MELSEC FX Series

MITSUBISHI ELECTRIC MELSEC FX Series Programmable Logic Controllers Introduction to FX Positioning Control Systems Beginners Manual Art. no.: 214562 21 03 2014 Version C MITSUBISHI ELECTRIC INDUSTRIAL AUTOMATION Version check Beginners Manual Introduction to MELSEC FX Positioning Control Systems Art. no: 214562 A B C Version 05/2008 pdp - rw 08/2012 pdp - dk 03/2014 pdp - dk Revisions / Additions / Corrections First edition Addition of FX3G main units Addition of FX3GC, FX3GE and FX3S main units About This Manual The texts, illustration, diagrams and examples in this manual are provided for information purposes only. They are intended as aids to help explain the operation, programming and use of programmable controllers of the programmable logic controllers of the MELSEC FX1S, FX1N, FX2N, FX2NC, FX3G, FX3GC, FX3GE, FX3S, FX3U and FX3UC series. If you have any questions about the installation and operation of any of the products described in this manual please contact your local sales office or distributor (see back cover). You can find the latest information and answers to frequently asked questions on our website at https://eu3a.mitsubishielectric.com. MITSUBISHI ELECTRIC EUROPE BV reserves the right to make changes to this manual or the technical specifications of its products at any time without notice. ©05/2008 MITSUBISHI ELECTRIC EUROPE B.V. Safety Guidelines General safety information and precautions For use by qualified staff only This manual is only intended for use by properly trained and qualified electrical technicians who are fully acquainted with the relevant automation technology safety standards. All work with the hardware described, including system design, installation, configuration, maintenance, service and testing of the equipment, may only be performed by trained electrical technicians with approved qualifications who are fully acquainted with all the applicable automation technology safety standards and regulations. Any operations or modifications to the hardware and/or software of our products not specifically described in this manual may only be performed by authorised Mitsubishi Electric staff. Proper use of the products The programmable logic controllers of the FX1S, FX1N, FX2N, FX2NC, FX3G, FX3GC, FX3GE, FX3S, FX3U and FX3UC series are only intended for the specific applications explicitly described in this manual. All parameters and settings specified in this manual must be observed. The products described have all been designed, manufactured, tested and documented in strict compliance with the relevant safety standards. Unqualified modification of the hardware or software or failure to observe the warnings on the products and in this manual may result in serious personal injury and/or damage to property. Only peripherals and expansion equipment specifically recommended and approved by Mitsubishi Electric may be used with the programmable logic controllers of the MELSEC FX family. All and any other uses or application of the products shall be deemed to be improper. Relevant safety regulations All safety and accident prevention regulations relevant to your specific application must be observed in the system design, installation, configuration, maintenance, servicing and testing of these products. The regulations listed below are particularly important in this regard. This list does not claim to be complete, however; you are responsible for being familiar with and conforming to the regulations applicable to you in your location. ● VDE Standards – VDE 0100 Regulations for the erection of power installations with rated voltages below 1000 V – VDE 0105 Operation of power installations – VDE 0113 Electrical installations with electronic equipment – VDE 0160 Electronic equipment for use in power installations – VDE 0550/0551 Regulations for transformers – VDE 0700 Safety of electrical appliances for household use and similar applications – VDE 0860 Safety regulations for mains-powered electronic appliances and their accessories for household use and similar applications. FX Positioning Control Systems I ● Fire safety regulations ● Accident prevention regulations – VBG Nr.4 Electrical systems and equipment Safety warnings in this manual In this manual warnings that are relevant for safety are identified as follows: II m DANGER: b WARNING: Failure to observe the safety warnings identified with this symbol can result in health and injury hazards for the user. Failure to observe the safety warnings identified with this symbol can result in damage to the equipment or other property. MITSUBISHI ELECTRIC General safety information and precautions The following safety precautions are intended as a general guideline for using PLC systems together with other equipment. These precautions must always be observed in the design, installation and operation of all control systems. m DANGER: ● Observe all safety and accident prevention regulations applicable to your specific application. Always disconnect all power supplies before performing installation and wiring work or opening any of the assemblies, components and devices. ● Assemblies, components and devices must always be installed in a shockproof housing fitted with a proper cover and fuses or circuit breakers. ● Devices with a permanent connection to the mains power supply must be integrated in the building installations with an all-pole disconnection switch and a suitable fuse. ● Check power cables and lines connected to the equipment regularly for breaks and insulation damage. If cable damage is found immediately disconnect the equipment and the cables from the power supply and replace the defective cabling. ● Before using the equipment for the first time check that the power supply rating matches that of the local mains power. ● Take appropriate steps to ensure that cable damage or core breaks in the signal lines cannot cause undefined states in the equipment. ● You are responsible for taking the necessary precautions to ensure that programs interrupted by brownouts and power failures can be restarted properly and safely. In particular, you must ensure that dangerous conditions cannot occur under any circumstances, even for brief periods. ● EMERGENCY OFF facilities conforming to EN 60204/IEC 204 and VDE 0113 must remain fully operative at all times and in all PLC operating modes. The EMERGENCY OFF facility reset function must be designed so that it cannot ever cause an uncontrolled or undefined restart. ● You must implement both hardware and software safety precautions to prevent the possibility of undefined control system states caused by signal line cable or core breaks. ● When using modules always ensure that all electrical and mechanical specifications and requirements are observed exactly. FX Positioning Control Systems III IV MITSUBISHI ELECTRIC Table of Contents Table of Contents Safety Guidelines 1 The Basics of Positioning Control 1.1 What is positioning control? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Actuators for positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.3 Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Brake motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Clutch brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Stepping motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 DC servo system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 General purpose inverter and general purpose motor . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 AC servo system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Positioning method type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.3.1 1.3.2 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Position control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 2 Positioning by AC Servo System 2.1 Advantages for using an AC servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Examples of AC servo systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 Constant feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Tapping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Drilling in steel sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Index table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Lifter moving-up/down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Cart travel control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Carrier robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 3 Components of Positioning Control and their Roles 3.1 Positioning controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.1.1 3.1.2 3.1.3 3.2 Servo Amplifier and Servo Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.3 Command pulse control method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Basic parameter settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Zero point return function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Positioning control in accordance with command pulse . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Deviation counter function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Servo lock function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Regenerative brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Dynamic brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 3.3.1 3.3.2 Concept of drive system movement quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Setting the target position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 FX Positioning Control Systems V Table of Contents 4 Learning to Use the FX Family for Positioning Control 4.1 MELSEC FX PLC positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1.1 4.1.2 4.1.3 4.2 Inverter Drive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 4.2.1 4.2.2 4.2.3 4.3 Overview of control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Important buffer memory locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 FX2N-10GM and FX2N-20GM positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 4.5.1 4.5.2 4.5.3 4.6 Overview of control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Important buffer memory locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 FX2N-10PG positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 4.4.1 4.4.2 4.4.3 4.5 Overview of control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Using the MELSEC FX and FREQROL Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 FX2N-1PG-E positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 4.3.1 4.3.2 4.3.3 4.4 Overview of control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Important memory locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Program Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Overview of control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 Using dedicated software to set positioning for the FX2N-20GM . . . . . . . . . . . . . . . 4-53 Testing and monitoring operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59 FX3U-20SSC-H positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 Overview of control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61 Using dedicated software to set positioning for the FX3U-20SSC-H. . . . . . . . . . . . . 4-62 Testing and monitoring operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65 Important buffer memory locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67 Index FX Positioning Control Systems VI What is positioning control? The Basics of Positioning Control 1 The Basics of Positioning Control 1.1 What is positioning control? The positioning controller, together with the programmable logic controller, personal computer and operator interface, is one of the four main units of FA (factory automation). Among these units, the positioning controller plays an important role and is regarded as the center of the mechatronics field in which many senior engineers have been playing active roles. Positioning is all about motion, and motion often involves speed and precision. And since speed can be directly related to productivity, positioning is an area of much development. When the speed of a machine increases, a problem with the stop precision is often generated. In order to solve this problem, diversified grades of positioning controllers have been required and developed. Improving machine efficiency generates immeasurable added value, including reduced labor costs and improved conservation of machine floor space for the same quantity of production. If there are no problems related to the positioning aspect of a machine, it may mean that the machine is not running as efficiently as it could be. This is where the science of developing and retrofitting an optimum positioning control system comes in. FX Positioning Control Systems 1-1 The Basics of Positioning Control 1.2 Actuators for positioning Actuators for positioning The options available for positioning control depend on the type of actuator driving the system. An actuator is a mechanical device that moves or controls a specific element or a series of elements within a system. In a mechanical system, an actuator is often used with a sensor to detect the motion or position of a workpiece. The following illustrations provide examples of diversified actuators, their features and their weak points. 1.2.1 Pneumatic Features and Drawbacks ● Air source and high grade piping are required. ● High torque is not available. ● Multi-point positioning is complex and very difficult to achieve. ● Change in positioning is difficult. Fig. 1-1: Piping Air cylinder Schematic drawing Pneumatic Workpiece Compressor 120010da.eps 1.2.2 Brake motor Features and Drawbacks ● Positioning mechanism is simple. ● Repeatability is poor. ● Change in positioning is difficult. (When optical sensors or limit switches are used for stop) Fig. 1-2: Schematic drawing Brake motor Motor with brake Limit switch 120020da.eps 1-2 MITSUBISHI ELECTRIC Actuators for positioning 1.2.3 The Basics of Positioning Control Clutch brake Features and Drawbacks ● Frequent positioning is possible. ● Life of friction plate is limited. ● Change in positioning is difficult. (When optical sensors or limit switches are used for stop) Fig. 1-3: Constant quantity feed hopper Speed reducer Schematic drawing Clutch Brake Clutch brake unit Optical sensor Motor 120030da.eps 1.2.4 Stepping motor Features and Drawbacks ● Simple positioning mechanism. ● If load is heavy, motor may step out and displacement can occur. ● Motor capacity is small. ● Precision is poor at high speed. Fig. 1-4: Schematic drawing Stepping motor Controller Stepping motor 120040da.eps FX Positioning Control Systems 1-3 The Basics of Positioning Control 1.2.5 Actuators for positioning DC servo system Features and Drawbacks ● Positioning precision is accurate. ● Maintenance is required for motor brushes. ● It is not suitable for rotation at high speed. Fig. 1-5: DC servo amplifier Schematic drawing DC servo system DC servomotor 120050da.eps 1.2.6 General purpose inverter and general purpose motor Features and Drawbacks ● Multi-speed positioning is available using a high-speed counter. ● High precision positioning is not available. ● Large torque is not available at start. (Specialized inverter is required) Lifter Motor with brake Fig. 1-6: Schematic drawing General purpose inverter and general purpose motor General-purpose inverter 120060da.eps 1-4 MITSUBISHI ELECTRIC Actuators for positioning 1.2.7 The Basics of Positioning Control AC servo system Features and Drawbacks ● Positioning precision is good. ● Maintenance is not required. ● Positioning address can be easily changed. ● It is compact, and offers high power. Fig. 1-7: Schematic drawing AC servo system Cutter Sheet material AC servo motor AC servo amplifier 120030da.eps FX Positioning Control Systems 1-5 The Basics of Positioning Control 1.3 Positioning method type Positioning method type In general, there are two methods to control the movement of a workpiece: speed control and position control. For basic, more rudimentary positioning, speed control can be used with an inverter and general purpose motor. For systems where precision is a must, servo systems are required for the advanced handling of pulse commands. 1.3.1 Speed control Limit switch method Two limit switches are provided in places where a system’s moving part passes. At the first limit switch, the motor speed is reduced. At the second limit switch, the motor turns off and the brake turns on to stop the moving part. In this method, because position controllers are not required, the system configuration can be realized at reasonable cost. – Guideline of stopping precision: Approximately ±1.0 to 5.0 mm (The stop precision shows a value in a case where the low speed is 10 to 100 mm/s.) Inductive motor Brake B Moving part Ball screw IM Limit switch for changeover to low speed Inverter INV Limit switch for stop High speed 0 to 10 V DC Low speed Movement distance 120080da.eps Fig. 1-8: Schematic drawing – Limit switch method 1-6 MITSUBISHI ELECTRIC Positioning method type The Basics of Positioning Control Pulse count method A position detector (such as a pulse encoder) is set up in a motor or rotation axis. The pulse number generated from the position detector is counted by a high-speed counter. When the pulse number reaches the preset value, the moving part stops. In this method, because limit switches are not used, the stop position can be easily changed. – Guideline of stopping precision: Approximately ±0.1 to 0.5 mm (The stop precision shows a value in a case where the low speed is 10 to 100 mm/s.) Inductive motor Pulses are fed back Moving part Ball screw PLG IM Pulse generator Inverter INV DC 0 to 10 V High speed Programmable controller PLC Low speed High speed counter unit Movement distance 120090da.eps Fig. 1-9: Schematic drawing – Pulse count method In speed control applications with inverters, stop precision is not very accurate. With the limit switch method, a system operates without any feedback to the controller to indicate the location of the workpiece. With the pulse count method, the speed can be changed and the stop command can be executed at specific distances (at specific timings) according to the feedback from the pulse generator connected to the motor. Both the limit switch method and the pulse count method, however, are subject to a loss in stop precision due to the dispersion of distance that occurs for workpieces at different speeds. ● When automatically stopping a moving part driven by a motor, stop the motor by a position signal (using a limit switch or pulse count comparison). In general conditions, turn on the brake at the same time. FX Positioning Control Systems 1-7 The Basics of Positioning Control Positioning method type ● The moving part continues by a coasting distance until it completely stops, after the stop command is given. The coasting distance is not controlled and it is represented as the shaded part in the figure below. Fig. 1-10: Positioning pattern Speed Coasting distance Time Stop Stop command 1200b0da.eps ● Dispersion in the stop distance changes as shown below. Dispersion is affected by the speed of the workpiece when the stop command is given and the speed reduction time delay after stop. Fig. 1-11: Positioning pattern Speed Speed recuction start Time delay Dispersion in stop Time Stop command Stop Stop 1200c0da.eps ● If the required stop precision is not satisfactory when stopping from the normal operation speed, the most effective method to improve the stop precision is to reduce the operation speed. However, if the operation speed is simply reduced, the machine efficiency may also be reduced. Therefore, in actual operation, the motor speed can be reduced from a high speed to a low speed before the motor is stopped, as shown below. Speed High speed Speed Time delay Poor stop precision High speed Low speed Improved stop precision Time Stop command Stop Speed reduction command Time Stop Stop command 1200d0da.eps Fig. 1-12: Positioning pattern 1-8 MITSUBISHI ELECTRIC Positioning method type 1.3.2 The Basics of Positioning Control Position control Pulse command method An AC servo motor which rotates in proportion to the input pulse number is used as the drive motor. When the pulse number corresponding to the movement distance is input to the servo amplifier of the AC servo motor, positioning can be performed at high speed in proportion to the pulse frequency. – Guideline of stopping precision: Approximately ±0.01 to 0.05 mm (The stop precision shows a value in a case where the low speed is 10 to 100 mm/s.) Servo motor Pulses are fed back Moving part Ball screw PLG SM Pulse generator Servo amplifier Programmable controller PLC Position controller Movement distance 1200a0da.eps Fig. 1-13: Schematic drawing – Pulse command method Using the pulse command method with a servo amplifier, the weak points described above for speed control are improved. A pulse encoder is attached to the servo motor to detect the motor rotation quantity (workpiece movement distance) and feed the information directly to the servo amplifier in order to continuously and directly control the high-speed positioning operation to the target position. This method allows the workpiece to stop with better precision and eliminates the coasting and dispersion distance at stop. Furthermore, limit switches to stop normal positioning operations, along with counting methods from the PLC are not needed. FX Positioning Control Systems 1-9 The Basics of Positioning Control 1 - 10 Positioning method type MITSUBISHI ELECTRIC Advantages for using an AC servo system Positioning by AC Servo System 2 Positioning by AC Servo System 2.1 Advantages for using an AC servo system With an AC servo system, positioning can be performed by many diversified methods. Typically, a position controller, servo amplifier and servo motor are required for positioning with an AC servo system. The representative servo system configuration is shown below. Servo amplifier Commercial power supply Converter Smoothing circuit AC  DC DC Command pulse Positioning controller Deviation counter DC  AC Speed command SM PLG Feedback current Encoder Current control The positioning controller generates a specified quantity of forward rotation (or reverse rotation) pulses at a specified frequency. Servo motor Inverter PWM (pulse width modulation control The command pulse number is subtracted by the feedback pulse number, and the speed command to drive the servo motor is made from the deviation (accumulated pulse number). When the accumulated pulse number becomes 0, the servo motor stops. Feedback pulse The servo motor is equipped with a built-in encoder (pulse generator), dedicated to high speed response, and suitable for positioning control. 210010da.eps Fig. 2-1: Block diagram of an AC servo system In the latest AC servo systems, conventional weak points have been improved as follows: ● Although the latest systems are completely digital, they are equipped with parameters in conformance to diversified mechanical specifications and electrical specifications so that simple set-up is possible. ● As frequent operation is enabled by a low inertia motor, the maximum torque is increased and the system can be applied to a wide variety of machines. ● The latest systems are equipped with an auto tuning function, with which the servo amplifier automatically detects the load inertia moment and adjusts the gain. This is possible even if the load inertia moment is unknown. ● The command communication cycle from the controller to the servo amplifier is improved for synchronization accuracy and better speed/positioning accuracy. ● The latest systems also allow for long-distance wiring, reduced noise resistance, and simplified wiring. The top advantages to using an AC servo system are described below. Compact and light servo system Robust servo system In the FA workplace, a down- In accordance with severe sized AC servo system occu- operation conditions, a pying less space is beneficial. tougher AC servo system is often required. FX Positioning Control Systems Easy servo system Good cost performance servo system AC servo systems are easier to handle than hydraulic equipment. Easy systems are also flexible for new staff. An AC servo system with good cost performance saves a company in overall engineering costs. 2-1 Positioning by AC Servo System 2.2 Examples of AC servo systems Examples of AC servo systems Positioning indicates the operation to move an object, such as a workpiece or tool (drill or cutter), from one point to another point and to stop it with efficiency and precision. In other words, the principle of positioning is the control of speed in accordance with the position, performed to promptly eliminate the remaining distance to the target position. The flexibility to change the target position electrically and easily is an important requirement. Several cases of positioning using an AC servo motor are systematically shown below. 2.2.1 Constant feed Description In the press/shear process for cutting, punching, etc., the processed material is positioned with high precision to produce a constant sized product. Fig. 2-2: Press main unit Schematic drawing Constant feed Roll feeder Uncoiler 220010da 2.2.2 Tapping Description In order to tap a workpiece,  Quick feed  Cutting feed and  Quick return are performed repeatedly. Fig. 2-3: Workpiece Drill Schematic drawing Tapping M Slide Timing belt Cutting feed Quick feed Ball screw M Pulley 2-2 Feed motor Quick return 220020da.eps MITSUBISHI ELECTRIC Examples of AC servo systems 2.2.3 Positioning by AC Servo System Drilling in steel sheet Description In order to perform processing on a flat face, positioning with high precision is performed by two motors (X axis feed motor and Y axis feed motor). Fig. 2-4: Drilling Drill unit X axis Schematic drawing Drilling in steel sheet Y axis Workpiece X-Y table M M X axis feed motor Y axis feed motor 200030da.eps 2.2.4 Index table Description The position of the circular table is indexed. The index position is set on the outside (digital switch) or the inside (program). Shortcut drive is performed depending on the index position. Fig. 2-5: Index table Schematic drawing Index table Worm wheel Servo motor 200040da.eps FX Positioning Control Systems 2-3 Positioning by AC Servo System 2.2.5 Examples of AC servo systems Lifter moving-up/down Description As negative load is applied on the servo motor in positioning of the lifter in the vertical direction, a regenerative option is also used. In order to hold the lifter stationary and prevent drop of the lifter by power interruption, a servo motor with an electromagnetic brake is used. Fig. 2-6: Servo amplifier Schematic drawing Lifter moving-up/down Lifter Regenerative option Servo motor 200050da.eps 2.2.6 Cart travel control Description A servo motor is mounted in the travel cart as the drive source. A mechanism such as rack and pinion is adopted to prevent slippage between the wheels and rails. Fig. 2-7: Cart Schematic drawing Cart travel control Drive wheel (on each of left and right sides) 200060da.eps 2-4 MITSUBISHI ELECTRIC Examples of AC servo systems 2.2.7 Positioning by AC Servo System Carrier robot Description After the conveyor stops, the 2-axis servo system and the arm lifting mechanism transfer workpieces to a palette. The workpiece input positions on the palette can be set to many points so that setup change can be easily performed, even if the palette position and the palette shape change. Fig. 2-8: Travel head Y direction Schematic drawing Carrier robot Servo motor to drive slide arm Slide arm Pallet Workpiece Conveyor A Servo motor to drive travel head 200070da.eps FX Positioning Control Systems 2-5 Positioning by AC Servo System 2-6 Examples of AC servo systems MITSUBISHI ELECTRIC Components of Positioning Control and their Roles 3 Components of Positioning Control and their Roles Positioning control requires a number of components such as a positioning controller, servo amplifier, servo motor and drive mechanism. This section describes the role of each component. To begin, the following two-page spread illustrates how the seven key elements function together to perform positioning. FX Positioning Control Systems 3-1 Components of Positioning Control and their Roles Postion controller AC power supply 앫 Outputs the positioning speed and the movement quantity in command pulses to the servo amplifier. 앫 Transfers signals between the programmable controller. 앫 Controls return to the zero point. Power factor improving AG Breaker Electromagnetic contactor Radio noise reactor filter Line noise filter Powerboard 앫 Improves the power factor and cuts noise. 앫 Protects the power circuit. Nearpoint DOG signal In some types, the limit switch signal is wired to the position controller Main circuit Servo amplifier Position controller Smoothing circuit Converter Positioning command control AC DC Regenerative brake DC Inverter Dynamic brake DC AC R Command pulse Parameter Pulse magnification Zero point return control Deviation counter Speed command Current control (Electronic gear) Counter clear Feedback current PWM (pulse width modulation) control Feedback pulse Servo ready Zero point signal (PGO) Servo amplifier 10 0 90 80 70 60 Operation switch Manual pulse generator 앫 Rectifies the AC power of the main circuit into the DC power in the converter, and smooths it in the smoothing circuit. When the DC power is converted into AC power in the inverter, the current supplied to the servo motor is changed by the PWM (pulse width modulation) control in the control circuit. 앫 The deviation counter receives and counts the command pulses from the positioning controller, subtracts the feedback pulses from them, then drives the servo motor until the accumulated pulse number becomes 0. Operation equipment 앫 Gives inputs for manual/automatic mode, start/stop, zero point return command, manual forward rotation/reverse rotation and manual pulse generator to the positioning controller. 300010da.eps Fig. 3-1: Components of Postioning Control (1) 3-2 MITSUBISHI ELECTRIC Components of Positioning Control and their Roles Servo motor 앫 Dedicated to high speed response optimal to positioning control, has large start torque, large maximum torque and wide variable speed range 1/1 or more (1/1,000 to 1/5,000). When a moving element goes beyond a limit switch (LS), the motor stops. Servo motor In the case of large motor Cooling fan Limit switch (LS) Servo motor SM Nearpoint dog switch Moving element Limit switch (LS) Speed reducer Ball screw PLG When required Encoder (pulse generator) Electromagnetic brake Auxiliary device such as chuck, drill and cylinder Sensor, actuator, auxiliary device Hand help programmer Personal Computer 앫 The actuator (moving part drive mechanism) is equipped with speed reducer, timing belt, ball screw and limit switch. 앫 Diversified auxiliary devices are also controlled in accordance with positioning. 앫 The PLC or the positioning controller also controls auxiliary devices. 앫 The auxiliary device operation completed signal is output to the PLC or the position controller. Setting / display unit 앫 Used to write programs to the position controller, allows setting and display of the data. 300020da.eps Fig. 3-1: Components of Postioning Control (2) FX Positioning Control Systems 3-3 Components of Positioning Control and their Roles 3.1 Positioning controller Positioning controller Positioning controllers use programs and parameters to send positioning commands to the servo amplifier. Contents related to programs and parameters are described below. 3.1.1 Command pulse control method There are two types of control formats used for outputting command pulses from an FX Series positioning controller: ● PLS/DIR (Pulse/Direction) method ● FP/RP (Forward Pulse/Reverse Pulse) method Each method requires two outputs from the controller to control specific signals for direction and pulse control. A third method, known as the A phase/B phase method, uses overlapping pulse signals to specify direction. PLS/DIR method In the PLS/DIR method, one output sends pulses to the drive unit while the other output specifies the direction of travel. Forward rotation Output # 1 Pulse train H L Output # 2 Direction H L ON  Reverse rotation Fig. 3-2: Timing diagram OFF  311010da.eps  "ON" and "OFF" represent the status of the controller’s output. "H" and "L" respectively represent the HIGH status and the LOW status of the waveform. The command pulse pattern in the figure assumes negative logic. FP/RP method In the FP/RP method, each output has a different direction and operates individually to send pulses to the drive unit. Forward rotation Output # 1 Forward rotation pulse train (FP) H L Output # 2 Reverse rotation pulse train (RP) H L Reverse rotation Fig. 3-3: Timing diagram OFF  OFF  311020da.eps  3-4 "ON" and "OFF" represent the status of the controller’s output. "H" and "L" respectively represent the HIGH status and the LOW status of the waveform. The command pulse pattern in the figure assumes negative logic. MITSUBISHI ELECTRIC Positioning controller 3.1.2 Components of Positioning Control and their Roles Basic parameter settings To send a series of pulses (a pulse train) to a servo amplifier, positioning controllers use a specified feed quantity, which is proportional to the number of pulses. A feed speed must also be specified to control the number of pulses output per second. Feed quantity The feed quantity determined by the target address tells the servo system how far to move the workpiece. So, for example, if a servo motor encoder generates 8,192 pulses for one rotation, the command pulse number "8,192" can be output to rotate the servo motor by 1 rotation. Feed speed The feed speed defines the amount of travel per unit of time for the workpiece. When a servo motor encoder generates 8,192 pulses for one rotation, the command pulse frequency (speed) "8,192 pulses/s" should be output to rotate the servo motor by 1 rotation per second. Decrease the pulse frequency to rotate the servo motor at a lower speed. Increase the pulse frequency to rotate the servo motor at a higher speed. Acceleration/deceleration time When the start command is given, acceleration, operation at constant speed, and deceleration are performed for positioning. Set the acceleration time and the deceleration time in the controller’s parameters. Fig. 3-4: Parameter: Max. speed Speed Actual acceleration time Parameter: Acceleration time Positioning pattern of acceleration/deceleration time Positioning speed Parameter: Deceleration time Actual deceleration time 312010da.eps 3.1.3 Zero point return function Many positioning systems include a "home position" to where a workpiece may need to return after performing various operations. For this reason, positioning controllers include a built-in function to return a workpiece to a defined position by using a mechanical DOG switch. To understand how this works, it is necessary to first understand when the function is needed according to the parameter setting of the servo amplifier and the type of servo motor encoder. Incremental type servo motor encoder (pulse count method) When the servo system uses an incremental or relative type encoder, the current value of the address stored in the position controller is not "remembered" or maintained when the power is turned off. This means that the address is set to zero every time the power is cycled, which can be disadvantageous in an application. Accordingly, every time the system is re-powered, it must be calibrated to the correct zero-point location by executing the zero point return function. FX Positioning Control Systems 3-5 Components of Positioning Control and their Roles Positioning controller Absolute type servo motor encoder (absolute position detection system) The absolute position detection system requires an absolute position motor encoder, a backup battery on the servo amplifier, and a parameter specification setting. It is constructed so that the current value stored in the positioning controller is always assured, regardless of power outages or movement while the power is turned off. The advantage to using this method is that after executing the zero point return function once, zero point return it is not needed again. NOTE Example 왓 The zero point return function does not actuate movement to a physical zero address. Instead, the zero point return function causes movement in a specified direction (positive or negative) in order to define the physical zero address after contact with a DOG switch. Example of DOG type zero return In the example in Fig. 3-5, the DOG (which is attached to the workpiece) comes in contact with the DOG switch to turn the DOG signal ON, which then initiates deceleration to creep speed. After the backward end of the DOG passes the DOG switch, turning the DOG signal OFF, the first detected zero point signal stops the motion, turns the CLEAR signal on, and sets the zero point address. The zero point address (specified in the controller’s parameters) is typically zero. When the zero return function finishes, the zero point address is written to the current value register of the positioning controller to overwrite the current address. Since the zero point address is not always zero, the zero return function should be thought of as a homing function instead of a return-to-zero function. The zero point return direction, zero point address, zero signal count, return speed, deceleration time and creep speed are all set by parameters in the positioning controller. Fig. 3-5: Zero point return speed Deceleration time DOG switch activated Creep speed Zero point Initial position DOG switch DOG Zero point return direction DOG Forward end  Positioning pattern of DOG type zero return Backward end CLEAR signal 313010da.eps  The location of the DOG switch should be adjusted so that the backward end of the DOG is released between two consecutive zero point signals (1 pulse per rotation of the motor). In this example, the DOG length should not be less than the deceleration distance of the machine. 왕 3-6 MITSUBISHI ELECTRIC Positioning controller Components of Positioning Control and their Roles DOG search function In some PLC models, if the zero point return function is performed while the workpiece is stopped beyond the DOG switch, the machine moves until the limit switch is actuated, changes direction, then returns to the zero point again (DOG search function, zero point return retry function). DOG switch Limit switch Initial position Fig. 3-6: Positioning pattern of DOG search function Zero point Escape operation 313020da.eps FX Positioning Control Systems 3-7 Components of Positioning Control and their Roles 3.2 Servo Amplifier and Servo Motor Servo Amplifier and Servo Motor The servo amplifier controls the movement quantity and the speed according to the commands given by the positioning controller. The servo motor then transmits rotation to the drive mechanism after receiving signals from the servo amplifier. 3.2.1 Positioning control in accordance with command pulse In accordance with speed and position command pulses from the positioning controller, PWM (pulse width modulation) control is performed by the main circuit of the servo amplifier in order to drive the motor. The rotation speed and the rotation quantity are fed back to the amplifier from the encoder attached to the servo motor. 3.2.2 Deviation counter function The difference between the command pulses and the feedback pulses counted by the deviation counter in the servo amplifier is called accumulated pulses. While the machine is operating at a constant speed, the accumulated pulse quantity is almost constant. During acceleration and deceleration, the accumulated pulse quantity changes more dramatically. When the accumulated pulse quantity becomes equivalent to or less than a specified quantity (in-position set value) after command pulses have stopped, the servo amplifier outputs the positioning complete signal. The servo motor continues operation even after that. Then, when the accumulated pulse quantity becomes 0, the servo motor stops. The time after the servo motor outputs the positioning complete signal until it stops is called the stop settling time. Command speed Speed Motor speed The accumulated pulse quantity is 0, and positioning is completed Accumulated pulses Time Stop setting time 322010da.eps Fig. 3-7: Positioning pattern 3-8 MITSUBISHI ELECTRIC Servo Amplifier and Servo Motor 3.2.3 Components of Positioning Control and their Roles Servo lock function The servo motor is controlled so that the accumulated pulse quantity counted in the deviation counter becomes 0. For example, if an external force for forward rotation is applied on the servo motor, the servo motor performs the reverse rotation operation to eliminate the accumulated pulses. Accumulated pulses in deviation counter Servo motor Minus pulses Reverse rotation operation Plus pulses Forward rotation operation 0 (zero) Stop Tab. 3-1: Control of servo motor by accumulated pulses 3.2.4 Regenerative brake function During deceleration, because the servo motor rotates by the load inertia of the drive mechanism, it functions as a generator and electric power returns to the servo amplifier. The regenerative resistor absorbs this electric power and functions as a brake (called a regenerative brake.) A regenerative brake is required to prevent regenerative over voltage in the servo amplifier when the load inertia is large and operations are frequently performed. The regenerative resistor is required when the regenerative power generation quantity during deceleration exceeds the allowable regenerative electric power of the servo amplifier. FX Positioning Control Systems 3-9 Components of Positioning Control and their Roles 3.2.5 Servo Amplifier and Servo Motor Dynamic brake function When a circuit inside the servo amplifier is disabled by a power interruption in the AC power of the main circuit or actuation of the protective circuit, the terminals of the servo motor are short-circuited via resistors, the rotation energy is consumed as heat, then the motor immediately stops without free run. When the motor stops by elimination of the rotation energy, the brake is not effective and the motor runs freely. Main circuit AC power supply NFB Position controller R S T Converter AC to DC Deviation counter Inverter DC to AC D/A conversion U V W SM PLG These contacts of the dynamic brake turn ON when the power is interrupted. Number of rotations of motor Motor stop characteristics when the dynamic brake is actuated When the dynamic brake is not actuated Time Power: OFF Contacts of dynamic brake: ON 325010da.eps Fig. 3-8: Dynamic brake function 3 - 10 MITSUBISHI ELECTRIC Drive mechanism 3.3 Components of Positioning Control and their Roles Drive mechanism The drive mechanism converts the rotation motion of the servo motor into reciprocating or vertical motion through a speed reducer, timing belt, ball screw, etc. to move the machine. 3.3.1 Concept of drive system movement quantity The following diagram is a representative AC servo motor positioning system. Fig. 3-9: Encoder Servo motor N0 Speed reducer 1 n Moving part v0 AC servo motor positioning system PB Pf Servo amplifier f0 Position controller 331010da.eps 욼l: Transfer distance per pulse (mm/pulse) v0: Moving part speed during quick feed (mm/min) PB: Lead of ball screw (mm/rev) 1/n: Speed reduction ratio 욼S: Transfer distance per rotation of motor (mm/rev) N0: Number of rotations of motor during quick feed (rev/min) Pf: Feedback pulse number (pulse/rev) f0 : Command pulse frequence during quick feed (pulse/sec) ● The servo motor stops with the precision 욼l, which is within 1 pulse against the command pulse. ● The movement quantity of the workpiece is: [Output pulses from position controller] × [욼l] ● The moving part speed is: [f0] × [욼l] ● Either "mm", "inch", "degree", or "pulse" can be selected for the positioning command unit. Accordingly, when data such as the movement quantity per pulse, positioning speed, or the positioning address in accordance with the positioning command unit are set, pulse trains are output for the target address, and positioning is performed. FX Positioning Control Systems 3 - 11 Components of Positioning Control and their Roles Drive mechanism Useful equations To define the system illustrated above, 욼l and v0 need to be determined using a series of equations. The speed of the moving part (v0) is constrained by the mechanical gearing system between the servo motor and moving part, the pitch of the ball screw, and the specification of the motor as shown through the following two formulas. Transfer distance per rotation of motor: mm ΔS rev 1 n = PB Number of rotations of motor during quick feed: rev N0 min = Rated number of rotations of servo motor v0 ΔS If N0 does not exceed the rated speed of the motor, this means that the servo system can be used for the application. In order to determine if the positioning controller is applicable, the command pulse frequency during quick feed (f0) should be checked to verify it does not exceed the maximum allowable frequency setting for the "maximum speed" parameter setting of the controller. Transfer distance per pulse: mm Δ l PLS = ΔS Pf (Electronic gear ratio) Command pulse frequency during quick feed: f0 PLS S = ΔS Δl N0 1 60 During the above process, the Electronic gear ratio (often "CMX/CDV" for Mitsubishi servos) and Speed reduction ratio can be adjusted to fit the application’s needs. In each of the absolute and incremental positioning methods, the entire movement distance of the machine should not exceed the maximum allowable pulse output number from the positioning controller. 3 - 12 MITSUBISHI ELECTRIC Drive mechanism 3.3.2 Components of Positioning Control and their Roles Setting the target position In positioning control, the target position can be set by the following two methods, specified by the controller’s parameter settings. (Available command units are "mm," "inch", "degree", or "pulse".) Absolute method In this method, a point (absolute address) is specified for positioning while the zero point is regarded as the reference. The start point is arbitrary. Startpoint Address 100 Address 100 Endpoint Address 150 Address 300 Address 150 Address 100 Address 150 0 Zero point 100 Point A 150 Point B 300 Point C 332010da.eps Fig. 3-10: Setting the target position, absolute method Incremental method In this method, positioning is performed through specification of the movement direction and the movement quantity while the current stop position is regarded as the start point. Movement quantity -100 Movement quantity +100 Startpoint Endpoint Movement quantity +100 Movement quantity +100 Movement quantity -150 Movement quantity +50 Movement quantity -100 0 Zero point 100 Point A 150 Point B 300 Point C 332020da.eps Fig. 3-11: Setting the target position, incremental method FX Positioning Control Systems 3 - 13 Components of Positioning Control and their Roles 3 - 14 Drive mechanism MITSUBISHI ELECTRIC MELSEC FX PLC positioning Learning to Use the FX Family for Positioning Control 4 Learning to Use the FX Family for Positioning Control 4.1 MELSEC FX PLC positioning The FX1S, FX1N, FX3G, FX3GC, FX3GE, FX3S, and FX3U(C) Series PLC main units include basic positioning instructions to send command pulses to a stepper motor or servo amplifier. While FX PLCs support point-to-point positioning, full control is also available for reading the absolute position from a servo amplifier, performing zero return, and altering the workpiece speed during operation. Important references for understanding positioning with FX PLCs include: ● Programming Manuals for the MELSEC FX Series ● User’s Manuals – Hardware Edition – for the various controllers of the MELSEC FX family ● FX3S/FX3G/FX3GC/FX3U/FX3UC Series User’s Manual – Positioning Control Edition – (JY997D16801) ● FX2N-1PG User’s Manual – (JY992D65301) ● FX2N-10PG User’s Manual – (JY992D93401) ● FX2N-10GM/FX2N-10GM User’s Manual – (JY992D77801) It is assumed that you will have read and understood the above manuals or that you will have them close at hand for reference. 4.1.1 Overview of control Number of Axes The FX1S, FX1N, FX3GC and FX3S transistor type PLCs support positioning on 2 axes with operation speeds up to 100,000 pulses/second (100 kHz). The main units FX3G-14MT/첸, FX3G-24MT/첸, and FX3GE-24MT/첸 (transistor outputs) can control up to two axes and the main units FX3G-40MT/첸, FX3G-60MT/첸, and FX3GE-40MT/첸 can control a maximum of three axes with up to 100 kHz. The FX3U(C) transistor type PLC main units support positioning speeds up to 100 kHz on 3 axes. If two FX3U-2HSY-ADP adapters are connected to the FX3U, 4 axes are available with operation speeds up to 200 kHz. The PLS/DIR pulse output method is used for all PLC main units to output pulses as shown in the following table. 1st Axis 2nd Axis FX1S, FX1N, FX3G-14MT/첸, FX3G-24MT/첸, FX3GC, FX3GE-24MT/첸, FX3S Applicable Model 3rd Axis 4th Axis — — FX3GE-40MT/첸, FX3U(C), FX3G-40MT/첸, FX3G-60MT/첸 FX3U + (2) FX3U-2HSY-ADP —  Pulse Output Y0 Y1 Y2 Y3 Direction Output  Y4 Y5 Y6 Y7 Tab. 4-1: Overview of applicable PLC main units  Output terminals for direction can be specified arbitrarily when the FX3U-2HSY-ADP is not used. Y4, Y5, Y6 and Y7 are used as an example.  The FP/RP pulse output method is also available with the FX3U-2HSY-ADP.  Connection of the FX3U-2HSY-ADP is only possible to a FX3U base unit. FX Positioning Control Systems 4-1 Learning to Use the FX Family for Positioning Control MELSEC FX PLC positioning Limit switches As with any other positioning system, inputs are needed to detect when the workpiece reaches the outer boundary limits in order to prevent damage to the machine. For the FX3G, FX3GC, FX3GE, FX3S and FX3U(C) programmable logic controller, limits are wired to the controller to be used with the DOG search zero return function for reversing the motor’s direction of travel in order to hunt for the DOG switch. These limits are called the forward rotation limit (LSF) and the reverse rotation limit (LSR). Hardware limits are used on the servo amplifier side to stop the motor in worst case scenarios. Reverse rotation limit 1 (Programmable controller side) LSR Reverse rotation limit 2 (Servo amplifier side) Forward rotation limit 1 (Programmable controller side) LSF Forward rotation limit 2 (Servo amplifier side) Servo motor Reverse rotation Forward rotation 141010da.eps Fig. 4-1: Example for limit switches Sink vs. Source outputs In general, MELSERVO Series amplifiers are configured with sink type inputs. To communicate appropriately with sink type inputs, sink type outputs are used on the PLC side. Therefore, when using a Mitsubishi servo control system, a transistor sink output type PLC is used. Options for positioning Before choosing a PLC for a positioning system, it is important to understand the instructions available for each PLC. The FX1S and FX1N include the same set of positioning instructions. The only disadvantage to choosing an FX1S PLC for positioning is that it does not include as many I/O and that it cannot be expanded with special function blocks for analog or communication control. The FX3U, combined with high speed positioning adapters, can operate with higher pulse output frequencies and includes 3 additional positioning instructions. The available instructions for FX PLCs are described in the chart below. Applicable Model FX1S FX1N FX3G FX3GC FX3GE FX3S FX3U FX3UC Description Positioning instruction Instruction Illustration JOG speed Speed JOG operation The motor moves in a specified direction depending on the logic and timing of the drive input signal. (There is no target position.) DRVI Start Stop JOG command Start Stop 411020da.eps Tab. 4-2: Instructions for FX PLCs (1) 4-2 MITSUBISHI ELECTRIC MELSEC FX PLC positioning Applicable Model Learning to Use the FX Family for Positioning Control Description FX1S FX1N FX3G FX3GC FX3GE FX3S FX3U FX3UC 1-speed positioning A start command accelerates the motor to a constant speed and moves the workpiece to a specified distance. FX1S FX1N FX3G FX3GC FX3GE FX3U FX3UC Zero return The machine moves at a specified speed until the DOG input turns ON. The workpiece then slows to creep speed and stops before the CLEAR signal is output. Positioning instruction Instruction Illustration Operation speed Speed DRVI DRVA Start Target position Travel distance 411030da.eps Zero point return Speed Creep speed ZRN Zero point DOG input ON Start CLEAR signal 411040da.eps FX1S FX1N FX3G FX3GC FX3GE FX3S FX3U FX3UC Variable speed operation After starting with a specified speed, the motor can change its speed depending on commands from the PLC. (For the FX1S and FX1N, acceleration to different speeds is approximated with the RAMP instruction.) FX3U FX3UC Interrupt 1-speed positioning When an interrupt signal turns ON, the workpiece travels a specific distance at the same speed before decelerating to stop. FX3G FX3GC FX3GE FX3S FX3U FX3UC DOG search zero return The machine operates similar to the zero return instruction except for features to hunt for the DOG switch and to use the zero-phase signal. Speed PLSV (RAMP) Start Speed change Speed change 411050da.eps Travel distance Speed DVIT Start Interrupt input 411060da.eps DOG Limit (LSR) Origin DSZR Start 411070da.eps Input FX3G FX3GC FX3GE FX3U FX3UC Table operation For programming simplicity, position and speed data can be organized in table format for the DRVI, DRVA, DVIT and PLSV instructions. DTBL Y0 K1 DTBL Y0 K2 Input DTBL Command are output at Y000 in accordance to the contents of the rows 1 to 3 of the table. Input DTBL Y0 K3 Axis Row No. 411080da.eps Tab. 4-3: Instructions for FX PLCs (2) FX Positioning Control Systems 4-3 Learning to Use the FX Family for Positioning Control 4.1.2 MELSEC FX PLC positioning Important memory locations For FX PLC programs using positioning instructions, there are several built-in special devices to define control parameters and facilitate system operation. These devices consist of 1-bit, 16-bit, and 32-bit address locations and are briefly outlined below according to their use in the example programs in the following section. Use this table as a reference to understand the example programs. For details on other memory addresses (for example, operation information for control on Y001 or Y002), refer to the FX3S/FX3G/FX3GC/FX3U/FX3UC Series User’s Manual - Positioning Control Edition (JY997D16801). Function name Device Length Description Applicable PLC RUN monitor M8000 1-bit ON when PLC is in RUN. Initial pulse M8002 1-bit ON for the first scan only. FX1S, FX1N, FX3G, FX3GC, FX3GE, FX3S, FX3U(C) Instruction execution complete flag M8029 1-bit Programmed immediately after a positioning instruction. Turns ON when the preceding instruction finishes its operation and stays ON until the instruction stops being driven. CLEAR signal output enable M8140 1-bit Enables a CLEAR signal to be output to the servo. FX1S, FX1N Pulse output stop command M8145 1-bit Stop outputting Y000 pulses. (Immediate stop) FX1S, FX1N Pulse output monitor flag M8147 Instruction execution abnormally complete flag M8329 CLEAR signal output function enable M8349 FX3G, FX3GC, FX3GE, FX3S, FX3U(C) 1-bit OFF when Y000 is READY ON when Y000 is BUSY FX1S, FX1N 1-bit Programmed immediately after a positioning instruction. Turns ON when an instruction fails to complete correctly and stays ON until the instruction stops being driven. FX3G, FX3GC, FX3GE, FX3S, FX3U(C) M8341 1-bit Enables an output to be used for the CLEAR signal for Y000. FX3G, FX3GC, FX3GE, FX3S, FX3U(C) (Y000) Zero return direction specification M8342 1-bit OFF  Reverse rotation ON  Forward rotation Forward rotation limit M8343 1-bit Forward pulses on Y000 stop when this relay turns ON. Reverse rotation limit M8344 1-bit Reverse pulses on Y000 stop when this relay turns ON. (Y000) Positioning instruction activation M8348 1-bit OFF when a positioning instruction is not active. ON when a positioning instruction is active. CLEAR signal device specification function enable M8464 1-bit Enables the output terminal for the CLEAR signal to be changed for Y000. Bias speed [Hz] D8145 16-bit Sets the bias speed for Y000. M8340 FX3G, FX3GC, FX3GE, FX3S, FX3U(C) FX1S, FX1N D8342 Maximum speed [Hz] D8146 FX3G, FX3GC, FX3GE, FX3S, FX3U(C) 32-bit Sets the maximum speed for positioning instructions on Y000. D8343 FX1S, FX1N FX3G, FX3GC, FX3GE, FX3S, FX3U(C) Acceleration/deceleration time [ms] D8148 16-bit Sets the acceleration and deceleration time. FX1S, FX1N Acceleration time [ms] D8348 16-bit Sets the acceleration time for Y000. Deceleration time [ms] D8349 16-bit Sets the deceleration time for Y000. FX3G, FX3GC, FX3GE, FX3S, FX3U(C) CLEAR signal device specification D8464 16-bit Sets the output terminal for the CLEAR signal for Y000. Tab. 4-4: Special devices of FX1S, FX1N, FX3G(C)(E), FX3S and FX3U(C) base units 4-4 MITSUBISHI ELECTRIC MELSEC FX PLC positioning 4.1.3 Learning to Use the FX Family for Positioning Control Program Examples Two positioning examples are included as a reference to get started with PLC programming. Hybrid programming example for FX1S, FX1N, FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs The first example below illustrates zero return and absolute positioning control on 1 axis. Since the special devices for utilizing positioning instructions are different depending on the PLC, please note that the following program is a hybrid program and that device addresses must be changed according to the type of PLC. NOTE A general understanding of step ladder and ladder logic is necessary to use the program. 500,000 Forward positioning  100 Output pulse frequency: 100,000 Hz Bias speed 500 Hz 500 Hz Origin after zero return  Reverse rotation limit 2 (Servo amplifier side) Forward rotation limit 2 (Servo amplifier side) Servo motor Reverse positioning  Reverse rotation Forward rotation Acceleration/deceleration time: 100 ms 413010da.eps Fig. 4-2: Configuration for the program example  See marker  in program fig. 4-5 (3).  See marker  in program fig. 4-5 (3).  See marker  in program fig. 4-6 (4). Inputs Outputs X000 Immediate stop Y000 Pulse train output X001 Zero return command Y002 CLEAR signal X002 Forward rotation positioning command Y004 Rotation direction signal X003 Reverse rotation positioning command Y010 CLEAR signal X004 Stop command — — X005 Near-point signal (DOG) — — X006 Servo ready — — Tab. 4-5: Used inputs and outputs FX Positioning Control Systems 4-5 Learning to Use the FX Family for Positioning Control MELSEC FX PLC positioning Use this for FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs X000 M8349  M8145  Immediate stop X006 Use this for FX1S and FX1N PLCs Servo ready RST M10 RST M11 RST M12 H0010 D8464 Use this for FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs M8000 FNC 12 MOVP RUN monitor M8464 M8341 Use this for FX1S and FX1N PLCs M8140 413020da.eps Fig. 4-3: Program example (1) Number  Description Stops outputting Y000 pulses. (Immediate stop) Resets "zero return completion" flag. Resets "forward rotation positioning completion" flag. Resets "reverse rotation positioning completion" flag. Enables the zero return operation with CLEAR signal outputting function (CLEAR signal: Y010) Return to the zero point with CLEAR signal output Y002 Tab. 4-6: Description of the program example in fig. 4-3 4-6 MITSUBISHI ELECTRIC MELSEC FX PLC positioning Learning to Use the FX Family for Positioning Control Use this for FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs S0 Return to zero point S20 S21 M8349 Positioning in reverse rotation Positioning in forward rotation M5  M5  Y000 output stop Use this for FX1S and FX1N PLCs S0 Return to zero point S20 Positioning in forward rotation S21 M8145 Positioning in reverse rotation Y000 output stop Use this for FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs M8002 Initial pulse FNC 12 DMOV K100000 D8343 FNC 12 MOV K500 D8342 FNC 12 MOV K100 D8348 FNC 12 MOV K100 D8349 FNC 12 DMOV K100000 D8146 FNC 12 MOV K500 D8145  FNC 12 MOV K100 D8148  RST M10  RST M11  RST M12  SET S0  RST M11  RST M12  SET S20  RST M11  RST M12  SET S21  Use this for FX1S and FX1N PLCs X001 M5 Return to zero point Operation stopped X002 Positioning in forward rotation X003 Positioning in reverse rotation M5 Operation stopped M5 Operation stopped M10 "Zero return completion" flag M10 "Zero return completion" flag 413030da.eps Fig. 4-4: Program example (2) FX Positioning Control Systems 4-7 Learning to Use the FX Family for Positioning Control Number  MELSEC FX PLC positioning Description Operation is stopped. Sets the maximum speed to 100,000 Hz. (100,000 in D8344, D8343) Sets the bias speed to 500 Hz. (500 in D8342) Sets the acceleration time to 100 ms. (100 in D8348) Sets the deceleration time to 100 ms. (100 in D8349) Sets the maximum speed to 100,000 Hz. (100,000 in D8147, D8146 )  Sets the bias speed to 500 Hz. (500 in D8145)  Sets the acceleration/deceleration time to 100 ms. (100 in D8148)  Resets "zero return completion" flag.  Resets "forward rotation positioning completion" flag.  Resets "reverse rotation positioning completion" flag.  Enters the zero point return state (S0).  Enters the forward rotation positioning state (S20).  Enters the reverse rotation positioning state (S21). Tab. 4-7: Description of the program example in fig. 4-4 4-8 MITSUBISHI ELECTRIC MELSEC FX PLC positioning Learning to Use the FX Family for Positioning Control  STL S0 X005 Y000  M50 Waiting for 1 scan time X004 FNC 156 DZRN Stop command K50000 K1000 Zero return Creep speed Near-point start speed signal Pulse output destination number M8029 SET M10 RST S0 RST S0  Zero return "Execution completion" flag Use this for FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs M8340 Y000 Outputting M50 Waiting for 1 scan time Use this for FX1S and FX1N PLCs M8147 Y000 Outputting M50 Waiting for 1 scan time  M8000 M50 RUN monitor STL S20 Y000 Y004 Pulse output destination number Rotation direction signal SET M11  RST S20  RST S20   M51  Positioning in forward rotation direction Waiting for 1 scan time X004 Stop command FNC 159 DDRVA K500000 K100000 Designation of absolute position Output pulse frequency M8029  "Execution completion" flag Use this for FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs M8340 Y000 Outputting M51 Waiting for 1 scan time Use this for FX1S and FX1N PLCs M8147 M51 Y000 Outputting Waiting for 1 scan time  M8000 M51 RUN monitor 413040da.eps Fig. 4-5: Program example (3)  To stop the positioning operation, be sure to insert the stop contact before the positioning instruction so that STL instruction cannot be turned off (reset) until "pulse output monitor" flag (M8340 or M8147 (for Y000)) is turned off.  To prevent simultaneous activation of positioning instructions, the instruction activation timing should be delayed by 1 scan time. FX Positioning Control Systems 4-9 Learning to Use the FX Family for Positioning Control Number Description  Zero return MELSEC FX PLC positioning Zero return instruction (CLEAR signal: Y010, Y002 for FX1S or FX1N) "Zero return completion" flag End of zero return (Self-reset) Waiting for 1 scan time Positioning in forward rotation direction  Moves to absolute position 500,000 using the drive to absolute instruction. (Y004=ON)  "Forward rotation positioning completion" flag  Ends the positioning operation in the forward rotation direction. (Self-reset) Tab. 4-8: Description of the program example in fig. 4-5 4 - 10 MITSUBISHI ELECTRIC MELSEC FX PLC positioning Learning to Use the FX Family for Positioning Control STL  S21  Positioning in reverse rotation direction  M52 X004 Waiting for 1 scan time Stop command FNC 159 DDRVA K100 K100000 Y000 Designation Output Pulse of absolute pulse output position frequency destination number Y004 Rotation direction signal M8029 SET M12 RST S21 RST S21 "Execution completion" flag Use this for FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs M8340 M52 Y000 Outputting Waiting for 1 scan time Use this for FX1S and FX1N PLCs M8147 M52 Y000 Outputting Waiting for 1 scan time  M8000 M52 RUN monitor RET END 413050da.eps Fig. 4-6: Program example (4)  To stop the positioning operation, be sure to insert the stop contact before the positioning instruction so that STL instruction cannot be turned off (reset) until "pulse output monitor" flag (M8340 or M8147 (for Y000)) is turned off.  To prevent simultaneous activation of positioning instructions, the instruction activation timing should be delayed by 1 scan time. Number  Description Positioning in reverse rotation direction Moves to absolute position 100 using the drive to absolute instruction. (Y004 = OFF) "Reverse rotation positioning completion" flag Ends the positioning operation in the reverse rotation direction. (Self-reset) Waiting for 1 scan time Tab. 4-9: Description of the program example in fig. 4-6 FX Positioning Control Systems 4 - 11 Learning to Use the FX Family for Positioning Control MELSEC FX PLC positioning Programming example for a FX3G, FX3GC, FX3GE or FX3U(C) PLC The following program is similar to the previous one except that it is programmed only in ladder logic and does not follow a specific sequence of step ladder states. Additionally, it includes control for relative positioning with JOG(+) and JOG(-) commands, a DOG search zero return function, and utilization of the DTBL instruction. When using an FX3G, FX3GC, FX3GE, or FX3U(C) PLC, the DOG search zero return function can be programmed with limit switches wired to the PLC as follows Reverse rotation limit 1 (Programmable controller side) LSR Reverse rotation limit 2 (Servo amplifier side) Forward rotation limit 1 (Programmable controller side) LSF Forward rotation limit 2 (Servo amplifier side) Servo motor Reverse rotation Forward rotation 413060da.eps Fig. 4-7: Configuration example The DTBL instruction helps to simplify the programming and is set up beforehand (along with positioning parameters such as the bias speed, acceleration/deceleration, etc.) with GX Developer, GX IEC Developer or GX Works2. In this example, positioning may be performed arbitrarily along the path in fig. 4-8. Using the JOG command, the workpiece is moved to any relative position. This is not illustrated in the figure below. Fig. 4-8: Forward positioning Positioning pattern 500,000 Output pulse frequency: 100,000 Hz 100 Bias speed 500 Hz 500 Hz Origin after zero return Reverse positioning Acceleration/deceleration time: 100 ms 413070da.eps Required hardware and software are as follows: ● FX3G, FX3GC, FX3GE PLC or ● FX3U(C) PLC version 2.20 or later ● GX Developer 8.23Z or later or ● GX IEC Developer or ● GX Works2 4 - 12 MITSUBISHI ELECTRIC MELSEC FX PLC positioning Learning to Use the FX Family for Positioning Control Parameters for the DTBL instruction are set for example in GX Developer as shown below.  Double-click Parameter and then PLC parameter from the project tree on the left side of the screen. If the project tree is not displayed on the screen, click View on the menu bar, and then click Project Data List. 413080da.eps Fig. 4-9: Project window  Click on the Memory capacity tab and then enter a check in the Positioning Instruction Settings check box. Take note that 9,000 steps are needed to set the positioning data. Therefore, it is necessary to specify a Memory capacity of 16,000 steps or more. 413090da.eps Fig. 4-10: "Memory capacity" window FX Positioning Control Systems 4 - 13 Learning to Use the FX Family for Positioning Control MELSEC FX PLC positioning  Click on the Positioning tab and then set Y000 (pulse output destination) as follows. 4130a0da.eps Fig. 4-11: "Positioning" window Setting item Bias speed [Hz]  Maximum speed [Hz] Creep speed [Hz] Zero return speed [Hz] Setting value 500 100,000 1000 50,000 Acceleration time [ms] 100 Deceleration time [ms] 100 Interrupt input for DVIT instruction  X000 Tab. 4-10: Settings for Y000 4 - 14  The "Bias speed" corresponds to the minimum speed.  Can only be set for a FX3U or FX3UC main unit. MITSUBISHI ELECTRIC MELSEC FX PLC positioning Learning to Use the FX Family for Positioning Control  Click the Individual setting button. The Positioning instruction settings window will appear. In this window, click on the Y0 tab to display the positioning table for Y000 (pulse output destination). Set the data in the positioning table as follows: 4130b0da.eps Fig. 4-12: "Positioning instruction settings" window Be sure to change the [Rotation direction signal] to "Y004". Setting item Setting value Rotation direction signal Y004 First device R0 Positioning type No. 1 No. 2 No. 3 No. 4 DDRVI (Drive to increment) Number of pulses (PLS) 999,999 Frequency [Hz] 30,000 Positioning type DDRVI (Drive to increment) Number of pulses (PLS) -999,9990 Frequency [Hz] 30,000 Positioning type DDRVA (Drive to absolute) Number of pulses (PLS) 500,000 Frequency [Hz] 100,000 Positioning type DDRVA (Drive to absolute) Number of pulses (PLS) Frequency [Hz] 100 100,000 Tab. 4-11: Settings for positioning instruction  Click the OK button and then the End button to close the parameters.  Create the ladder program as shown in fig. 4-12. FX Positioning Control Systems 4 - 15 Learning to Use the FX Family for Positioning Control MELSEC FX PLC positioning  Once the ladder program is complete, click on Online from the top menu bar in GX Developer and select Write to PLC. The following window will appear. 4130c0da.eps Fig. 4-13: "Write to PLC" window  Click the Param + Prog button and then click the Execute button. The parameters and the created program will be transferred to the PLC. To enable the transferred parameters, stop the PLC and then restart it. Inputs Outputs X004 Zero-point signal Y000 Pulse train output X010 Near-point signal (DOG) Y004 Rotation direction signal X014 Servo ready Y020 X020 Immediate stop — — X021 Zero return command — — X022 JOG(+) command — — X023 JOG(-) command — — X024 Forward rotation positioning command — — X025 Reverse rotation positioning command — — X026 Forward rotation limit (LSF) — — X027 Reverse rotation limit (LSR) — — X030 Stop command — — CLEAR signal Tab. 4-12: Used inputs and outputs 4 - 16 MITSUBISHI ELECTRIC MELSEC FX PLC positioning Learning to Use the FX Family for Positioning Control X020 M8349  Immediate stop X014 RST M10 RST M12 RST M13 Servo ready X026 M8343 Forward rotation limit X027 M8344 Reverse rotation limit M8000 FNC 12 MOVP RUN monitor H0020 D8464  M8464 M8341 M8000 M8342  RUN monitor X021 M8348 M101 M102 Zero return Positioning being performed (Y000) Normal end of zero return Abnormal end of zero return DOG search zero return M100 RST M10 RST M12 RST M13 Zero return being performed X030 FNC 150 DSZR Stop command X010 X004 Near-point Zero-point signal signal M8029 Y000 M100  Y004  Pulse Rotation output direction destination signal number SET "Execution completion" flag M8329 M10  M101  M102  Abnormal end X022 M8348 JOG (+) operation JOG (+) Positioning being performed (Y000) M104 Completes the JOG (+) operation. RST M12 RST M13 M103 JOG (+) operation is being performed. X030 Stop command X022 FNC 152 DTBL M103  Y000 K1  Pulse output destination number No. of row in table M104  JOG(+) M8329 Abnormal end 4130d0da.eps Fig. 4-14: Program example (1) FX Positioning Control Systems 4 - 17 Learning to Use the FX Family for Positioning Control Number  MELSEC FX PLC positioning Description Stops outputting Y000 pulses. (Immediate stop) Resets "zero return completion" flag. Resets "forward rotation positioning completion" flag. Resets "reverse rotation positioning completion" flag. Normal rotation limit (Y000) Reverse rotation limit (Y000)  Enables the zero return operation with CLEAR signal outputting function. (CLEAR signal: Y020)  Performs zero return in the forward rotation direction.  Zero return is being performed.  Zero return instruction with DOG search function (CLEAR signal: Y020)  "Zero return completion" flag  Normal end of zero return  Abnormal end of zero return  JOG(+) operation is being performed.  Executes the row No. 1 of the positioning table of Y000 (pulse output destination).  Completes the JOG(+) operation. Tab. 4-13: Description of the program example in fig. 4-14  4 - 18 The forward and reverse rotation limit switches must be wired so that they are turned ON by default (Normally closed contacts). When these limit switches turn OFF (due to the workpiece going out-of-bounds), M8343 or M8344 will turn ON and cause the pulse operation to stop. MITSUBISHI ELECTRIC MELSEC FX PLC positioning Learning to Use the FX Family for Positioning Control M106 X023 M8348 JOG (-) Positioning being performed (Y00) Completes the JOG (-) operation. RST M12  RST M13  JOG(-) operation M105 M105 JOG (-) operation is being performed. X030 FNC 152 DTBL Stop command Y000 Pulse output destination number X023 K2 No. of row in table M106 JOG(-) M8329 Abnormal end Positioning in forward rotation direction X024 M8348 Position-i ng in forward rotation direction Positioning operation being performed (Y00) M10 "Zero return completion" flag M108 Normal end of positioning in forward rotation direction M109 Abnormal end of positioning in forward rotation direction RST M12 RST M13 M107  Y000 K3  Pulse output destination number No. of row in table M107 X030 Positioning operation being performed in forward rotation direction Stop command FNC 152 DTBL M8029 SET "Execution completion" flag M12 M108  M109  RST M12  RST M13 M8329 Abnormal end Positioning in reverse rotation direction X025 M8348 Position-i ng in forward rotation direction Positioning operation being performed (Y00) M10 M111 "Zero return completion" flag Normal end of positioning in forward rotation direction M112 Abnormal end of positioning in forward rotation direction M110  Y000 K4  Pulse output destination number No. of row in table SET M13 M110 X030 Positioning operation being performed in reverse rotation direction Stop command M8029 "Execution completion" flag M8329 FNC 152 DTBL M111  M112  Abnormal end END 4130e0da.eps Fig. 4-15: Program example (2) FX Positioning Control Systems 4 - 19 Learning to Use the FX Family for Positioning Control Number  MELSEC FX PLC positioning Description Resets "forward rotation positioning completion" flag. JOG(-) operation is being performed. Executes the row No. 2 of the positioning table of Y000 (pulse output destination). Completes the JOG(-) operation. "Forward rotation positioning completion" flag "Reverse rotation positioning completion" flag  Positioning operation being performed in forward rotation direction  Executes the row No. 3 of the positioning table of Y000 (pulse output destination).  "Forward rotation positioning normal end" flag  "Forward rotation positioning abnormal end" flag  Positioning operation being performed in reverse rotation direction  Executes the row No. 4 of the positioning table of Y000 (pulse output destination).  "Reverse rotation positioning normal end" flag  "Reverse rotation positioning abnormal end" flag Tab. 4-14: Description of the program example in fig. 4-15 4 - 20 MITSUBISHI ELECTRIC Inverter Drive Control 4.2 Learning to Use the FX Family for Positioning Control Inverter Drive Control A frequency inverter, or inverter for short, is installed between the mains supply and the motor. An inverter converts a fixed voltage and frequency into a variable voltage with a variable frequency.Thus the speed of a asynchronous electric motor can be adjusted continuously. In factory automation, inverters (sometimes known as variable frequency drives) are used to efficiently control large current loads through voltage regulation to drive large fans, pumps or AC motors. Drive control with inverters can lead to great reductions in energy consumption for a factory. With a Mitsubishi general-purpose inverter connected to an FX2N(C), FX3G, FX3GC, FX3GE, FX3S or FX3U(C) PLC, a motor can be controlled to move at a specific speed. Through monitoring feedback or by using limit switches, a basic positioning functionality is achieved. However, as described in section 1.3, the disadvantage to using an inverter to move a workpiece to a specific location is a loss in the stop precision. Therefore, inverters should not be thought of as positioning controllers. Important references for understanding inverter drive control for this section include: ● FX Series User’s Manual - Data Communication Edition – (JY997D16901) ● Inverter Instruction Manuals It is assumed that you will have read and understood the above manuals or that you will have them close at hand for reference. 4.2.1 Overview of control Programmable logic controllers and inverters communicate with each other through passing parameter data and control operation data back and forth. Inverters, when used for variable frequency drive, require a frequency command and a start command to operate. Mitsubishi’s FREQROL Series inverters communicate with FX2N(C), FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs via the Mitsubishi inverter computer link protocol to asynchronously control operations. FX Positioning Control Systems 4 - 21 Learning to Use the FX Family for Positioning Control 4.2.2 Inverter Drive Control Using the MELSEC FX and FREQROL Inverter In order to enable RS485 serial communication to a MELCO inverter(s), a special BD board or adapter (ADP) is connected to the main unit FX2N(C), FX3G, FX3GC, FX3GE, FX3S or FX3U(C). The following table describes connection options for using one channel of communication. FX Series Communication equipment (option) FX2N FX2N-485-BD (Terminal board) Total extension distance 50 m 422020da.eps FX 2N-ROM-E1 (Function extension memory casette or FX2N-CNV-BD FX2NC-485ADP (Terminal block) 500 m FX2N-CNV-BD FX0N-485ADP (Terminal block) 422030da.eps 422010da.eps 1 MITSUBISHI X0 X1 X2 X3 X4 X5 Y0 Y1 Y2 Y3 Y4 Y5 X6 Y6 X7 Y7 or FX2NC 500 m FX2NC-485ADP (Terminal block) FX0N-485ADP (Terminal block) FX 2NC-ROM-CE1 (Function extension memory board 422040da.eps 422050da.eps Tab. 4-15: Applicable communication interface boards and adapters for data exchange with frequency inverters 4 - 22 MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Family for Positioning Control FX Series Total extension distance Communication equipment (option) 50 m FX3G-485-BD (Terminal block) FX3G-485-BD_front.eps FX3G (14 or 24 I/O) 500 m FX3U-485ADP(-MB) (Terminal block) FX3G-CNV-ADP FX3G_24_front.eps RS485_FX3G.eps CH 1 50 m FX3G-485-BD (Terminal block) FX3G-485-BD_front.eps CH 1 500 m FX3U-485ADP(-MB) (Terminal block) FX3G-CNV-ADP RS485_FX3G.eps FX3G (40 or 60 I/O) CH 2 50 m FX3G-485-BD (Terminal block) FX3G-485-BD_front.eps CH 1 CH 2 500 m FX3G-CNV-ADP FX3G_24_front.eps FX3U-232ADP(-MB) or FX3U-485ADP(-MB) FX3U-485ADP(-MB) (Terminal block) RS485_FX3G_ch2.eps Tab. 4-15: Applicable communication interface boards and adapters for data exchange with frequency inverters FX Positioning Control Systems 4 - 23 Learning to Use the FX Family for Positioning Control FX Series Inverter Drive Control Total extension distance Communication equipment (option) CH 1 500 m FX3U-485ADP(-MB) (Terminal block) 4220a0dab.eps CH 1 CH 2 FX3GC 500 m FX3U-첸ADP  FX3U-485ADP(-MB) (Terminal block) FX3GC-32M_front.eps RS485_FX3UC_D_DS_ch2 CH 2 50 m FX3G-485-BD (Terminal block) FX3G-485-BD_front.eps CH 2 FX3GE 500 m FX3U-485ADP(-MB) (Terminal block) FX3GE-32M_front.eps 4220a0dab.eps CH 2 50 m FX3G-485-BD (Terminal block) FX3G-485-BD_front.eps + FX3S FX3S-CNV-ADP FX3S-30M_front.eps 500 m FX3U-485ADP(-MB) (Terminal block) RS485_ADP_FX3S Tab. 4-15: Applicable communication interface boards and adapters for data exchange with frequency inverters 4 - 24 MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Family for Positioning Control FX Series Total extension distance Communication equipment (option) CH 1 RD A RD RD B SD A SD SD B SG 50 m FX3U-485-BD (Terminal block) 422070dab.eps CH 1 500 m FX3U-CNV-BD FX3U-485ADP(-MB) (Terminal block) 422080dab.eps RUN CH 1 STOP CH 2 FX3U 500 m FX3U-첸-BD  FX3U-485ADP(-MB) (Terminal block) RS485_FX3U_ch2_1.eps. CH 1 CH 2 500 m FX3U-첸ADP  FX3U-CNV-BD FX3U-485ADP(-MB) (Terminal block) 422060da.eps RS485_FX3U_ch2_2.eps CH 1 500 m FX3U-485ADP(-MB) (Terminal block) 4220a0dab.eps CH 1 CH 2 FX3UC 500 m FX3U-첸ADP  422090da.eps FX3U-485ADP(-MB) (Terminal block) RS485_FX3UC_D_DS_ch2 Tab. 4-15: Applicable communication interface boards and adapters for data exchange with frequency inverters  FX3U-232-BD, FX3U-422-BD, FX3U-485-BD or FX3U-USB-BD  FX3U-232ADP(-MB) or FX3U-485ADP(-MB) FX Positioning Control Systems 4 - 25 Learning to Use the FX Family for Positioning Control Inverter Drive Control To use the special inverter communication instructions from the PLC, inverter and PLC communication parameters must be set. The FX2N(C), FX3G, FX3GC, FX3GE, FX3S and FX3U(C) PLCs include the following special instructions to communicate with one or more inverters. FX2N(C) EXTR FX3G, FX3U(C) Function/Description K10 IVCK Monitors operations of an inverter. K11 IVDR Controls operations of an inverter. K12 IVRD Reads a parameter from an inverter. IVWR Writes a parameter to an inverter. K13 IVBWR  — Writes a block of parameters to an inverter. Tab. 4-16: Instructions to communicate with inverters  This instruction is only available for FX3U(C) PLCs. The programmable controller special relays and inverter instruction codes listed in the table below are used in Section 4.2.3. For information on memory addresses that contain error codes and inverter communication operation statuses, refer to the FX Series User’s Manual - Data Communication Edition (JY997D16901). Function name Device Length RUN monitor M8000 1-bit Initial pulse M8002 1-bit Instruction execution complete flag M8029 1-bit Description Applicable PLC ON when PLC is in RUN. FX2N(C) FX3G Programmed immediately after an inverter commu- FX3GC nication instruction. Turns ON when the preceding FX3GE instruction finishes its operation and stays ON until FX3S FX3U(C) the instruction stops being driven. ON for the first scan only. Tab. 4-17: Programmable controller special relays Function name Instruction Code No. of Data Digits Description Inverter reset H0FD 4-digits Resets the inverter and does not request a response. Inverter reset takes about 2.2 seconds to complete.  Operation mode H0FB 4-digits Sets the communication operation for the inverter.  Running frequency write H0ED 4-digits Changes the drive frequency by writing directly to the inverter RAM.  Run command H0FA 2-digits Sets forward rotation (STF) or reverse rotation (STR).  Inverter status monitor H07A 2-digits Monitors operation bits of the inverter.  Output frequency [speed] H06F 4-digits Monitors the frequency of the inverter.  Applicable Inverter Tab. 4-18: Inverter instruction codes  4 - 26 Applicable for all Mitsubishi FREQROL inverters. MITSUBISHI ELECTRIC Inverter Drive Control 4.2.3 Learning to Use the FX Family for Positioning Control Program example The following programming example is a hybrid program for FX2N(C) and FX3G/FX3GC/FX3GE/FX3S/ FX3U(C) controllers to be used with an E500 Series inverter. For the communication between PLC and inverter, CH 1 is used.* * When a FX3GE main unit is used, the communication channel of the built-in Ethernet is CH1. When a communication expansion board or a communication special adapter is connected to the PLC, that communication channel becomes CH2. Please modify the example program accordingly. The travel path and operation pattern are shown below. In the program below, the section "Controlling the inverter to move in the forward or reverse rotation direction" drives the inverter in the forward or reverse direction. When the forward rotation limit (X001) or reverse rotation limit (X000) is reached, the operation stops. For details on connecting the hardware for testing, refer to the appropriate product manual. Reverse rotation limit (X000) General purpose motor Forward rotation limit (X001) Forward rotation (H0FA bit1 is ON) Reverse rotation (H0FA bit2 is ON) Acceleration time (Pr.7) Speed (Hz) Deceleration time (Pr.8) 1s 1s (Pr.20) Accel/Decel reference frequency (Default: 60Hz) Running frequency (H0ED 씮 40 Hz) Time (s) 423010da.eps Fig. 4-16: Configuration and positioning pattern for the E500 Series inverter Before programming, there are several parameter settings that must be set to the inverter and PLC. Setting communication parameters for the E500 Series inverter While all operations are stopped (i.e. - the RUN indicator on the E500 is OFF), use the MODE key UP/DOWN keys parameters: and the SET key SET MODE , to change and/or confirm the following Parameter No. Parameter item Set value Setting contents Pr.79 Operation mode selection 0 External operation mode is selected when power is turned ON. Pr.117 Communication station number 00 to 31 Up to eight inverters can be connected. Pr.118 Communication speed 96 9600 bps (default) Pr.119 Stop bit / Data length 10 Data length: 7-bit Stop bit: 1-bit Pr.120 Parity check presence/absence selection 2 Even parity present Pr.122 Communication check time interval 9999 Communication check suspension Pr.123 Waiting time setting 9999 Set with communication data Pr.124 CRLF presence/absence selection 1 With CR, without LF Tab. 4-19: Communication parameters FX Positioning Control Systems 4 - 27 Learning to Use the FX Family for Positioning Control Inverter Drive Control Setting communication parameters for the FX2N(C)/FX3G/FX3GC/FX3GE/FX3S/FX3U(C) PLC For example, parameters are set in GX Developer as shown below.  Double-click Parameter and then PLC parameter from the project tree on the left side of the screen. If the project tree is not displayed on the screen, click View on the menu bar, and then click Project Data List. 423060da.eps Fig. 4-17: Project window  Click on the PLC system(2) tab in the "FX parameter" window and set the parameters as shown below:    ! " 423070da.eps Fig. 4-18: FX parameter window  Set CH1 as the channel to be used. (Set CH2 when a FX3GE PLC is used.) Put a checkmark in the Operate communication setting checkbox to activate the communication settings. Set [Protocol] to "Non-procedural", [Data length] to "7bit", [Parity] to "Even", and [Stop bit] to "1bit". Set [Transmission speed] to "9600" to match the speed setting in the inverter. Ignore these items.  Click the [End] button. 4 - 28 MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Family for Positioning Control  Create the ladder program as shown below.  Once the ladder program is complete, click on Online from the top menu bar in GX Developer and select Write to PLC. The "Write to PLC" window will appear.  Click the Param+Prog button and then click the Execute button. The parameters and the created program will be transferred to the PLC. To enable the transferred parameters, stop the PLC and then restart it. 423080da.e Fig. 4-19: Write to PLC window Inputs Outputs X000 Reverse rotation limit Y000 Inverter running (RUN) X001 Forward rotation limit Y001 Forward rotation X002 Forward rotation command input Y002 Reverse rotation X003 Reverse rotation command input Y003 Up to frequency (SU) — — Y004 Overload is applied (OL) — — Y006 Frequency detection (FU) — — Y007 Alarm occurrence Tab. 4-20: Used inputs and outputs FX Positioning Control Systems 4 - 29 Learning to Use the FX Family for Positioning Control Inverter Drive Control M8002 SET M10  Initial Pulse Use this for FX3G, FX3GC, FX3GE, FX3S or FX3U(C) PLCs M10 FNC271 IVDR Driving of write instruction FNC271 IVDR K0 H0FD H9696 K1 Inverter station number Inverter instruction code Write value CH 1 K0 H0FB H2 K1 Inverter instruction code Write value CH 1 K11 K0 H0FD H9696 Function number (Control) Inverter station number Inverter instruction code Write value K11 K0 H0FB H2 Function number (Control) Inverter station number Inverter instruction code Write value Inverter station number Use this for FX2N(C) PLCs FNC180 EXTR FNC180 EXTR 423090da.eps Fig. 4-20: Program example (1) Function Writing parameters to the inverter while the PLC is in RUN mode. Number  Description The write instruction is driven The inverter is reset [H9696 씮 "H0FD"] Computer link operation is specified [H2 씮 "H0FB"] Tab. 4-21: Description of the program example in fig. 4-20 4 - 30 MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Family for Positioning Control Use this for FX3G, FX3GC, FX3GE, FX3S or FX3U(C) PLCs FNC 12 MOVP K1 D200  Pr.1 FNC 12 MOVP K12000 D201 120 Hz FNC 12 MOVP K2 D202 Pr.2 FNC 12 MOVP K500 D203 5 Hz FNC 12 MOVP K7 D204 Pr.7 FNC 12 MOVP K10 D205 1s FNC 12 MOVP D206  D207  D200 K1  Write 4 D200 to parameters D207 CH 1 K8 Pr.8 FNC 12 MOVP K10 1s FNC 274 IVBWR K0 Inverter station number K4 Use this for FX2N(C) PLCs FNC 180 EXTR FNC 180 EXTR FNC 180 EXTR K13 K0 K1 K12000 Function Number (Write) Inverter station number Pr.1 120 Hz K13 K0 K2 K500 Function Number (Write) Inverter station number Pr.2 5 Hz K7 K10 K13 Function Number (Write) FNC 180 EXTR K0 Inverter station number Pr.7   1s K13 K0 K8 K10 Function Number (Write) Inverter station number Pr.8 1s M8029 RST  M10   "Execution completion" flag 4230a0da.eps Fig. 4-21: Program example (2) FX Positioning Control Systems 4 - 31 Learning to Use the FX Family for Positioning Control Function Number  Inverter Drive Control Description The maximum frequency (Pr. 1) is specified The maximum frequency (Pr. 1) is set to "120 Hz" The minimum frequency (Pr. 2) is specified The minimum frequency (Pr. 2) is set to "5 Hz" The acceleration time (Pr. 7) is specified Writing parameters to the inverter while the PLC is in RUN mode. The acceleration time (Pr. 7) is set to "1 sec"  The deceleration time (Pr. 8) is specified  The deceleration time (Pr. 8) is set to "1 sec"  The parameters are written at one time [Contents of D200–D207 씮 Pr. 1, Pr. 2, Pr. 7 and Pr. 8]  The maximum frequency (Pr. 1) is set to "120 Hz" [K12000 씮 Pr. 1]  The minimum frequency (Pr. 2) is set to "5 Hz" [K500 씮 Pr. 2]  The acceleration time (Pr. 7) is set to "1 sec" [K10 씮 Pr. 7]  The deceleration time (Pr. 8) is set to "1 sec" [K10 씮 Pr. 8]  Reset driving of write instruction Tab. 4-22: Description of the program example in fig. 4-21 4 - 32 MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Family for Positioning Control M8002 SET M11  Initial Pulse M11 FNC 12 MOVP Driving of write instruction K4000 D10 40 Hz Operation speed Use this for FX3G, FX3GC, FX3GE, FX3S or FX3U(C) PLCs FNC271 IVDR K0 H0ED D10 K1 Inverter Inverter Operation station instruction speed number code CH 1 Use this for FX2N(C) PLCs FNC180 EXTR K11 Function number (Control) M8029 K0 H0ED D10 Inverter Inverter Operation station instruction speed number code RST M11 SET M15 RST M15 "Execution completion" flag X000 Reverse rotation limit X001 Forward rotation limit X002 X000 X001 Forward rotation command input Reverse rotation limit Forward rotation limit X003 Reverse rotation command input M15 Operation stop M8002 X002 X003 Forward rotation command input Reverse rotation command input X003 X002 Reverse rotation command input Forward rotation command input Initial Pulse FNC228 K2M20 LD<> FNC 12 K2M20 MOV M21  M22  D81 Operation command is withdrawn D81 Operation command is withdrawn SET  M12 The write instruction is driven 4230b0da.eps Fig. 4-22: Program example (3)  The forward and reverse rotation limit switches must be wired so that they are turned ON by default (Normally closed contacts). When either of these limit switches turns OFF (due to the workpiece going out-of-bounds), the inverter operation will be stopped. FX Positioning Control Systems 4 - 33 Learning to Use the FX Family for Positioning Control Function Setting the operation speed of the inverter to 40 Hz while the PLC is in RUN mode. Number  Inverter Drive Control Description The write instruction is driven The operation speed is set as "40 Hz" The preset frequency is written to the inverter [Contents of D10 씮 "H0ED"] Reset driving of write instruction Operation stop "H0FA" is set to "00H" Controlling the inverter to move in the forward or reverse rotation direction. Operation is driven by input X002 or X003  Forward rotation command b1 of "H0FA" is set to ON  Reverse rotation command b2 of "H0FA" is set to ON  Changes in the operation commands (M20 to M27) are detected Tab. 4-23: Description of the program example in fig. 4-22 4 - 34 MITSUBISHI ELECTRIC Inverter Drive Control Learning to Use the FX Family for Positioning Control Use this for FX3G, FX3GC, FX3GE, FX3S or FX3U(C) PLCs M12 FNC271 IVDR Driving of write instruction K0 H0FA K2M20 K1  Inverter Inverter Write value ch.1 station instruction number code Use this for FX2N(C) PLCs FNC180 EXTR K11 H0FA K2M20 K0 Function Inverter Inverter number station instruction (Control) number code M8029  Write value RST M12 N0 M70 "Execution completion" flag M10 M11 M12  MC Driving of Driving of Driving of write write write instruction instruction instruction N0 M70 Use this for FX3G, FX3GC, FX3GE, FX3S or FX3U(C) PLCs M8000 FNC270 IVCK RUN monitor K0 H07A K2M100 Inverter Inverter Read station instruction destinanumber code tion K1 CH1 Use this for FX2N(C) PLCs FNC180 EXTR K10 K0 H07A K2M100 Function Inverter Inverter Read number station instruction destination (Monitor) number code M100 Inverter running M101 Forward rotation M102 Reverse rotation M103 Up to frequency M104 Overload is applied M106 Frequency is detected M107 Alarm occurrence Y000 Indicator lamp, etc. Y001 Indicator lamp, etc. Y002 Indicator lamp, etc. Y003 Indicator lamp, etc. Y004 Indicator lamp, etc. Y006 Indicator lamp, etc. Y007 Indicator lamp, etc. 4230c0da.eps Fig. 4-23: Program example (4)  MC denotes the start of a master control block. In this example, the master control block "N0" is only executed when data is not being written to the inverter. FX Positioning Control Systems 4 - 35 Learning to Use the FX Family for Positioning Control Function Controlling the inverter to move in the forward or reverse rotation direction. Number  Inverter Drive Control Description Operation commands are written [M20-M27 씮 "H0FA"] Reset driving of write instruction While data is not being written to the inverter, data is monitored. Monitoring operations of the inverter. Inverter status is read ["H07A" 씮 M100–M107] Contents of status (according to necessity) Tab. 4-24: Description of the program example in fig. 4-23 Use this for FX3G, FX3GC, FX3GE, FX3S or FX3U(C) PLCs FNC270 IVCK K0 H06F D50 K1 Inverter station number Inverter instruction code Read destination CH 1 K0 H06F D50 Inverter station number Inverter instruction code Read destination  Use this for FX2N(C) PLCs FNC180 EXTR K10 Function number (Monitor)  MCR  N0 END 4230d0da.eps Fig. 4-24: Program example (5)  MCR denotes the end of a master control block. In this example, the master control block "N0" is only executed when data is not being written to the inverter. Number Monitoring operations of the inverter.  Description Monitor frequency value with D50 ["H06F" 씮 D50] Tab. 4-25: Description of the program example in fig. 4-24 4 - 36 MITSUBISHI ELECTRIC FX2N-1PG-E positioning 4.3 Learning to Use the FX Family for Positioning Control FX2N-1PG-E positioning The FX2N(C) and FX3U(C) PLCs support connection with the FX2N-1PG-E special function block. Special function blocks are separate pieces of hardware that can be connected to PLCs to enhance control. Since special function blocks process information separately from the PLC, the scan time of the PLC is not adversely affected during operations controlled by special function blocks. This provides an advantage for programming. Additionally, special function blocks such as the FX2N-1PG-E offer separate, more advanced control through the use of their own inputs and outputs. An important reference for understanding positioning with the FX2N-1PG-E is: ● FX2N-1PG/FX-1PG User’s Manual – (JY992D65301) It is assumed that you will have read the above manual or that you will have it nearby for reference. 4.3.1 Overview of control The FX2N-1PG-E is a popular unit for performing general point-to-point positioning operations on 1 axis up to 100,000 pulses/second (100 kHz). A stepper motor or servo motor can be used with the FX2N-1PG-E to perform positioning operations. Some of the main advantages to using the FX2N-1PG-E for positioning as opposed to the FX1S, FX1N or FX3U(C) include: ● The flexible use of the zero point signal PG0 ● Two speed positioning operations with or without interrupt ● The option to choose the FP/RP pulse output method. FX Positioning Control Systems 4 - 37 Learning to Use the FX Family for Positioning Control 4.3.2 FX2N-1PG-E positioning Important buffer memory locations The FX2N-1PG-E contains 32 buffer memory (BFM) addresses, which are 16-bit (1 word) areas of memory that contain information relevant to the control of positioning operations. The FX2N(C) or FX3U(C) PLC that is connected to the FX2N-1PG-E can send and receive data to the buffer memory addresses to change and/or update information. This exchange of information takes place through dedicated PLC instructions known as the FROM/TO instructions. (For FX3U(C) PLCs, the MOV instruction can also be used to transfer data to/from special function blocks.) The following buffer memory addresses are used in the ladder program example below. For details on other BFM addresses, refer to the FX-1PG/FX2N-1PG User’s Manual (JY992D65301). BFM # Item Set value Note #0 Pulse rate 4,000 PLS/rev #2, #1 Feed rate 1,000 μm/rev Parameters — — Bit 1, Bit 0 System of units Bit 1: 1, Bit 0: 0 Combined system Bit 5, Bit 4 Multiplication factor Bit 5: 1, Bit 4: 1 103 Maximum speed 40,000 Hz #6 Bias speed 0 Hz #15 Acceleration/Deceleration time 100 ms #3 #5, #4 #18, #17 Target address 1 100 mm #20, #19 Operating speed 1 40,000 Hz #22, #21 Target address 2 150 mm #24, #23 Operating speed 2 10,000 Hz #25 Operation command — — Bit 0 M0 X000 Error reset Bit 1 STOP command M1 X001 Bit 2 Forward rotation limit M2 X002 Bit 3 Reverse rotation limit M3 X003 Bit 7 Relative/Absolute positioning M7 (Bit 7 = 0) Absolute positioning Bit 10 Two speed positioning START command M10 X007 D11, D10 mm #27, #26 Current address #28 Status information M20–M31 — #29 Error code D20 — Tab. 4-26: Buffer memory addresses of FX2N-1PG-E  4 - 38 Using a multiplication factor of 103 changes the units from μm to mm. MITSUBISHI ELECTRIC FX2N-1PG-E positioning 4.3.3 Learning to Use the FX Family for Positioning Control Program example In the example that follows, a two speed positioning instruction is used to move a drill 100 mm toward a block of wood with a high speed pulse frequency of 40 kHz. When the drill reaches the wood, the speed decreases to 10 kHz. The drill is then driven for 50 mm into the wood before decelerating to stop. Drill Wood M 1PG High speed Low speed 433010da.eps Fig. 4-25: Configuration The two speed positioning operation is illustrated in the following graph. Neither the zero point return nor the JOG instructions are used in the ladder program. Frequency (Hz) 40,000 Operation speed 2 BFM #24, #23 Operation speed 1 20,000 BFM #20, #19 0 100 Target address 1 BFM #18, #17 50 Target address 2 BFM #22, 21 0 50 100 150 200 433020da.eps Fig. 4-26: Positioning pattern FX Positioning Control Systems 4 - 39 Learning to Use the FX Family for Positioning Control FX2N-1PG-E positioning Although the following ladder program is not very complicated, it is important to establish good programming practice by paying attention to the order with which the PLC writes and reads to the buffer memory of the FX2N-1PG-E. Before writing the operation command (START command) to the module’s BFM from the PLC, several settings must be established such as target addresses 1 & 2, operation speeds 1 & 2, and various settings such as the bias speed, maximum speed, and the acceleration/ deceleration time. The most critical part of the program is the section where the operation commands are enabled by writing bits M0 to M15 to BFM#25. When the positioning START command turns ON, the operation begins with the specified settings. The ladder program example on the following page can be programmed with an FX2N(C) or FX3U(C) PLC and does not require an actuator (i.e., servo system) for testing. The following inputs are used in the program: Inputs X000 Error reset X001 STOP command X002 Forward rotation limit X003 Reverse rotation limit X007 2-speed positioning START command Tab. 4-27: Used inputs 4 - 40 MITSUBISHI ELECTRIC FX2N-1PG-E positioning Learning to Use the FX Family for Positioning Control M8002 Initial pulse FNC79 TO FNC79 DTO FNC79 TO FNC79 DTO FNC79 TO FNC79 TO M8000 RUN monitor M27 Error flag FNC78 FROM FNC78 FROM K0 K0 K4000 Unit No. BFM # Pulse rate K0 K1 K1000 Unit No. BFM # Feed rate No. of transfer points H32 K1 K0 K3 Unit No. BFM # K0 K4 Unit No. BFM # K1  No. of transfer points K1 Parameter No. of setting transfer points K40000 K1 Maximum No. of speed transfer points K0 K6 K0 Unit No. BFM # Bias speed K1 No. of transfer points K0 K15 Unit No. BFM # K0 K28 K3M20 K1 Unit No. BFM # Status info. M20-M31 No. of transfer points K0 K29 D20 K1 Unit No. BFM # Error code No. of transfer points K100 Accel/ Decel time K1 No. of transfer points   X000 M0  M1  M2  M3  M7  Error reset X001 STOP X002 Forward rotation limit X003 Reverse rotation limit M8000 RUN monitor 433030da.eps Fig. 4-27: Program example (1)  The forward and reverse rotation limit switches must be wired so that they are turned ON by default (Normally closed contacts). When these limit switches turn OFF (due the workpiece going out-of-bounds), M2 or M3 will turn ON and cause the pulse operation to stop. FX Positioning Control Systems 4 - 41 Learning to Use the FX Family for Positioning Control Number  FX2N-1PG-E positioning Description Set the pulse rate (PLS/rev) [K4000 씮 #0] Set the feed rate (μm/rev) [K1000 씮 #2,#1] Set the units to μm × 103 씮 mm; combined system [H32 씮 #3] Set the maximum speed (Hz) [K40000 씮 #5,#4] Set the bias speed (Hz) [K0 씮 #6] Set the acceleration/deceleration time (ms) [K100 씮 #15]  Read status information [K3M20 씯 #28]  Read error code [D20 씯 #29]  Reset error  STOP operation  Forward rotation limit  Reverse rotation limit  Use absolute positioning Tab. 4-28: Description of the program example in fig. 4-27 4 - 42 MITSUBISHI ELECTRIC FX2N-1PG-E positioning Learning to Use the FX Family for Positioning Control X007 FNC 79 DTO START K0 K17 K100 Unit No. BFM # Target address 1 K0 K19 K40000 K1 Unit No. BFM # Operation speed 1 No. of transfer points FNC 79 DTO FNC 79 DTO FNC 79 DTO K0 K21 K150 Unit No. BFM # Target address 2 K0 K23 K10000 Unit No. BFM # Operation speed 2 K1  No. of transfer points K1 No. of transfer points K1 No. of transfer points M10 M8000 RUN monitor FNC 79 TO K0 K25 K4M0 Unit No. BFM # Operation commands M0-M15 K0 K26 D10 FNC 78 DFROM Unit No. BFM # Current address K1 No. of transfer points K1  No. of transfer points END 433040da.eps Fig. 4-28: Program example (2) Number  Description Set the target address 1 [K100 씮 #18,#17] Set the operation speed 1 [K40000 씮 #20,#19] Set the target address 2 [K150 씮 #22,#21] Set the operation speed 2 [K10000 씮 #24,#23] Set the START command for two-speed positioning Write operation commands to the FX2N-1PG [K4M0 씮 #25]  Monitor the current address (mm) [D11, D10 씮 #27, #26] Tab. 4-29: Description of the program example in fig. 4-28 FX Positioning Control Systems 4 - 43 Learning to Use the FX Family for Positioning Control 4.4 FX2N-10PG positioning FX2N-10PG positioning The FX2N(C) and FX3U(C) PLCs support connection with the FX2N-10PG special function block. As described in section 4.3, special function blocks are separate pieces of hardware that can be connected to a PLC to enhance control. Due to the separate processing sequence that takes place in special function blocks through the use of buffer memory data, special function blocks provide a distinct advantage to PLC programming through individualized control that expands and improves PLC operations. Additionally, special function blocks such as the FX2N-10PG include extra input points and output points. An important reference for understanding positioning with the FX2N-10PG is: ● FX2N-10PG User’s Manual – (JY992D93401) It is assumed that you will have read the above manual or that you will have it nearby for reference. 4.4.1 Overview of control The FX2N-10PG is used to perform point-to-point positioning operations on 1 axis up to 1,000,000 pulses/second (1 MHz). With the FX 2N-10PG differential line driver type outputs that provide improved stability and better noise immunity, a stepper motor or servo motor can be controlled to perform a variety of positioning operations including multi-speed positioning and interrupt stop positioning. The controller also supports the connection of a manual pulse generator dial to control individual pulses from a position dial. Another advantage to using the FX2N-10PG is the ability to use a defined set of positioning operations in table format with up to 200 predefined table operations. 4 - 44 MITSUBISHI ELECTRIC FX2N-10PG positioning 4.4.2 Learning to Use the FX Family for Positioning Control Important buffer memory locations The FX2N-10PG contains 1,300 buffer memory (BFM) addresses, which are 16-bit (1 word) areas of memory that contain information relevant to the control of positioning operations. Most of these addresses are reserved for data to be used in table operations. The FX2N(C) or FX3U(C) PLC that is connected to the FX2N-10PG can send and receive data to the buffer memory addresses to change and/ or update information. This exchange of information takes place through dedicated PLC instructions known as the FROM/TO instructions. (For FX3U(C) PLCs, the MOV instruction can also be used to transfer data to/from special function blocks.) The following buffer memory addresses are used in the ladder program example below. For details on other BFM addresses, refer to the FX2N-10PG User’s Manual (JY992D93401). BFM # Item Set value Note #1, #0 Maximum speed 50,000 Hz #2 Bias speed 0 Hz #11 Acceleration time 100 ms #12 Deceleration time 100 ms #14, #13 Target address 1 50 mm #16, #15 Operation speed 1 50,000 Hz #25, #24 #26 #27 Current address D11, D10 mm Operation command — — Bit 0 Error reset M0 X000 Bit 1 STOP M1 X001 Bit 2 Forward rotation limit M2 X002 Bit 3 Reverse rotation limit M3 X003 Bit 8 Relative/Absolute positioning M8 (Bit 8 =1) Relative positioning Bit 9 START command M9 X007 Operation pattern — — b0 — — 1-speed positioning operation #28 Status information M20 – M31 #33, #32 Pulse rate 4,000 #35, #34 #36 #37 PLS/rev Feed rate 1,000 μm/rev Parameters — — Bit 1, Bit 0 System of units Bit 1: 1, Bit 0: 0 Combined system Bit 5, Bit 4 Multiplication factor Bit 5: 1, Bit 4: 1 103 D20 — Error code Tab. 4-30: Buffer memory addresses of FX2N-10PG  Using a multiplication factor of 103 changes the units from μm to mm. FX Positioning Control Systems 4 - 45 Learning to Use the FX Family for Positioning Control 4.4.3 FX2N-10PG positioning Program example In the program example that follows, a series of three individual 1-speed positioning operations are controlled from the FX2N-10PG with an output signal from the PLC that turns ON between each operation. An event timing chart is included on the next page to help understand the logic flow of the program. This example uses a conveyor system to carry boxes from one location to another. Each intermittent positioning operation positions a box in front of a scanner to scan it for 2 seconds. During each 2-second scan, Y000 from the PLC turns ON to illuminate an indicator light. The number of boxes to be scanned can be varied by changing the value of the counter, C100, in the program. Barcode scanner M Conveyor belt 10PG 443010da.eps Fig. 4-29: Configuration The positioning pattern is shown in the following figure. Neither the zero point return nor the JOG instructions are used in the ladder program example. Frequency (Hz) Operation speed 1 BFM #16, #15 50,000 25,000 0 Target address 1 BFM #14, #13 0 50 100 Distance (mm) 150 200 Y000 turns ON for 2 sec. 443020da.eps Fig. 4-30: Positioning pattern In order for the program to function correctly for the specified number of repetition cycles, the START command input (X007) must not be turned ON again during the positioning operation. If the START command is turned ON again, the counter C100 is reset, which clears the number of repetitions. 4 - 46 MITSUBISHI ELECTRIC FX2N-10PG positioning Learning to Use the FX Family for Positioning Control The following program can be used with an FX2N(C) or FX3U(C) PLC and does not require an actuator (i.e., servo system) for testing. The input and output points include: Inputs Outputs X000 Error reset X001 STOP command X002 Forward rotation limit X003 Reverse rotation limit — — X007 START command — — Y000 Indicator lamp (ON for 2 sec. intervals) — — Tab. 4-31: Used inputs and outputs The following figure is an event timing chart for part of the operation in the program below. X007 (START) M9 (START command) C100 T0 M26 (Positioning Complete Flag) 1 0 Positioning complete Y000 2 sec. One operation cycle 443030da.eps Fig. 4-31: Timing chart  The positioning complete flag will only be ON at the very beginning of the program when it is not the first time to operate the equipment and the power has not been recycled. FX Positioning Control Systems 4 - 47 Learning to Use the FX Family for Positioning Control M8002 Initial pulse FX2N-10PG positioning FNC 79 DTO FNC 79 DTO FNC 79 TO FNC 79 DTO FNC 79 TO FNC 79 TO FNC 79 TO M8000 RUN monitor M25 Error flag FNC 78 FROM FNC 78 FROM K0 K32 K4000 K1 Unit No. BFM # Pulse rate No. of transfer points K0 K34 K1000 K1 Unit No. BFM # Feed rate No. of transfer points H32 K1 K0 K36 Unit No. BFM #  Parameter No. of setting transfer points K0 K0 Unit No. BFM # K50000 K1 K0 K2 K0 Unit No. BFM # Bias speed K0 K11 K100 K1 Unit No. BFM # Accel time No. of transfer points K0 K12 K100 Unit No. BFM # Decel time K0 K28 K3M20 Unit No. BFM # Status info. M20-M31 No. of transfer points K0 K37 D20 K1 Unit No. BFM # Error code No. of transfer points Maximum No. of speed transfer points K1 No. of transfer points K1  No. of transfer points K1   X000 M0  M1  M2  M3  Error reset X001 STOP X002 Forward rotation limit X003 Reverse rotation limit 443040da.eps Fig. 4-32: Program example (1)  4 - 48 The forward and reverse rotation limit switches must be wired so that they are turned ON by default (Normally closed contacts). When these limit switches turn OFF (due to the workpiece going out-of-bounds), M2 or M3 will turn ON and cause the pulse operation to stop. MITSUBISHI ELECTRIC FX2N-10PG positioning Number  Learning to Use the FX Family for Positioning Control Description Set the pulse rate (PLS/rev) [K4000 씮 #1, #0] Set the feed rate ( μm/rev) [K1000 씮 #35, #34] Set the units to μm × 103 씮 mm; combined system [H32 씮 #36] Set the maximum speed (Hz) [K50000 씮 #1, #0] Set the bias speed (Hz) [K0 씮 #2] Set the acceleration/deceleration time (ms) [K100 씮 #11]  Set the acceleration/deceleration time (ms) [K100 씮 #12]  Read status information [#28 씮 K3M20]  Read error code [#37 씮 D20]  Reset error  STOP operation  Forward rotation limit  Reverse rotation limit Tab. 4-32: Description of the program example in fig. 4-32 FX Positioning Control Systems 4 - 49 Learning to Use the FX Family for Positioning Control FX2N-10PG positioning M8000  M8 RUN monitor X007 M9 START T0 2-sec. timer M8002 FNC 79 TO Initial pulse K0 Unit No. FNC 79 DTO K0 T0 X001 H1 K1 1-speed positioning No. of transfer points K13 K50 K1 BFM # Target address 1 No. of transfer points K0 K15 K50000 K1 Unit No. BFM # Operation speed 1 No. of transfer points Unit No. FNC 79 DTO K27 BFM # K2 M25 C100 2-sec. timer STOP M26 C100 Error flag Y000 Positioning complete flag  Counter K20 T0  RST C100  K1  X007 START M8000 RUN monitor FNC 79 TO FNC 78 DFROM K0 K26 K4M0 Unit No. BFM # Operation commands M0-M15 No. of transfer points K0 K24 D10 K1 Unit No. BFM # Current address No. of transfer points  END 443050da.eps Fig. 4-33: Program example (2) 4 - 50 MITSUBISHI ELECTRIC FX2N-10PG positioning Number  Learning to Use the FX Family for Positioning Control Description Use relative positioning START positioning Set 1-speed positioning [H1 씮 #27] Set the target address 1 [K50 씮 #14, #13] Set the operation speed 1 [K50000 씮 #16, #15] Counter to repeat operation 2 times  Y000 indicator light  2 second timer  Reset C100  Write operation commands to the FX2N-10PG [#26 씮 K4M0]  Monitor the current address (mm) [# 24, #25 씮 D11, D10] Tab. 4-33: Description of the program example in fig. 4-33 FX Positioning Control Systems 4 - 51 Learning to Use the FX Family for Positioning Control 4.5 FX2N-10GM and FX2N-20GM positioning FX2N-10GM and FX2N-20GM positioning The FX2N-10GM and FX2N-20GM controllers (also referred to as the 10GM and 20GM) are unique in that they can operate as individual stand-alone units with their own programming language, power supplies and separate sets of inputs and outputs. This means that the 10GM and 20GM can be used with or without a PLC to control logic instructions and standard positioning operations. Important references for understanding positioning with the FX2N-10GM and FX2N-20GM are: ● FX2N-10GM/FX2N-20GM Hardware/Programming Manual – (JY992D77801) ● FX-PCS-VPS/WIN-E Software Manual – (JY992D86801) It is assumed that you will have read and understood the above manuals or that you will have them nearby for reference. 4.5.1 Overview of control Along with the capability to be used for independent control, the FX2N-10GM (1 axis of control) and FX2N-20GM (2 axes of control) can be used as special function blocks in conjunction with an FX2N(C) or FX3U(C) PLC to transfer data back and forth via dedicated buffer memory addresses. These addresses overlap with and replace the special M and special D registers in the 10GM and 20GM. One particular advantage to using a PLC with the FX2N-10GM is the ability to use the table method where up to 100 positioning operations can be defined and saved for consecutive execution. The FX2N-10GM and FX2N-20GM output pulse trains to control a stepper/servo motor with a maximum output frequency of 200,000 pulses/second (200 kHz). This offers the same speed as the FX3U high speed positioning adapters, except that the GM controllers use open collector type outputs instead of differential line driver type. Combined with standard positioning operations such as 1-speed and 2-speed positioning, the 10GM and 20GM include an electrical zero return function to return the motor(s) to a specific user-defined address without the use of a hardware DOG switch. This feature is unique since it is not available with any of the other FX Series controllers. The main differences between the FX2N-10GM and FX2N-20GM are listed in the following table. FX2N-10GM FX2N-20GM Inputs/Outputs 4 inputs, 6 outputs 8 inputs, 8 outputs Expandable I/O No Yes (48 additional I/O) Memory type EEPROM Built-in RAM (RAM has battery backup) (EEPROM cassette optional) Memory size 3.8K steps 7.8K steps Table method Yes No Connectors CON1: Control + I/O CON2: Axis1 CON1: I/O CON2: Control CON3: Axis1 CON4: Axis2 Tab. 4-34: FX2N-10GM compared with FX2N-20GM 4 - 52 MITSUBISHI ELECTRIC FX2N-10GM and FX2N-20GM positioning 4.5.2 Learning to Use the FX Family for Positioning Control Using dedicated software to set positioning for the FX2N-20GM In the example that follows, an FX2N-20GM is used with the FX-PCS-VPS/WIN-E software to perform positioning on two axes. The FX-PCS-VPS/WIN-E software (also referred to as VPS) is beneficial for defining positioning parameters and setting positioning operations. Operations can be visually organized in a flow chart format and a monitoring window can be configured with user-defined objects. To test operations with an FX2N-20GM, an actuator (i.e., servo system) and PLC are not required. For information on the cables necessary to connect an FX2N-20GM to a personal computer for programming, refer to the FX2N-10GM/FX2N-20GM Hardware/Programming Manual (JY992D77801). Operation objective The objective of this example is to use the FX2N-20GM to trace a path using 1-speed, linear interpolation, and circular interpolation operations. Fig. 4-34: Path of travel 270 D E Start point A G F C H END point B 270 0 452010da.eps Point Coordinate Description A (X, Y) This point can be anywhere. B (0, 0) Move to zero point, wait for 2 seconds C (80, 100) Output Y0 turns ON, wait for 2 seconds D (110, 200) — E (200, 200) — F (200, 100) — G (150, 100) Output Y0 turns OFF, wait for 2 seconds H (150, 70) End point Tab. 4-35: Operation details FX Positioning Control Systems 4 - 53 Learning to Use the FX Family for Positioning Control FX2N-10GM and FX2N-20GM positioning The output Y0 is used to imitate a pen, or other end effector. Each point-to-point operation is described as follows: ● (A to B) – Return to Electrical Zero ● (B to C) – High speed positioning ● (C to D) – Linear interpolation ● (D to E) – High speed positioning ● (E to F) – Clockwise circular interpolation ● (F to G) – High speed positioning ● (G to H) – High speed positioning Getting started with FX-PCS-VPS/WIN-E Open a new file with VPS and choose [FX(2N)/E-20GM with simultaneous 2 axis]. This setting allows for linear and circular interpolation operations to be placed on a flow chart for positioning. Take a minute to familiarize yourself with the layout and menu items of the software. The panel on the left side of the screen is required for selecting the Flow, Code, and Func components to place into the Flow Chart window. To place an item into the Flow Chart window, click on the item once and then click anywhere within the Flow Chart window. Once an item has been placed in the Flow Chart window, it can be dragged to any position. Items are connected by using the wire tool to drag a wire between each item. Creating a Flow Chart The flow chart on the next page demonstrates basic positioning using the FX2N-20GM. Since this program is designed to be used without a mechanical plotter, an electrical zero point is used for reference. Re-create the diagram on the next page by using the Code and Func buttons on the left panel of the VPS software to select and place each function block. 4 - 54 MITSUBISHI ELECTRIC FX2N-10GM and FX2N-20GM positioning Learning to Use the FX Family for Positioning Control Many programs can be stored in a GM controller at one time. This example uses program number 0. A to B The "DRV Ret" command is used to move from the start point to the electrical zero point. Wait 2 seconds Here, the program waits for 2 seconds, using a 10ms timer. B to C This command indicates a high speed positioning command to position C. Turn Y0 ON Here, Y0 is turned ON to mimic the use of an end effector tool. Wait 2 seconds This timer allows for a tool to be activated, or for an operation to be executed. C to D This command is the start of a continuous steady path using linear interpolation to position D. D to E Only the X-axis is used in this 1-speed positioning instruction to move to position E. E to F For a smooth arc to position F, circular interpolation is used. This example shows the start and end positions as well as the radius (r) and speed (f ). F to G Only the X-axis is used in this 1-speed positioning instruction to move to position G. Turn Y0 OFF Here, Y0 is turned OFF to mimic the end of use for an end effector. Wait 2 seconds A timer is used to ensure the end effector operation has finished completely. G to H This command rapidly moves the Y-axis for a short distance so that it can reach position H. This denotes the end of the program, where the controller waits for the next start command. 452020da.eps Fig. 4-35: Flow chart of path of travel on page 4-53 FX Positioning Control Systems 4 - 55 Learning to Use the FX Family for Positioning Control FX2N-10GM and FX2N-20GM positioning Creating a Monitor Window Along with the flow chart, create a monitoring window similar to the one shown below. All of the items on the monitoring window can be found using the Insert menu at the top of the screen. 452030da.eps Fig. 4-36: Monitoring window Item Description Current Position This displays (monitors) the current address during positioning. Plotting Double click on the plot area to change the scale. Device Status Select Y0, 1 point. Rectangle Create a rectangle around Y000 by selecting the rectangle button from the drawing toolbar at the top of the screen. While the rectangle is selected, the background color can be changed by pressing the [B] Brush Color button. Manual operation FX-GM Status X-axis Y-axis Start Start Stop Stop + Jog + Jog - Jog - Jog This is a lamp that automatically monitors positioning operations. Tab. 4-36: Used items from the Insert menu Setting parameters In addition to the preparation of a positioning program, diversified parameters should be set in the FX2N-20GM. In this example, only a few parameters need to be set. (When working with various equipment such as a mechanical plotter that uses an X-Y plotting table, the parameters should be set in accordance with the mechanism being used. These settings depend on the specific plotter type and should be located in the documentation provided with the plotter.) 4 - 56 MITSUBISHI ELECTRIC FX2N-10GM and FX2N-20GM positioning Learning to Use the FX Family for Positioning Control Below are the four positioning parameter windows from VPS. The settings on these windows should be copied for BOTH the X- and Y- axes before performing positioning.  Open the "Parameter Units" window by selecting Parameters main menu bar at the top of the screen. Positioning Units from the Specify the same settings for the Y-axis 452040da.eps Fig. 4-37: Parameter Units window  Open the Parameter Speed window by selecting Parameters the menu bar at the top of the screen. Positioning Speed from Specify the same settings for the Y-axis 452050da.eps Fig. 4-38: Parameter Speed window The Max speed is set very low in order for the VPS software to trace the path during operation through the Monitoring window. In turn, both the JOG speed and interpolation value must be reduced. (In practice, it is impossible to have the JOG speed set to a value higher than the Max speed setting.) FX Positioning Control Systems 4 - 57 Learning to Use the FX Family for Positioning Control FX2N-10GM and FX2N-20GM positioning  Open the Parameter Machine Zero window by selecting Parameters Machine Zero from the menu bar at the top of the screen. Positioning Specify the same settings for the Y-axis 452060da.eps Fig. 4-39: Parameter Machine Zero window Since mechanical hardware will not be connected to the FX2N-20GM for this example, it is not necessary to configure the limit switch and DOG switch settings in the parameters. It is, however, necessary to reduce the Creep speed and the Zero return speed.  For the last parameter screen, open the Parameter Settings window by selecting Parameters Positioning Settings from the menu bar at the top of the screen. NO CHANGES 452070da.eps Fig. 4-40: Parameter Settings window None of the parameters in the Parameter Settings window need to be changed. When using a mechanical plotter, however, these settings become more important. 4 - 58 MITSUBISHI ELECTRIC FX2N-10GM and FX2N-20GM positioning 4.5.3 Learning to Use the FX Family for Positioning Control Testing and monitoring operations After setting the parameters and defining the positioning travel paths described in the previous section, testing can be performed as follows. Check the communication between the FX2N-20GM and the personal computer by selecting FX-GM Com Port and then the Test button. Make sure the GM unit is in ‘MANU’ mode by checking the hardware switch on the unit. Download the project by selecting FX-GM Write to FX-GM from the menu bar at the top of the screen and select the Write after saving file button. The program will be downloaded to the 20GM.  In VPS, start the Monitor mode by clicking the Monitor icon on the tool bar as shown below. Fig. 4-41: VPS icon bar Monitor icon 453010da.eps The monitor mode window will appear with three windows: Monitoring window X-axis and Y-axis – Monitor Mode Sub-Task – Monitor Mode This is the window that has already been created where the unit will be controlled and monitored from. At first, this window will be empty, but as soon as the program is started, the flow chart will appear. Each positioning operation will be highlighted in RED as it is performed. This window is not needed since there are not any sub-routines being used. This window can be minimized to create more space on the screen.  After minimizing the Sub-Task – Monitor Mode window, resize the Monitoring Window and X-axis and Y-axis – Monitor Mode windows. 453020da.eps Fig. 4-42: X-axis and Y-axis – Monitor mode windows Before starting the operation, it is necessary to set the start point. This can be done by using the X JOG+ and Y JOG- buttons or by double clicking on the current position [X: 0 Y: 0] display. FX Positioning Control Systems 4 - 59 Learning to Use the FX Family for Positioning Control FX2N-10GM and FX2N-20GM positioning  Double click the current position display in the Monitoring window to set the start point. After editing the current address to X: 50 and Y: 125, click on the Write to FX-GM button for each axis. As the address information is changed, red lines will appear on the plotter. This shows the current position. To clear these red lines before positioning, double click on the plotting area, and then click on the Clear button. 453030da.eps Fig. 4-43: Monitoring Window  The next step is to switch the FX2N-20GM to "AUTO" mode by moving the switch on the unit to "AUTO".  Finally, on the Monitoring Window screen, click on either the X START or Y START buttons. The positioning operation will be performed and the plot result should look identical to the one shown in the following picture. 453040da.eps Fig. 4-44: Resulting path of travel and flow chart  To run the program again, set a new start position (or let it start from where it is), clean the plot area, and press the X START or Y START button again. If the plot does not look like the one above, check the flow chart program against the program listed in section 4.5.2 (Creating a Flow Chart). 4 - 60 MITSUBISHI ELECTRIC FX3U-20SSC-H positioning 4.6 Learning to Use the FX Family for Positioning Control FX3U-20SSC-H positioning The FX3U(C) PLC supports connection with the FX3U-20SSC-H special function block, which is an advanced module to perform positioning operations on two axes using Mitsubishi’s fiber optic communication servo network known as SSCNET III (Servo System Controller Network). Important references for understanding positioning with the FX3U-20SSC-H include: ● FX3U-20SSC-H User’s Manual – (JY997D21301) ● FX Configurator-FP Operation Manual – (JY997D21801) It is assumed that you will have read the above manuals or that you will have them nearby for reference. 4.6.1 Overview of control Using an FX3U PLC with the FX3U-20SSC-H (20SSC-H) module and two Mitsubishi MR-J3-B servo amplifier systems, high speed positioning with pulse output frequencies up to 50,000,000 pulses/second (50 MHz) is possible on two axes. However, since motors compatible with the MR-J3-B servo amplifier system have a maximum rated speed of 6,000 RPM, the maximum controllable speed from the 20SSC-H becomes: 6,000 rev min 262,144 PLS rev PLS 1 = 26,214,400 60 sec The FX3U-20SSC-H provides several advantages compared to other controllers in the FX family: FX3U-20SSC-H Feature Advantage Bidirectional communication With SSCNET III, the PLC can communicate with the servo amplifier to monitor torque, servo status flags, servo parameters and absolute position data. Easy to use wiring. Wiring High immunity to noise from external devices. Long distance wiring (50m). Software Easy setup of parameters and table data (up to 300 table operations per axis). Convenient use of monitoring and testing functions. Tab. 4-37: Features and advantages of FX3U-20SSC-H With the use of a built-in Flash ROM, the FX3U-20SSC-H can store data permanently via non-volatile storage. Since the flash memory transfers all of its data to the buffer memory of the 20SSC-H each time the power is turned ON, the flash memory provides extra benefit for applications requiring a default set of data to be automatically loaded. This eliminates the need to use a PLC program for setting parameters and table data, which can greatly simplify the length and complexity of a ladder program. The FX3U-20SSC-H includes an input connector to connect manual pulse generator dials and various switches such as the START, DOG, and interrupt switches. These inputs assist in controlling positioning operations and are necessary to operate instructions such as the interrupt 1-speed constant quantity feed instruction and the DOG type mechanical zero return command. FX Positioning Control Systems 4 - 61 Learning to Use the FX Family for Positioning Control 4.6.2 FX3U-20SSC-H positioning Using dedicated software to set positioning for the FX3U-20SSC-H In the example that follows, an FX3U-20SSC-H is used with FX Configurator-FP to perform positioning on two axes with an XY-axis table operation. FX Configurator-FP is convenient for defining servo parameters, positioning parameters and table information. It is also recommended to be used whenever possible since the use of a sequence program for setting parameters and table data requires many steps and devices, resulting in a complex program and increased PLC scan time. Different from other FX positioning controllers, the FX3U-20SSC-H requires connection to a servo system to perform positioning. For details on connecting an MR-J3-B servo system, refer to the appropriate servo manual. Setting parameters Prior to setting positioning parameters and servo parameters, check to verify the connection between the PLC and the personal computer is valid. Since ladder logic in the PLC is not used in this example, set the RUN/STOP switch on the PLC to STOP.  Open a new file in FX Configurator-FP by clicking on the Make new file button.  Expand the tree of folders in the File data list panel on the left-hand side of the screen by double clicking on Unset file / FX3U-20SSC-H, Edit, and then Monitor.  Go to Online  Connection setup  Comm. Test Verify that the devices are communicating properly.  Double click on Positioning parameters in the File data list panel on the left-hand side of the screen to modify the positioning parameters. Set items in the Item column for both the X- and Y- axes as shown: 462020da/462030da/462040da.eps  Next, double click on Servo parameters in the File data list panel on the left-hand side of the screen to modify the servo parameters. Set items from the Kind column for both the X- and Y- axes as shown: 462050da/462060da.eps 4 - 62 MITSUBISHI ELECTRIC FX3U-20SSC-H positioning Learning to Use the FX Family for Positioning Control Creating XY-axis table operation data Double click on XY-axis Table information in the File data list panel on the left-hand side of the screen to open the XY table. Maximize the window to enter the following data: No. Command Code 0 Incremental address specification 1 X-axis positioning at 1-step speed 2 Y-axis positioning at 1-step speed 3 XY-axis positioning at 1-step speed 4 Circular interpolation (CNT,CW) 5 Dwell 6 XY-axis positioning at 2-step speed 7 XY-axis positioning at 2-step speed 8 Dwell 9 XY-axis positioning at 2-step speed 10 XY-axis positioning at 2-step speed 11 Dwell 12 Circular interpolation (CNT,CCW) 13 Dwell 14 XY-axis positioning at 2-step speed 15 XY-axis positioning at 2-step speed 16 Dwell 17 Linear interpolation 18 Dwell 19 Jump 20 End Address x:[PLS] y:[PLS] Speed fx:[Hz] fy:[Hz] Arc center i:[PLS] j:[PLS] — — — — — — 20,000,000 10,000,000 — — — — — — — 20,000,000 10,000,000 5,000,000 2,000,000 — -5,000,000 2,000,000 — 0 15,000,000 5,000,000 0 — 5,000,000 — — — — — — 10,000,000 10,000,000 — -10,000,000 10,000,000 — -10,000,000 10,000,000 — 10,000,000 10,000,000 — — — — — — — 10,000,000 10,000,000 — -10,000,000 10,000,000 — -10,000,000 10,000,000 — 10,000,000 10,000,000 — — — — — — — 0 7,000,000 5,000,000 0 — 5,000,000 — — — — — — 10,000,000 15,000,000 — 5,000,000 7,500,000 — -5,000,000 7,500,000 — -10,000,000 15,000,000 — — — — — — — 20,000,000 26,214,400 — -20,000,000 — — — — — — — — — — — — — — — — — Time [10ms] Jump No. m code — — -1 — — -1 — — -1 — — -1 — — -1 30 — -1 — — -1 — — — 30 — -1 — — -1 — — — 30 — -1 — — -1 30 — -1 — — -1 — — — 30 — -1 — — -1 150 — -1 — 0 — — — — Tab. 4-38: XY-axis table operation data FX Positioning Control Systems 4 - 63 Learning to Use the FX Family for Positioning Control FX3U-20SSC-H positioning Writing data to the FX3U-20SSC-H Write the servo parameters, positioning parameters and table information to the FX3U-20SSC-H BFM button and placing check marks in the following and Flash ROM by pressing the Write to module boxes. Change the range of table data to be written to 0–25. 462080da.eps Fig. 4-45: Write to module window Next, reset the module by pressing the System reset servo parameters. 4 - 64 button. This is necessary to refresh the MITSUBISHI ELECTRIC FX3U-20SSC-H positioning 4.6.3 Learning to Use the FX Family for Positioning Control Testing and monitoring operations With the parameters and table information saved to the FX3U-20SSC-H module from section 4.6.3 and the PLC in STOP mode, testing is performed by using TEST MODE in FX Configurator-FP.  Enter TEST MODE by pressing the Test On/Off button.  After entering TEST MODE, click on the operation Test X-axis Operation test window. button to display the X-axis  Next, select the XY-axis table operation from the X-axis/Pattern combination box and click on the Start button to begin positioning. Note that because the table operation includes a "Jump" command, the operation will continuously loop from row 0 to row 20. 463030da.eps Fig. 4-46: X-axis operation test window  To stop positioning, click on the All axis stop or Stop button. After stopping the table operation, a variety of other positioning operations can be tested from the X-axis/Pattern combination box such as 1-speed positioning, 2-speed positioning, and linear interpolation. For additional control in TEST MODE, the other tabs at the top of the X-axis Operation test window can be used according to the following information: Position start Feed present value Speed CHG CHG Positioning operations can be executed from this window. Target address and operation speed data is defined here. The value of the current address can be changed using this window. FX Positioning Control Systems Two operations for changing the speed of the motor are available from this window. OPR JOG/MPG By clicking on the [REQ. OPR] button, zero return is executed. JOG operation and manual pulsar operation testing can be performed from this window. 4 - 65 Learning to Use the FX Family for Positioning Control 4.6.4 FX3U-20SSC-H positioning Important buffer memory locations The FX3U-20SSC-H buffer memory includes five separate data areas for: Monitor data, Control data, Table data, Positioning parameter data, and Servo parameter data. With "read only" or "read/write" access, buffer memory addresses use bit and word information to control positioning operations. Similar to the FX2N-10PG, a large percentage of the BFM is dedicated to the control of table positioning operations. Monitor data Control data Table information Used to store predeUsed to monitor the Used to control current position, sta- positioning opera- fined table data. tions. tuses, etc. Positioning parameters Servo parameters Used to store parameters such as the max. speed and accel/decel times. Used to store parameters relevant to the servo(s). The following buffer memory addresses are used in the ladder program example below. For details on other BFM addresses, refer to the FX3U-20SSC-H User’s Manual (JY997D21301). BFM Area Monitor data BFM # Item Set value Note #1, #0 X-axis current address D1, D0 PLS #101, #100 Y-axis current address D101, D100 PLS #28 X-axis status information D10 — #128 Y-axis status information D110 — #501, #500 X-axis target address 1 10,000,000 PLS X-axis operation speed 1 2,000,000 Hz (PLS/sec) X-axis operation command 1 M0–M15 — #503, #502 #518 Control data Bit 0 Error reset M0 X007 Bit 1 STOP M1 X006 Bit 2 Forward rotation limit M2 X000 Bit 3 Reverse rotation limit M3 X010 Bit 4 Forward rotation JOG(+) M4 X001 Bit 5 Reverse rotation JOG(-) M5 X002 Bit 6 Zero-return M6 X003 Bit 8 Relative/Absolute positioning M8 (Bit 8 = 1) Relative positioning Bit 9 START command M9 X004, X005 M100–M115 — Y-axis operation command 1 #618 #519 #520 Positioning parameter data Bit 0 Error reset M100 X007 Bit 6 Zero-return M106 X003 X-axis operation command 2 M20–M35 — Bit 4 M24 X001, X002 X-axis operation pattern selection — — Bit 0 1-speed positioning H1 X004 Bit 10 Table operation (simultaneous) Positioning parameter enable command H400 X005 #521 Table operation start number 0 Table row #0 #14013, #14012 X-axis JOG speed 1,000,000 Hz (PLS/sec) Tab. 4-39: Buffer memory addresses of FX3U-20SSC-H 4 - 66 MITSUBISHI ELECTRIC FX3U-20SSC-H positioning 4.6.5 Learning to Use the FX Family for Positioning Control Program example The following program uses buffer memory communication to perform JOG positioning, 1-speed positioning, and table operation control. The XY-table created in the previous section can be used in this example. For this example, FX Configurator-FP should be used to specify the servos, change the maximum speed, and to set the zero return mode as described in section 4.6.2. The ladder program is to be used with an FX3U(C) PLC and MR-J3-B servo system. Without these components, the program cannot be tested. Input points from the PLC include: Inputs X000 X-axis Forward rotation limit X005 X001 X-axis Forward rotation JOG(+) X006 START command (XY-axis table operation) STOP command X002 X-axis Reverse rotation JOG(-) X007 Error reset X003 X- and Y-axis Zero return X010 X-axis Reverse rotation limit X004 START command (X-axis 1-speed operation) — — Tab. 4-40: Used inputs FX Positioning Control Systems 4 - 67 Learning to Use the FX Family for Positioning Control FX3U-20SSC-H positioning M8000 U0\ G0 FNC 12 DMOV RUN monitor BFM # FNC 12 DMOV U0\ G100 BFM # FNC 12 MOV U0\ G28 BFM # FNC 12 MOV U0\ G128 BFM # D0  X-axis current address D100 Y-axis current address D10 X-axis status information D110 Y-axis status information X000 M2 Forward rotation limit X010 M3 Reverse rotation limit X001 X-axis JOG(+) FNC 12 DMOVP K100000 X-axis JOG speed U0\ G14012 BFM # X002 PLS X-axis JOG(-)  M24  Positioning parameter enable command 465010da.eps Fig. 4-47: Program example (1)  The forward and reverse rotation limit switches must be wired so that they are turned ON by default (Normally closed contacts). When these limit switches turn OFF (due to the workpiece going out-of-bounds), M2 or M3 will turn ON and cause the pulse operation to stop. Number Description A Monitor X-axis current address [#1, #0 씮 D1, D0] B Monitor Y-axis current address [#101, #100 씮 D101, D100] C Monitor X-axis status info. [#28 씮 D10] D Monitor Y-axis status info. [#128 씮 D110] E X-axis forward rotation limit F X-axis reverse rotation limit G Set the X-axis JOG speed (Hz) [K100000 씮 #14013, #14012] H Enable the X-axis JOG speed Tab. 4-41: Description of the program example in fig. 4-47 4 - 68 MITSUBISHI ELECTRIC FX3U-20SSC-H positioning Learning to Use the FX Family for Positioning Control M8000 FNC 12 MOV RUN monitor K4M20 X-operation command 2 M20-M35 X001 X002 X-axis JOG(+) X-axis JOG(-) X002 X001 X-axis JOG(-) X-axis JOG(+) U0\ G519  BFM # M4 M5 X003 PLS M6 PLS M106 H1 U0\ G520 Zero return X004 X005 X-axis 1-speed operation XY-axis Table operation FNC 12 MOVP X-axis 1-speed positioning FNC 12 DMOVP FNC 12 DMOVP K10000000 X004 XY-axis Table operation X-axis 1-speed operation U0\ G500 X-axis Target address 1 BFM # K2000000 U0\ G502 X-axis Operation speed 1 X005 BFM # FNC 12 MOVP H400   BFM # M8  U0\ G520  XY-Table BFM # operation (simultaneous) FNC 12 MOVP K0 U0\ G521 XY-Table row #0 BFM # PLS M9 X004   X-axis 1-speed operation X005 XY-axis Table operation 465020da.eps Fig. 4-48: Program example (2) FX Positioning Control Systems 4 - 69 Learning to Use the FX Family for Positioning Control Number  FX3U-20SSC-H positioning Description Write X-axis operation command 2 [K4M20 씮 #519] X-axis JOG(+) operation is being performed X-axis JOG(-) operation is being performed X-axis zero return Y-axis zero return Set X-axis 1-speed positioning [H1 씮 #520]  Set X-axis target address 1 [K10000000 씮 #501, #500]  Set X-axis operation speed 1 [K2000000 씮 #503, #502]  Use relative positioning  Set XY-axis simultaneous table operation [H400 씮 #520]  Set starting row No. for XY-table operation [K0 씮 #521]  START positioning Tab. 4-42: Description of the program example in fig. 4-48 X006 M1  X-axis STOP X007 PLS M0 PLS M100 K4M0 U0\ G518 Error reset M8000 FNC 12 MOV RUN monitor X-operation BFM # command 1 M0-M15 FNC 12 MOV K4M100 U0\ G618 Y-operation BFM # command 1 M100-M115 END 465030da.eps Fig. 4-49: Program example (3) Number  Description STOP operation Reset X-axis error Reset Y-axis error Write X-axis operation command 1 [K4M0 씮 #518] Write Y-axis operation command 1 [K4M100 씮 #618] Tab. 4-43: Description of the program example in fig. 4-49 4 - 70 MITSUBISHI ELECTRIC Index Index A AC servo system E Encoder Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Absolute type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Incremental type . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Acceleration time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Relative type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Actuator type Equation AC servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Command pulse frequency . . . . . . . . . . . . . . . . . 3-12 Brake motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Moving speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Clutch brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Number of rotations . . . . . . . . . . . . . . . . . . . . . . . . 3-12 DC servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Transfer distance per pulse . . . . . . . . . . . . . . . . . 3-12 General purpose inverter . . . . . . . . . . . . . . . . . . . . 1-4 Transfer distance per rotation . . . . . . . . . . . . . . . 3-12 General purpose motor . . . . . . . . . . . . . . . . . . . . . . 1-4 F Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Stepping motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 B Feed quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 FREQROL Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Brake Dynamic brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 G Regenerative brake . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 C GX Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 GX IEC Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 GX Works2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Command pulse control FP/RP method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 H PLS/DIR method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Command pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Control method J Limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Pulse command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 JOG Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Pulse count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 L D DDRVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Ladder program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 DDRVI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 M Deceleration time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Deviation counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 DOG search function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Memory addresses DOG type zero return . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 FX1S, FX1N, FX3G, FX3GC, FX3GE, FX3S, FX3U(C) PLCs 4-4 DTBL instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 FX2N-10PG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 FX2N-1PG-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 FX3U-20SSC-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 FX Positioning Control Systems I Index S P Position control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 Servo lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Positioning example Setting of target position Carrier robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Absolute method . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Cart travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Incremental method . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Constant feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Sink type input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Drilling in steel sheet . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Sink type output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Index table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Special function block Lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 FX2N-10PG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44 Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 FX2N-1PG-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 Programming example E500 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 FX1N PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 FX1S PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 FX2N-10PG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 FX3U-20SSC-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-61 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 X XY-axis table operation . . . . . . . . . . . . . . . . . . . . . . . . . .4-63 FX2N-1PG-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 FX2N-20GM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 FX3G/FX3GC/FX3GE/FX3S/FX3U(C) PLC . . . . . . . . 4-12 FX3U-20SSC-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62 II MITSUBISHI ELECTRIC HEADQUARTERS EUROPEAN REPRESENTATIVES EUROPEAN REPRESENTATIVES EUROPE GEVA Wiener Straße 89 A-2500 Baden Phone: +43 (0)2252 / 85 55 20 Fax: +43 (0)2252 / 488 60 AUsTRIA Beijer Electronics SIA Ritausmas iela 23 LV-1058 Riga Phone: +371 (0)6 / 784 2280 Fax: +371 (0)6 / 784 2281 Mitsubishi Electric Europe B.V. 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