e-drives handbook and technical documentation …...the cd should autostart when inserted into a...

680073 en

04/04

e-drives

Handbook and

Technical

Documentation

TP 800

Order no.: 680073

Edition: v1.0 (04/04)

Authors: Martin Williams, Thomas Häckel, Edward Gasper, David Hoey

Support: Stefan Grabein, José Leonett, Gerhard Nölle, Hans-Juergen Eberhardt

Layout: 30.06.04 Wolfgang Schreiner, David Hoey, Martin Williams

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf/Germany, 2004

Internet: www.festo.com/didactic

E-mail: [email protected]

The copying, distribution and utilization of this document as well as the

communication of its contents to others without expressed authorization is

prohibited. Offenders will be held liable for the payment of damages. All rights

reserved, in particular the right to carry out patent, utility model or ornamental

design registration.

© Festo Didactic GmbH & Co. KG • TP 800 e-drives – Handbook & Technical Documentation 3

1. Introduction___________________________________________________ 4

2. TP 801 Servo motor equipment set ________________________________ 5

3. TP 802 Stepper motor equipment set ______________________________ 6

4. Extension Kits TP 801-E & TP 802-E _______________________________ 7

5. Using the CD __________________________________________________ 8

6. Assembly of servo motor equipment set___________________________ 10

7. Assembly of stepper motor equipment set _________________________ 13

8. Exercises ____________________________________________________ 15

8.1 Guidelines to exercises _________________________________________ 15

8.2 Servo motor training aims_______________________________________ 16

8.3 List of exercises for servo motor training system_____________________ 17

8.4 Stepper motor training aims _____________________________________ 21

8.5 List of exercises for stepper motor training system___________________ 22

9. Training preparation___________________________________________ 26

Contents

4 © Festo Didactic GmbH & Co. KG • TP 800 e-drives – Handbook & Technical Documentation

Welcome to the Festo Didactic e-drives TP 800 Training Packages.

There are 4 Training Packages available:

1. TP 801 Servo motor equipment set (Order no. 539016)

2. TP 802 Stepper motor equipment set (Order no. 539015)

3. TP 801-E Extension kit servo (Order no. 539017)

4. TP 802-E Extension kit stepper (Order no. 539739)

Components Quantity Order no.

Either

Profile plate 700 x 350 mm 1 162386

Power supply 1 162417*

Or

Profile plate 350 x 250 mm 2 159333

Rubber feet (pack of 4) 1 158343

Profile plate connectors 2 162228

Power supply 1 162417*

* This is the part number for a power supply with European plug – refer to the Festo Didactic catalog for

the relevant part number for other countries.

1. Introduction

Recommended accessories:


Fig. 1: Assembled servo motor equipment set.


Axis 1 678837

Motor 1 678860

Controller 1 538703

Cable 1 683032

Simubox 1 683011

Systainer Maxi 1 539732

Technical Documentation 1 680073

CD-ROM 1 680074

2. TP 801 Servo motor equipment set

The TP 801 Servo motor

equipment set (Order no.

539016) consists of:


Fig. 2: Assembled stepper motor equipment set.


Axis 1 678837

Motor 1 678835

Controller 1 678838

Adaptor 1 683033

Cable 1 683031

Systainer Maxi 1 539732

Technical Documentation 1 680073

CD-ROM 1 680074

Programming software 1 170097

3. TP 802 Stepper motor equipment set

The TP 802 Stepper motor

equipment set (Order no.

539015) consists of:


The extension kits allow a user with servo or stepper to upgrade to a complete kit for

both servo and stepper with no duplication of generic hardware.


Motor 1 678860

Motor Controller 1 538703

Cable 1 683032

Simubox 1 683011

Systainer size 3 1 526716


Motor 1 678835

Controller 1 678838

Adaptor 1 683033

Cable 1 683031

Systainer size 3 1 526716

Programming software 1 170097

4. Extension Kits TP 801-E & TP 802-E

The TP 801-E Extension kit

servo (Order no. 539017)

consists of:

The TP 802-E Extension kit

stepper (Order no. 539739)

consists of:


The CD provided with this handbook was designed as a user-friendly interface to the

courseware and handbooks and manuals. It lists and organises the courseware into

exercises to be conducted on the hardware.

The CD should autostart when inserted into a DVD/CD drive. If it doesn’t autostart,

then open Windows Explorer and browse the CD. Double click the index.htm file

found in the root directory of the CD.

Use the navigators at the top and on the right of the page to explore the CD and its

contents.

The CD will work on any PC with a DVD/CD player but requires the following software

to view everything correctly:

• Internet Explorer (5 or higher) as browser

• Adobe Acrobat Reader

Note: When you select a slideshow from the CD (refer Fig. 3), the slide will open

within your browser as shown in Fig. 4. The slides are pdf and to open them in full

screen, go View > Full Screen as shown in Fig 4.

Fig. 3: Selecting a slideshow from a training outcome page on the CD.

5. Using the CD

5. Using the CD


Fig. 4: Opening the slide in full screen.

To revert back to a normal browser window, select the Restore button on the top

right of your window.

Fig. 5: Select Restore to revert to normal viewing in a browser.


The following diagrams indicate assembly of the servo motor equipment set.

3

1

2

Fig 6: Assembly of servo motor equipment set.

Item no. Components

1 Axis

2 Controller

3 Motor

6. Assembly of servo motor equipment set



4

5


Item no. Components

4 Power cable

5 Encoder cable



LIM+

8 (2x)

LIM-

9

6

7


Item no. Components

6 Mains plug

7 Test box

8 Limit switches

9 Power supply 24 V


The following diagrams indicate assembly of the stepper motor equipment set.

3

2

1

Fig 9: Assembly of stepper motor equipment set.

Item no. Components

1 Axis

2 Controller

3 Motor

7. Assembly of stepper motor equipment set

7. Assembly of stepper motor equipment set


4 (2x)

5

6

LIM-

LIM+

Fig 10: Assembly of stepper motor equipment set.

Item no. Components

4 Limit switch

5 Motor cable

6 Power supply 24 V


Each exercises builds on the previous one to achieve the overall learning outcomes

and therefore maybe considered as “one big exercise”. However, they have been

organised into outcomes to facilitate learning and integration into a training course.

The resources allow the instructor to progressively introduce the key concepts of

stepper and servo motor system installation, application and programming.

The outcome defines what the participant is expected to be able to do upon

successful completion of the exercise.

The Reason explains why the outcome is important for achieving the overall

objectives of the course and most importantly for the participant – "What is in it for

me?"

The resources provide the exercise and solution documents as well as courseware to

assist in the theory associated with the outcome.

The exercise is designed to achieve the learning outcome. The solution is provided

because due to safety and the inherent nature of stepper and servo motors, learning

is best done by participants implementing the provided solution.

Note that the exercise is provided on a separate page so the instructor can discuss

possible solutions before handing out the actual solution.

To support the practical exercises, slideshows are provided that may be used by the

instructor as required. They may be projected in the classroom and discussed or

printed and handed out as resources.

8. Exercises

8.1 Guidelines to exercises

Outcome

Reason

Resources

Exercises and solutions

Slideshows

8. Exercises


On the completion of these exercises, you can:

• Assemble a servo motor system

• Commission a servo system

• Conduct a reference move

• Use speed control

• Use position control

• Set ramps

• Use torque control

• Use electronic gears/synchronous speed control

• Describe the benefits and applications of each feature

The features and benefits of servo motor control need to be understood (and

experienced if possible) in order to be able to design, install, commission, maintain

and troubleshoot applications in industry.

8.2

Servo motor training aims

Objectives & outcomes

Reason

8. Exercises


Assembly of servo motor system.

You are able to correctly and safely assemble a servo motor system.

The correct and safe assembly of a servo motor system will familiarise you with the

various components of a system, the purpose of these components and how they

are connected together to form a functioning system.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Commissioning of servo system and introduction to Wmemoc.

You are able to correctly and safely commission a servo system using the main

commissioning functions of Wmemoc.

The correct and safe commissioning of a stepper system will familiarise you with the

software and associated settings that must be made before using the system.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

8.3

List of exercises for servo

motor training system

Exercise 1

Outcome

Reason

Notes

Exercise 2

Outcome

Reason

Notes

8. Exercises


Speed control in a servo motor system.

You are able to set the speed in a system and can explain the benefits of speed

control.

For safety reasons controllers include the speed control feature. You need to know

how to adjust it. When commissioning, it is good practice to test the motor in the

directions of rotation with the functions of the speed control.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Initiating a reference move.

You are able to conduct a reference move on a servo system.

To work accurately, servo systems need a reference point from which all positions

are calculated. This is done after commissioning before normal operation.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Exercise 3

Outcome

Reason

Notes

Exercise 4

Outcome

Reason

Notes

8. Exercises


Setting system positions, speeds and ramps.

You know how to define position sets and three ways of selecting positions.

The positions, speeds and ramps have to be defined before they can be called in a

program. Therefore it is important that you know how these parameters are defined

and stored in the system. It is also important to know

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Torque control.

You know how to control the torque of a system and know how to use torque control

in applications.

Torque control is an important feature and benefit that offers safety to man, machine

and products. It is important that you are familiar with it and how to make best use

of it.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Exercise 5

Outcome

Reason

Notes

Exercise 6

Outcome

Reason

Notes

8. Exercises


Use of Speed Synchronous Positioning.

You are familiar with the electronic gear of the system and can explain the concept

of synchronous movement and the electronic gear and know how to use it with

Wmemoc.

You are familiar with speed synchronous positioning and the features and benefits it

offers.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Exercise 7

Outcome

Reason

Notes

8. Exercises


On the completion of these exercises, you can:

• Assemble a stepper motor system

• Create a simple WinPISA program

• Commission a stepper system using WinPISA

• Describe the advantages and disadvantages of current reduction and how to set

it

• Conduct a reference move

• Use speed control

• Use position control

• Set ramps

The features and benefits of stepper motor control need to be understood (and

experienced if possible) in order to be able to design, install, commission, maintain

and troubleshoot applications in industry.

8.4

Stepper motor training aims

Objectives & outcomes

Reason

8. Exercises


Assembly of stepper motor system.

You are able to correctly and safely assemble a stepper motor system.

The correct and safe assembly of a stepper motor system will familiarise you with

the various components of a system, the purpose of these components and how

they are connected together to form a functioning system.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Commissioning of stepper system and introduction to WinPISA.

You are able to correctly and safely commission a stepper system using the main

commissioning functions of WinPISA.

The correct and safe commissioning of a stepper system will familiarise you with the

software and associated settings that must be made before using the system.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

8.5

List of exercises for stepper

motor training system

Exercise 1

Outcome

Reason

Notes

Exercise 2

Outcome

Reason

Notes

8. Exercises


Current reduction in a stepper motor system.

You are able to set current reduction and can explain the advantages and

disadvantages of current reduction.

Current reduction has advantages and disadvantages that you should understand

and be able to explain.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Starting the reference move via WinPISA and the Program Sequence in a Project.

You are able to conduct a reference move on a stepper system.

To work accurately, stepper systems need a reference point from which all positions

are calculated. This position is reset in the reference move.

The reference move is essential for the system to know the reference point for all the

required positions. It must be conducted:

• After powering up a stepper system.

• Whenever slippage (loss of steps) has occurred.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Exercise 3

Outcome

Reason

Notes

Exercise 4

Outcome

Reason

Notes

8. Exercises


Setting system speeds (velocity profiles).

You know how speeds are stored in the system and how they are called.

The speeds and positions have to be defined before they can be called in a program.

Therefore it is important that you know how these speeds are defined and stored in

the system.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Setting system positions.

You know how positions are stored in the system and how they are called.

The speeds and positions have to be defined before they can be called in a program.

Therefore it is important that you know how these positions are defined and stored

in the system.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Exercise 5

Outcome

Reason

Notes

Exercise 6

Outcome

Reason

Notes

8. Exercises


Setting ramps (with different profiles).

You know how to set the ramp up and ramp down for a move to a position.

Ramping the speed up and down is an important feature for providing smooth but

fast motion. You must know the benefits of ramps and how to set them.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Exercise 7

Outcome

Reason

Notes


This is a checklist of items that are needed in the training room.

Description Comment Organiser �/�

Training room

Access & starting/finish

times

Electricity supply Supply to PC, Beamer, and Training

Equipment

Electrical power: 230 V AC and 24 V DC,

3 plugs/Training place (2 for Training set and

1 for Laptop)

Safety glasses Safety glasses for all participants if required

Beamer PC projector – ensure compatibility with your

PC e.g. VGA

Spare bulb for beamer Ensure there is a spare bulb or contingency

plan (some bulbs are very expensive)

Whiteboard

Flipchart

Whiteboard markers &

eraser

Refreshments & meals Morning break, lunch, afternoon break

Other

9. Training preparation

Training room checklist

9. Training preparation


This is a checklist of items that the instructor needs to prepare and take to the

course.

Description Comment Quantity �/�

PC with e-drives CD 1

PC software Internet Explorer or other browser, Adobe

Acrobat Reader

1

Pointer Overhead type, laser or telescopic pointer

Consumables Pens, pencils etc for participant 1 per

participant

Desk name cards 1 per

participant

Industrial catalog/Product

CD

As appropriate 1 per

participant

Participant handouts 1 per

Participant

Supplementary resources Printed copies of Reference Notes and other

files that participants are to receive

Description Quantity �/�

Instructor checklist

Training resources

Customized resources

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