e-drives Handbook and Technical Documentation TP 800

e-drives Handbook and Technical Documentation TP 800 680073 en 04/04

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: did@festo.com 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.

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

1. Introduction 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) Recommended accessories: 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. 4 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

2. TP 801 Servo motor equipment set Fig. 1: Assembled servo motor equipment set. The TP 801 Servo motor equipment set (Order no. 539016) consists of: Components Quantity Order no. 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 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 5

3. TP 802 Stepper motor equipment set Fig. 2: Assembled stepper motor equipment set. The TP 802 Stepper motor equipment set (Order no. 539015) consists of: Components Quantity Order no. 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 6 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

4. Extension Kits TP 801-E & TP 802-E 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. The TP 801-E Extension kit servo (Order no. 539017) consists of: Components Quantity Order no. Motor 1 678860 Motor Controller 1 538703 Cable 1 683032 Simubox 1 683011 Systainer size 3 1 526716 The TP 802-E Extension kit stepper (Order no. 539739) consists of: Components Quantity Order no. Motor 1 678835 Controller 1 678838 Adaptor 1 683033 Cable 1 683031 Systainer size 3 1 526716 Programming software 1 170097 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 7

5. Using the CD 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. 8 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

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. Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 9

6. Assembly of servo motor equipment set The following diagrams indicate assembly of the servo motor equipment set. 2 1 3 Fig 6: Assembly of servo motor equipment set. Item no. Components 1 Axis 2 Controller 3 Motor 10 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

6. Assembly of servo motor equipment set 4 5 Fig 7: Assembly of servo motor equipment set. Item no. Components 4 Power cable 5 Encoder cable Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 11

6. Assembly of servo motor equipment set 7 6 LIM+ 8 (2x) LIM- 9 Fig 8: Assembly of servo motor equipment set. Item no. Components 6 Mains plug 7 Test box 8 Limit switches 9 Power supply 24 V 12 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

7. Assembly of stepper motor equipment set The following diagrams indicate assembly of the stepper motor equipment set. 2 1 3 Fig 9: Assembly of stepper motor equipment set. Item no. Components 1 Axis 2 Controller 3 Motor Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 13

7. Assembly of stepper motor equipment set LIM+ 4 (2x) LIM- 5 6 Fig 10: Assembly of stepper motor equipment set. Item no. Components 4 Limit switch 5 Motor cable 6 Power supply 24 V 14 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

8. Exercises 8.1 Guidelines to exercises 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 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?" Resources The resources provide the exercise and solution documents as well as courseware to assist in the theory associated with the outcome. Exercises and solutions 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. Slideshows 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. Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 15

8. Exercises 8.2 Servo motor training aims Objectives & outcomes 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. 16 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

8. Exercises 8.3 List of exercises for servo motor training system Exercise 1 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. Exercise 2 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. Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 17

8. Exercises Exercise 3 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. Exercise 4 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. 18 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

8. Exercises Exercise 5 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 Exercise 6 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. Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 19

8. Exercises Exercise 7 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. 20 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

8. Exercises 8.4 Stepper motor training aims Objectives & outcomes 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. Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 21

8. Exercises 8.5 List of exercises for stepper motor training system Exercise 1 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. Exercise 2 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. 22 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

8. Exercises Exercise 3 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. Exercise 4 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. Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 23

8. Exercises Exercise 5 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. Exercise 6 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. 24 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

8. Exercises Exercise 7 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. Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 25

9. Training preparation Training room checklist This is a checklist of items that are needed in the training room. Description Comment Organiser / Training room Access & starting/finish times Electricity supply Safety glasses Beamer Spare bulb for beamer 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 for all participants if required PC projector ensure compatibility with your PC e.g. VGA 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 26 Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation

9. Training preparation Instructor checklist This is a checklist of items that the instructor needs to prepare and take to the course. Training resources Description Comment Quantity / PC with e-drives CD 1 PC software Pointer Internet Explorer or other browser, Adobe Acrobat Reader Overhead type, laser or telescopic pointer 1 Consumables Pens, pencils etc for participant 1 per participant Desk name cards Industrial catalog/product CD Participant handouts Supplementary resources As appropriate Printed copies of Reference and other files that participants are to receive 1 per participant 1 per participant 1 per Participant Customized resources Description Quantity / Festo Didactic GmbH & Co. KG TP 800 e-drives Handbook & Technical Documentation 27