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Our G-MAS uses a CANopen virtual encoder to improve master-slave performance on advanced industrial printing machines. Find out how you can save money by using motion controllers virtual encoder.
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ECAM-Based Motion Control Solution for Printing & Textile Machines
Application Study
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Solution Application for
Different types of printing machines
Letterpress, electrostatic , screen printing (textiles, ceramics, metal, wood, paper, glass and plastic), offset printing, digital printing, label printing, flexo printing, CD and Wafer printing machines
Different types of textile machines
Knitting, weaving, weaving and braiding, etc.
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Machine Description For decoration of cylindrical plastic tubes using a silk screen and/or flexo printing technology. Uses 32 servo drives to operate axes at stationary stations located around 24 mandrels on a round table.
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There are 32 axes located on the stationary part of the machine.
There are 24 rotating mandrels arranged in a circular configuration on the main perimeter rotating platform.
Machine Description
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Main Perimeter Rotating Platform
Mandrels pass through stationary stations, each responsible for a different part of the printing process:
Tube feeding/tube removing
Heating
Cleaning
Coating
UV drying
I mark finding (capturing)
Printing
Etc.
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18-60mm mandrel
diameter
Direct motor cupling
Mandrels are driven by individual servo-motors (no gear).
Allows very simple and quick “change-over”
Enables high printing precision
Requires high-power/small-size drives, located behind the motor
Mandrel
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Transforming a mechanical CAM-based machine into an electrical ECAM.
Transferring high power and communication via special slip rings.
High speed of operation that ultimately results in a high-throughput machine.
One central electronic station to control all mcahine operations via serial communications channel.
Solution Challenges
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High performance of the System due to synchronization, speed, accuracy, etc.
High reliability, working in an EEC industrial vibrating environment.
Limited machine space.
Solution Challenges
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Host–G-MAS Communication
Host HMI station for controlling the machine via standard Modbus TCP/IP or EtherNet/IP channel.
Elmo Solution Highlights
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G-MAS real-time deterministic network-based master controller
Deterministic network management
Error handling
Callback functionality for fast processing of events
Management of ECAM functionality
And much more…
Multi-Axis Motion Controller
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Distributed CANopen fieldbus
Intelligent servo drives for enhanced and high overall system processing power
Synchronized cyclic ECAM mode of operation
High throughput up to 200 tubes/min
Network-Based Solution
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DS406 CAN encoder support
Virtual master encoder support
Virtual master axis (internal G-MAS virtual axis profiler)
Real master encoder (mapped via PDOs)
Elmo Solution Highlights
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Compact, high-power Elmo servo drives located in EEC vibrating environment
Elmo Solution Highlights
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High Precision & Fast I Mark Registration
I Mark Triggering
Auxiliary Position Scan
(ECAM table Entry from
Main station Encoder) of
one station
Mandrel Stop and
disengage from ECAM on
IMARK sensing
Mandrel Start It’s ECAM
following when engaging
the next station
Synchronization jitter is
<1mSec
Elmo Solution Highlights
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Real-time drive disengagement/engagement from ECAM table
Command to Disengage
on the next ECAM cycle
Disengage from ECAM
Engage to ECAM Table
without loosing
Synchronization
Command to Disengage
on the next ECAM cycle
Elmo Solution Highlights
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Advanced servo tools to achieve high motion performance on the single-axis drive level:
Frequency domain analysis
Advanced high-order filters
Elmo Solution Highlights
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ECAM_LeftRightUnit(Mandrel_Size, EndPos, FirstScan);
ECAM table profile calculation
Fast ECAM table downloading to each drive using fast asynchronous binary interpreter functions:
G-MAS Program Main Functions
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ConfigVirtualEncoder(MainAxisRef);
Virtual encoder options: Generated from a position profile of a virtual axis
Received from a master axis in the system via mapped RPDO
In both options, the G-MAS sends position data to a group of axes via TPDO3 or TPDO4
Virtual encoder configuration ENC_HIGH_POS, ENC_LOW_POS, ENC_GROUP_ID, ENC_ACTUAL_POS_MODE (PX)
ENC_TARGET_POS_MODE (PA, used in virtual axis)
G-MAS Program Main Functions
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ConfigAxisToRecieveVirtualEncoderPosition (iAxisCount);
Sending SDOs to configure all axes in the System into a CAN encoder special mode of operation
RPDO position mapping (via RPDO3 or RPDO4)
ECAM interpolation time setting
Interpolation on every sync
Set drive to Can encoder special mode(-3)
G-MAS Program Main Functions
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EcamTrigger();
Axis immediate home (BIN interpreter)
Axis ECAM triggering
MainAxisImmediateHome();
Master axis immediate home
StateFunction_1_PTPMotion();
Main axis PTP motion
G-MAS Program Main Functions
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Advanced motion and servo control
Distributed networking
Advanced drive level programming
High power density
High reliability
Rigidness
High efficiency
Complexity reduction
High machine throughput
Why Elmo?