the Alarm Signal (normally ON) is turned OFF from

the Robo Cylinder. * Positions 0~3 refer to the No.0~3 of the position data located within the controller.

(For details, please refer to the section, “PC Display Screen” located on the next page of this manual.

Note:1. The Hold Signal (normally ON) will turn OFF when the drum stops. In order to continue with the move simply turn the

Hold Signal ON again. To cancel the move in progress, toggle the Reset Signal before turning ON the Hold Signal. 2. The start position transfer command, Rolling Complete Signal and the Operation Ready Signal from the Drum

Rolling Controller turn OFF when either the Increment Pulse Signal or RCS control recognizes the signal.3. If the RCS is in alarm or emergency stop, the Drum Roll Controller will not give a System Ready or Move Signal to

any device on the controller. 4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel. 5. The Drum Roll Controller checks for the Operation Ready Signal and the Start Move Signal. The RCS Controller

does not perform the check. 6. This program is specifically for the Robo Cylinder Controller.

Hold

Reset

Servo ON

Complete Position 1

Complete Position 2


Homing

Alarm

Moving

Emergency stop

MPiT

END

AL1

AL2

*iLK

ZFiN

CN

*ALM

*EMG

RES

SON

PM1

PM2

PFiN

Rolling complete

Alarm 1(Overtime)

- Incremental transfer(Reverse direction)

Alarm 2(RCS alarm)

ALRSTAlarm reset

PLC

Drum Rolling Controller RCS Controller

RCS Controller

Prepare operation Start

Command Position 1

Command Position 2

RDY

PPiT

CSTR

PC1

PC2+ Incremental transfer

STRStart location move

· I/O Signal Terminal Diagram

24

Robo Cylinder Setting:The Incremental move function of the Robo Cylinder is a relative movement. Thenumeric value in the position data* is incremented from the current position. Theprocedure for the incremental movement is the same as a normal movement. Byassigning the position data* number and toggle the start signal input, the RoboCylinder moves to the coordinate value. However, with the increment setting, the actuator increments [+] or [-] for only the amount in the position data.

Incremental Move Method (with direct numeric input of move amount):

Position 0 is the stand-by point.Position 1 is the start point (coordinate value 0).Position 2 is the increment amount in the positive direction (move amount 10).Position 3 is the incremental amount in the negative direction (move amount -10).

1) Input 0 into the position of No. 0.2) Input 500 into the speed of No.0.3) Input 100 into the position of No.14) Input 400 into the speed of No.1.5) Input 10 into the position of No.2.6) Input 300 into the speed of No.2.7) Input 1 into the incremental assign of No.2.8) Input 1 into the incremental assign of No.3.9) Input -10 into the position of No.3.

10) Input 300 into the speed of No.3.

The above steps complete position data input.

When in normal positioning mode (move distance from home), the incremental column value is0, and to increment move (distance from current position), the incremental column value is 1. Inthe above scenario, if you select to move to Position 1, the actuator move 100mm away fromhome, or if you select Position 2, the actuator moves 10mm in the positive [+] direction from thecurrent position (Position 3 move 10mm in the negative [-] direction).

·PC Display Screen:

The following screen shows the Point Data Edit Screen seen through the PC software.

Position Data

* To input a negative numeric value to aposition, first input 1into the incrementalassign.

25

Rolling drum incremental flow

Alarm detection

End

End

Servo ON Signal ON

Move to Position 0

Move to Position 1

Move to Position 2

Move to Position 3

Move to Position 0

Timer set

RCS controllerabnormal detection

RCS Controllerabnormal detection reset

Over-time

Overtime reset

Stand-by position

(Homing)

Stand-by

Rollingmovement

Operation preparesHoming

Hold Signal ON

Operation Ready Signal ON

Start positionmove command

Position 0Positioning Complete

Position 1Positioning

Position 2Positioningcomplete


complete

[+] incrementalmove command

N

N

N

N

Y

Y

Y

[-] Incrementalmove command

Y

Y

Y

Y

Y

Y

Rolling complete

Y

OperationEnd

Set Position 0and turn ON theStart Signal.

Set Position 1snf turn ON theStart Signal.

Wait for start position movecommand from rolling drumcontroller.

Wait for startposition move command from rolling drum controller.

Normally ON.

N

N

N

N

N

N

N

Position 0Positioningcomplete

Y

NN

N

Positioningcomplete signal ON

[-]Incremental

command

[+] Incmrental command

Time-up

Y

Y

Y

Y

NAlarm Signal

Y

NAlarm reset

Y

N

The rolling drumcontroller starts the drumrotation from this signal.

Incremental Signal from controller executes incremental move in [-] direction.

[Rolling Drum Incremental Flow Chart]


Movement Flow (For reference)

Execute homingfor the first commandupon homing.

Incremental Signal from controller executes incremental move in [+] direction.

26

Servo ON

Hold


Complete Position 0

Complete Position 1

Homing start pulse






SON

Timer 1

R01

R02

R05

R06

R08

*iLK

0.1sec

PFiN

Timer 1PM1

PM1

RDY R06

R05

R06

PM2

PM2

PM2

PM2

RDY

Position 3 positioning start pulseR20

MPiT


R05 ZFiN

R25 R04

R07

R08PFiN

STR R11

R07 CN

R08

R09CSTR


R12 CN

R13

R14CSTR

Position 2 start confirm R18

R17 CN

R18

R19CSTR

Position 2 positioning start pulse support R16

R15

R16


R18 R17

R19

R22

R21

R03

R09

R11

R10

R08

R09

R12R01


R01

R12

R13R10


PPiT

PPiT


R02

R03 R19

R17

R14 R15

R16

Position 1 positioning complete R14

R13

R14

R17

R18

R02

R10

R11

STR

PLC Ladder Diagram

Timer 1

Complete Position 2

Complete Position 3

R03

R04

Timer 1PM1

PM1Timer 1

Reference

The following is a basic circuit to control the Robo Cylinder. Therefore, it does not connect with the circuit that controls the entire machine. In addition, this circuit was not designed for a particular PLC manufacturer and instead, describes a Robo Cylinder controller circuit from a general standpoint. When desigining your circuit, please remember the aforementioned.

27

Start wait





Timer 2

R25

R21

R23

0.1sec

1sec

5sec

R07

Timer 2

END R26

R20

R21

END

MPiT

Position 0 positioning start pulse supportR26

R25

R26

Position 0 setR27

R07

R27

R12

R17

R22 CN

R23

R24CSTR


R03 R20

R22

R23R19

R04 R24

R24R23

R24

R22

R12 R17 R22 R28 R29 R30

Position 1 setR28

R12

R28

R07 R17 R22 R27 R29 R30

Position 2 setR29

R17

R29

R07 R12 R22 R27 R28 R30

Position 3 setR30

R22

R30

R07

R19

R12 R17 R27 R28 R29


R28

R30


Start SignalCSTR

R29

R30

Position 2 increment overtime detection supportR31

R17

R31

R24

R09

ALRST

Position 3 increment overtime detection supportR32

R22

R32

Pitch transfer overtimeTimer 3

R31

R32

Complete positioning overtime detection supportR33

Complete position positioning overtime Timer 4

END

R33

AL1

ALRSTAL2

*ALM

R33

R22

R07R04

Timer 3Alarm 1 (overtime)

Alarm 2 (RCS alarm)

AL1

AL2

Timer 4

Reference

28

Application Example 4:Device Function: Stacking boxes traveling on a conveyor Movement: Move down at a constant increment stacking a constant

number of boxes

Existing Specifications:The robot receives the box traveling on the conveyor and stacks them up until the set amount isreached then transfers the stacked boxes to the next machine.

Existing Problems: Increasing the line is not possible to decrease the cycle time.

Machine Changes:Use the increment function of the Robo Cylinder and lower the items in a constant amount in themiddle of the conveyor. Then stack the items one after another until the set amount is reached andsend them to the next station.

Appropriate Robo Cylinder:RCS-RA55 Low Speed Rod Type 300 stroke (model number: RCS-RA55I-100-GN-L-300B)

RCS-RA55Low Speed Rod TypeSpecifications Range

Benefits:1. Cycle time dramatically reduced.

2. The increment amount is adjustable to allow for multiple box sizes.

3. In comparison to an articulate robot system, cost is reduced.

Speed Maximum 200mm/sec (minimum setting is 1mm/sec)



Multiple Positions (Increment) Function:

Characteristics: The Incremental move function of the Robo Cylinder is a relative movement. The numeric value inthe position data* is incremented from the current position.

The procedure for the incremental movement is the same as a normal movement. By assigning theposition data* number and toggle the start signal input, the Robo Cylinder moves to the coordinatevalue. However, with the increment setting the actuator increments [+] or [-] for only the amount inthe position data.

29

Movement Flow1. The boxed item travels on the conveyor.2. After the box hits Stopper 1, the Robo Cylinder lowers the thickness of one box. 3. The next box traveling on the conveyor stacks on top of the previous box. Once the box hits

Stopper 1, the actuator lowers the thickness of one box again.4. Repeat above moves until the assigned number of boxes has been stacked. Then Stopper

2 rises and Stopper 1 lowers. The Robo Cylinder rises after the stoppers are done moving. 5. Once the Robo Cylinder rises parallel with the conveyor, the stacked boxes transfer to the next

packaging machine.

1

3

2

4

5

4

4

3

2Stopper 1

Stopper 2

30

M

System Diagram


RCSController

I/O

Power Unit

Power

Power

Electrical Control Box


Operation

End

Part count

Stopper 1 rises

Stopper 2 lowers

Stopper 1 lowers

Stopper 2 rises

RCS start RCS rises

RCSActuator

Part Detection Sensor

Part

Part

Part

Separate Packaging MachinePackaging Machine

Stopper 2Stopper 1

ConveyorDriveMotor

Part detection ON

N

Part detectionOFF

N

Y

Part countercount UP

Y

1 incrementalcomplete

NY

N

RCS risingcomplete

N

Y

Y

System start viaoperation panel

RCS start1 increment lowers via increment function

OperationPanel

31

· Control Specifications:1) Under normal circumstances, Servo ON Signal and Hold Signal are turned ON.2) After receiving Operation Ready Signal from the Packaging Controller, move to Position 0*. 3) Upon Position 0*, move complete, move the Robo Cylinder to Position 1 (stand-by position). 4) After Positioning Complete Signal of Position 1, the Packaging Controller raises Stopper 1 and lowers

Stopper 2. 5) When the part hits the stopper on the conveyor, the Packaging Controller counts the part. 6) Next, move to Position 2* after receiving Lower Command (increment=height of box). 7) Repeat steps, 5 and 6 until the value on the counter matches the preset amount. 8) Once the counter matches the preset amount, the Packaging Controller raises Stopper 2 and lowers

Stopper 1.9) Then, when given the Rise Command, the Robo Cylinder moves to Position 1 (stand-by position). 10) When the Robo Cylinder completes the move to Position 1, the rollers on the conveyor rotate sending

the part to the next packaging machine, 11) After the Part Detection Sensor turns OFF, Stopper 1 rises up, and Stopper 2 lowers.12) Repeat steps 5 through 11.13) If the Increment movement does not complete within 2 seconds, the alarm output will turn OFF.14) The alarm LED indicator will turn ON if the Alarm Output is turned OFF by the Robo Cylinder.

* Positions 0~2 refer to No. 0~2 in the position data stored in the controller. (For details, please refer to thesection,“PC Display Screen” which is located on the next page of this manual.)

Note:1. To stop the Robo Cylinder in the event of a part clog, turn OFF the Hold Signal (normally ON). turn OFF the Hold

Signal (normally ON). To continue the move in progress, run the Hold Signal ON. To cancel the move in progress, toggle the Reset Signal ON before turning ON the Hold Signal.

2. The Operation Ready Signal, Rise command, and Lower command from the Packaging Controller turn OFF when thePulse Signal or RCS controller recognizes the signals.

3. If the RCS is in alarm or emergency stop, the Conveyor Controller will not give a System Ready or Move Signal to any device on the controller.

4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel. 5. This control is specifically for the Robo Cylinder.

Hold

Reset

Servo ON

Complete Position 1

Complete Position 2


Homing Complete

Alarm

Moving

Emergency Stop

ALRST

AL1

AL2

*iLK

ZFiN

CN

*ALM

*EMG

RES

SON

PM1

PM2

PFiN

Alarm Reset

Alarm 1(Overtime)

Alarm 2(RCS Alarm)

PLC

Packaging Control Sequence RCS Control Sequence

RCS Controller


Command Position 1

Command Position 2

RDY

UP

CSTR

PC1

PC2Riser Command

DWNLower Command


32


Increment Function (Direct numeric input of coordinate value):

When a layer of box is 50 and is stacked up in 5 layers:

Position 0 is home (coordinate value of 0).Position 1 is the stand-by position (coordinate value of 300).Position 2 is the increment amount in the negative direction (move amount -50).

1) Input 0 into the position of No. 0.2) Input 100 into the speed of No.0.3) Input 300 into the position of No.1.4) Input 200 into the speed of No.1.5) Input 1 into incremental column of No.2.6) Input -50 into the position of No.2.7) Input 100 into the speed of Position No.2.

Position data is now complete.

For normal positioning (coordinate value from home), the Incremental Flag column is 0. The value 1in the Incremental Flag is for Increment Function. When Position 1 is selected, the rod moves300mm away from home. If Position 2 is selected, the rod will move 50mm back from the currentlocation.

PC Display Screen

The following screen is the Point Data Edit Screen located within the controller.

Position Data

To input a negativenumeric value into theposition, first input 1into the incrementalcolumn.

33

Work stacking

Alarm detection

End

End

Servo Signal ON

Move to Position 1

Increment Position 2 amount

Move to Position 1

Timer set

RCS ControllerAbnormal detection


Overtime

Overtime reset

Ready position

(Home)

Stand-by position

Stand-by

Pitchtransfer


Hold Signal ON

Operation ReadySignal ON

Loweringcommand

Position 0homing complete


N

Lowercommand

N

N

Y

Y

Y

Y

Positioning 2positioningcomplete


Y

Risecommand

Operationend

Y

Y

Set Position 0 and toggle theStart Signal.

Set Position 1 andtoggle the StartSignal.

Set Position 2 and toggle Start Signal(increment).

Wait for the OperationReady Signal fromthe packaging controller.

Wait for LowerSignal from packaging controller.

Normally ON.

N

N

N

N

Position 1move complete

Y

N

N

NTime Up

Y

Y

Y

NAlarm Signal

Y

NAlarm Signal

Y

N

Wait for the Alarm ResetSignal from the packagingcontroller.

[Work Stacking Flow Chart]


Movement Flow Chart (For reference)

If first command after power UP, execute home.

Move to Position 1

34

Servo ON

Hold


Complete Position 0

Complete Position 1

Homing start pulse




Position 1 start pulse

Position 1 start pulse support

SON

Timer 1

R01

R02

R04

R05

R07

*iLK

0.1sec

PFiN

Timer 1PM1

PM1

RDY R05

R04

R05

PM2

PM2

PM2

RDY


R04 ZFiN

R06

R07PFiN

UP R10

R06 CN

R07

R08CSTR


R11 CN

R12

R13CSTR


R16 CN

R17

R18CSTR

R08

R10

R09

R07

R08

R09

R12

R01


R12

R13

R14R02


R17

R18

R16R03


R02

R03

R16

R17

Position 2 start pulse R14

DWN R15

R14

R09

R10

UP

Position 2 start pulse support R15

R14

R15

DWN


R08

R09

R11

R01

R03

PLC Ladder Diagram

Timer 1

Complete Position 2R03

Timer 1PM1

Reference

The following is a basic circuit to control the Robo Cylinder. Therefore, it does not connect with the circuit that controls the entire machine. In addition, this circuit was not designed for a particular PLC manufacturer and, instead, describes a Robo Cylinder controller circuit from a general standpoint. When desigining your circuit,please remember the aforementhioned.

35

Start Signal

Start wait

Increment overtime detection support

CSTR

Position 0 setR19

R06

R19

R20 R21R11 R16

Position 1 setR20

R11

R20

R19 R21R06 R16

Position 2 setR21

PC1

PC2

R16

R21

Command Position 1R20

Command Position 2R21

R19 R20R06 R11

R22R16

R22

AL1

R18

ALRST

R06

R11

R16

Timer 20.1sec

Increment overtimeR22Timer 3

2sec

Timer 2

Alarm 1 (overtime)AL1

Timer 3

AL2 ALRST

Alarm 2 (RCS Alarm)AL2

*ALM

Reference

36

Application Example 5:Device Function: Press-fit a lid onto a plastic container Movement: Press-fit a lid onto a plastic container

Existing Specifications:The push functions ideal for press-fit and clamp applications because push power percentage canbe controlled.

Existing Problems: The supplied air pressure to the air cylinder fluctuates. When the air pressure is raised to increasethe speed of the rod, too much power is supplied causing damage to the product.

Modification Suggestion:Used an air cylinder to press-fit a lid.

Appropriate Robo Cylinder:RCP-RSA Rod High Speed Type 100 stroke (model type: RCP-RSAI-H-100-B)

RCP-RSARod High Speed TypeSpecifications Range

Benefits:1. Adjustable push power reduces part damage.

2. Cycle time is reduced by moving faster until right before the push point.

Speed Maximum 458mm/sec (1mm/sec minimum input speed)(Note: In case the stroke is 300mm, the maximum speed is 350mm/sec.

Payload Horizontal: Maximum 25kgVertical: Maximum 4.5kg


Push Function:

Characteristics: Although the Robo Cylinder is an electrical cylinder with an AC servo motor, pushing can be maintained similar to an air cylinder.

37

Movement Flow1. A box with its lid placed by the previous station flows on the conveyor.2. When the Part Detection Sensor sees the part, the Robo Cylinder lowers and presses the lid

into position.3. Once the press-fit is complete, the box moves to the next station, and the Robo Cylinder rises to

stand-by position.

1

3

23

2

38

M

RCPController

I/O

Power Unit

Power

Power

Electrical Control Panel


Operation

End

Conveyor stops

RCP actuator rise

Conveyor start

RCP Actuator

Part Detection Sensor

Conveyor Drive Motor

Part DetectionSensor ON

N

Y

Push completeN

Y

Risecomplete

N

YStopdetection

N

Y


RCP startActuator riser

Operation Panel

System Diagram

[Rough Operation Flow Chart]

39

Control Specifications:1) Under normal circumstances, Hold Signal is turned ON.2) Move to Position 0* upon receiving Operation Ready Signal from the Conveyor Controller.3) When the part on the conveyor reaches the point right underneath the Robo Cylinder, the Conveyor

Controller stops the conveyor and send the Press-fit command to lower the Robo Cylinder to Position 1. 4) After receiving the Positioning Complete Signal from Position 1, the Robo Cylinder returns to Position 1.5) Repeat steps, 3 through 4.6) If the Increment move does not complete within 2 seconds, the Alarm will turn OFF. 14) The Alarm LED Indicator will turn ON when the Alarm Signal Output is turned OFF from the Robo

Cylinder.

* Positions 0 and 1 refer to the No.0 and 1 of the position data located within the controller. (For details, please refer to the section, “PC Display Screen” located on the next page of this manual.

Note:1. The Hold Signal (normally ON) stops the Robo Cylinder’s movement due to the hold of the conveyor. To stop the

actuator, turn OFF the Hold Signal. To continue movement in progress, turn the Hold Signal back ON. To cancel the movement in progress, toggle the Reset Signal ON before turning back ON the Hold Signal.

2. The Operation Ready Signal and Press-Fit Move Signal from the Conveyor Controller will turn OFF once the RCPcontroller recognizes these Signals.

3. If the RCS is in alarm or emergency stop, the Conveyor Controller will not give a System Ready or Move Signal toany device on the controller.

4. After the alarm source is corrected, reset the alarm circuit on the Operation Panel. 5. This program is specifically for the Robo Cylinder Controller.

Hold

Complete Position 1


Homing Complete

Alarm

Emergency Stop

AL1

AL2

*iLK

ZFiN

*ALM

*EMG

PM1

PFiN

Alarm 1(Overtime)

Alarm 2(RCP Alarm)

PLC

Cable Control Sequence RCP Control Sequence

RCP Controller


Command Position 1

RDY

ALRST

CSTR

PC1Alarm reset

PUSHPress-Fit


40


Pitch Method (In case of direct numeric input (coordinate value):

Position 0 is home (coordinate value of 0).Position 1 is push start position (coordinate value of 300).Push power of Position 1 is set as 20% (approximately 2kgf).

1) Input 0 into the position of No. 0.2) Input 458 into the speed of No.0.3) Input 50 into the position of No.14) Input 458 into the speed of Position 1.5) Input 20 into the push of No.1.6) Input 30 into the positioning width of No.1.

Position data input is completed.

If numeric data is input into the Push Percentage Column and a Positioning width is specified, theactuator will move to the specified location at the designated speed and begin to push at a fixed lower speed to the specified distance at the push percentage. With the above specifications, theRobo Cylinder moves 50mm away from home at 458mm/sec, and from there, the Robo Cylinderpushes at a slow fixed speed within the 30mm range. Once it hits the part, the Push function turns ON the Positioning Complete Signal and continues pushing until reaching 2kgf.

PC Display Screen:

The below screen is the Point Data Edit Screen that is located within the controller.

Position Data

41

Press-Fit (Push)

Alarm detection

End

End

Move to Position 0

Move to Position 1

Move to Position 0

Timer set

RCP ControllerAbnormal detection

RCP ControllerAbnormal detection reset

Overtime

Overtime reset

(Homing)

Stand-by positionStand-by

Push movement


Hold ON

Operation ReadySignal ON

Press-fitcommand


N

Press-fitcommand

N

N

Y

Y

Y


complete

N

Y

Position 0positiong complete


Y

Operationend

Y

If first command after power UP, execute home.

Set Position 0 and toggle ON the Start Signal.

Set Position 1 and toggle ON the Start Signal (push movement).

Wait for OperationReady Signal from the Conveyor.

Wait for the Press-Fit Move Signal from the Conveyor Controller.

Normally ON.

N

N

N

NTimer up

Y

Y

Y

NAlarm Signal

Y

NAlarm reset

N

N


Y

N

Wait for the Alarm Reset Signal from the Conveyor Controller.

[Press-Fit (Push] Flow Chart]


Movement Flow Chart (Reference)

42

Hold


Complete Position 0

Complete Position 1

Homing Start Pulse

Homing Start Pulse Support

Position 0 Positioning Start Support

Position 0 Start Confirm

Position 0 Positioning Complete

Position 1 Push Start Pulse

Position 1 Push Start

Timer 1

R01

R02

R03

R04

R05

R06

*iLK

0.1sec

PFiN

Timer 1PM1

PM1

RDY R04

R03

R04

R03

RDY

ZFiN

R02 R12

R05

R06

Start waitTimer 2

0.1sec

R05

PFiN

PUSH R09

R05 PFiN

R06

R07CSTR


R10 PFiN

R11

R12CSTR

R07

R09

R08

R06

R07

R10R01

Position 1 push start supportR10

R01

R10

R11R08


R11

R12

R05

R14

R02

R08

R09

PUSH

Position 0 setR13

R05

R13

R10

R13 Position 1 setR14

R10


Start SignalCSTR

R14

R14

R10

Push overtime Timer 3

2sec

R16

R05

Push overtime detection support 1R15

R10

R15

R12

Push overtime detection support 2R16

R15

R16

R07

· PLC Ladder Diagram

Timer 1

Timer 2

Reference

The following is a basic circuit to control the Robo Cylinder. Therefore, it does notconnect with the circuit that controls the enire machine. In addition, this circuit wasnot designed for a particular PLC manufacturer and, instead, describes a Robo Cylinder controller circuit from a general standpoint. When desigining your circuit, please remember the aforementioned.

43

Alarm 1 (Overtime)

Alarm 2 (RCP Alarm)

AL1AL1 ALRST

*ALM

Timer 3

AL2AL2 ALRST

Reference

Intelligent Actuator, Inc.2690 W. 237th St.

Torrance, CA 90505(310) 891-6015 / (310) 891-0815 Fax

www.intelligentactuator.com

Documents

Robo Cylinder Automation Examples Manual (Part 1) This publication was written to assist you in better understanding this part of your IA system. If you require further assistance,