Introducing the fully automated application of motion control systems in the mechanical field

For machinery manufacturers, the pressure of performance and cost is constantly increasing. Even in the field of actuator technology, it is absolutely necessary to create new control structures to meet the ever-increasing new requirements. Today, motion control based on electronic transmission systems provides greatly increased flexibility, which can never be achieved by mechanical systems.

　　The primo device provided by Pilz is specially designed for packaging machinery and is flexible to use. It is also suitable for other application areas with similar requirements.

　　The primo device provides an opportunity to replace the common structure and expand the system. According to customer requirements, the automation function can be fully realized by using the PMC (Pilz Motion Control) primo control system or connecting it to a main control system (such as PLC, IPC). This is particularly interesting for packaging machinery manufacturers.

　　The PMC primo control system is a high-performance product series that can meet various requirements and realize full automation functions, including completing various complex motion sequences. It issues instructions and selects the appropriate solution according to the respective requirements. The controller-based PMC primo16+ control system with separate power components is suitable for multi-axis control and is very flexible in application, but requires a large space.

　　The PMC primo transmission control system has an integral power unit with which up to 9 transmissions can be controlled.

　　Open complete system for controlling small and medium numbers of axes

　　The control system with integral drives is specially designed for a small or medium number of spindles. In a local area network in stand-alone mode, it can further operate and control up to 8 drives. In this case, the drive equipped with the PMC primo control system has the function of a central controller.

　　The system has all the functions required for full automation. It has traditional I/O input/output expansion interfaces and Ethernet service interfaces for effective programming and remote maintenance, as well as compact flash memory card slots. It can communicate via CAN, Modbus or PROFIBUS, which makes the entire system very open.

　　Since 9 axes are synchronized and run as 8 electronic cams, the integrated soft PLC can scan 1000 instructions in IL coding form with a scanning time of less than 50 microseconds. This integrated hardware design is suitable for high-speed operation and simple operation. In addition to the battery-powered RAM buffer as the remaining data storage, a 2 Mbyte flash memory is also provided for the user. This means that all project-related data can be stored in the system.

　　This device has a new feature, namely the ability to perform multi-dimensional motion control in accordance with DIN 66025 (special programs designed for CNC machine tools). For example, it allows simple standardized programming during entry-level applications. Motion control can be programmed via text or images on the soft PLC programming interface. The algorithm for optimizing time efficiency has nothing to do with whether the axis operation is interpolated or whether the existing cam function is used. The short scan time of the soft PLC can always remain unchanged.

　　Networking capabilities enable a wide range of shaft drive systems

　　In standalone mode, the controller-based PMC primo 16+ system can be used as a central controller for up to 16 axes. Its performance data corresponds to that of the drive-related ones, as the internal design is identical. This means that applications will run on both systems without any modifications.

　　The difference lies in the scalable fieldbus options and the network capabilities of the system to accept a large number of spindles. With several PMC primo 16+ system units, it is possible to implement a decentralized motion control unit that can control an almost unlimited number of spindles. One of the special benefits is that the user can achieve high dynamic clock speeds and thus achieve a high level of precision. The conceptual design of the system can control up to 700 axes. Automation solutions used in practice have controlled up to 53 axes. Such challenges can fully demonstrate their value when more than one machine needs to be automated, for example for complete production processes. In addition, appropriate transportation and transfer technology is required to control the feed and output drives.

　　Therefore, with just one product, the flexibility and performance of the entire system can be increased, which is only possible through decentralized drive technology with high-end motion control systems and an integrated PLC.

　　Full automation from one interface

　　The centralized Ethernet interface makes it possible to access the entire system and thus facilitates programming and diagnostics of all connected axes. Regardless of the decentralized design, from the user's point of view the entire system represents itself as a centralized system, since the differentiation of the axes takes place automatically in the background.

　　Its most important feature is that all components and data are included in a single user engineering project and are implemented in Pilz's new generation of drive-integrated motion control systems.

　　In practice, the setting of the transmission and the generation of the cam play an important role, but first of all, it depends on the relationship between the linkage axes. This is the case in almost all packaging machines. These important tools for users are now integrated into the programming interface. Because of its simple and intuitive, easy operation, and the absence of redundant interfaces, design engineers can save a lot of development time and costs. Compared with programming, its various parameters make the entire system easier to use and reduce the workload required to create a new application. These advantages can indeed be naturally reflected when the packaging machinery is updated and upgraded.

　　Predefined function blocks stored in a database form the basis for this simple process. Their central function is to establish a connection to the common program and to store the data and parameters generated there. The function blocks can be used as desired within the project, for example, drive parameters can be downloaded at each repeated start or, as an alternative, only from the service menu. When the data is transferred to the user project, a new function block is generated, which is a modified version of the original function block from the database. In this way, each drive or cam is assigned its own individual data record. This sounds like a matter of course for drive parameters, but it is of particular importance for the generation of a cam.

　　"Cam Generator" provides support for axis calibration

　　In an active program, the user can define whether the cam should remain flexible and, if so, which part, so that the drive can be adjusted to changes in the production process via parameters. Once the active program is closed, the cam parameters are stored in the function block, where the variable parts, such as the corner point, are generated as input values. These values ​​can then be reset and modified within the program cycle via the fieldbus or the operator terminal.

　　This program gives the user an opportunity to observe the cam images and to modify them at any time on the machine. The "Cam Generator" helps the user to select acceleration and braking values ​​to ensure that the transmission mechanism does not shake during movement. This can significantly reduce the debugging setting time.

　　In addition to simplicity, this ability to store all machine data within a project also brings other positive effects. The PMC primo unit is equipped with a large internal flash memory, which allows all data to be uploaded to the programming interface at any time. In this way, the current project can be stored locally in the device, if possible, also in a small and exquisite flash memory. When service use is required, this project can be copied to the service PC, making it possible to start an effective diagnostic device immediately.

　　If the device needs to be replaced, a removable data memory can be used, which has the advantage of "plug and play". In addition, due to its ease of use, all data can be automatically stored in the device again as long as the hardware is started with the card.

　　Many users want to achieve complete automation from a single interface; thanks to the PMC primo controller family and now the Soft PLC, this wish has finally become a reality. Combined with a wide range of tested motion control function blocks and the Soft PLC interface, expanded to include "cam" and "drive setting" functions, this provides machine builders and end users with a tool that can be used to independently and quickly implement complex applications.