Festo

TP 800 e-drives

Handbook and Technical Documentation

Description:         TP 800 e-drives - Handbook and Technical Documentation

Edition:                    v1.0 (04/04)

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

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

Layout:  David Hoey, Martin Williams

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

Internet: www.festo.com/didactic

E-mail: did@festo.com

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.

Contents        3

Introduction to the Training Packages__________ ______ ____ __________ 4

TP 801 Servo motor equipment set __________ ______ ____ ___________ 5

TP 802 Stepper motor equipment set __________ ______ ____ __________ 6

Extension Kits TP 801-E & TP 802-E __________ ______ ____ ___________ 7

Using the CD__________ ______ ____ _____ _______ ______ ____________ 8

Assembly of servo motor equipment set__________ ______ ____ ________ 10

Assembly of stepper motor equipment set__________ ______ ____ ______ 13

Guideline to exercises__________ ______ ____ ___________________ 15

Servo motor exercises__________ ______ ____ ___________________ 16

Stepper motor exercises__________ ______ ____ __________________ 21

Training room checklist__________ ______ ____ __________________ 26

Insturctor checklist__________ ______ ____ _____ _______ ______ ______ 27

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

There are 4 Training Packages available:

TP 801 Servo motor equipment set (part no. 539016)

TP 802 Stepper motor equipment set (part no. 539015)

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

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

The recommended accessories are:

	Description	Qty	Part no.
Either
	Profile plate 700 x 350 mm
	Power supply
Or
	Profile plate 350 x 250 mm
	Rubber feet (pack of 4)
	Profile plate connectors
	Power supply

* This is the part number for a power supply with European plug - refer to the Festo Didactic catalog for the relevant part number for other countries.

Fig. 1 Assembled servo motor equipment set.

The TP801 servo motor equipment set (D.DTC-SERVO part no. 539016) consists of:

	Description	Type	Qty	Part no.
	Axis	D.DCT-DGE-300
	Motor	D.DTC-MO-Servo
	Controller	D.DCT-SEC-AC-305
	Cable	D.DSUB-9POL-ST-ST-PAR
	Simubox	D.DCT-BED-SEC
	Systainer Maxi	D.SYS.168 x 545 x 330
	Technical Documentation	D.DTC-Step-Servo
	CD-ROM	D.DTC-CD

Fig. 2 Assembled stepper motor equipment set.

The TP 802 Stepper motor equipment set (D.DTC-STEP part no. 539015) consists of:

	Description	Type	Qty	Part no.
	Axis	D.DCT-DGE-300
	Motor	D.DTC-MO-Step
	Controller	D.DCT-SEC-ST-48-SP200
	Adaptor	D.DSUB-9POLSTST-GEN-CHA
	Cable	D.NULLMOD-BU-BU-9POL-3M
	Systainer Maxi	D.SYS.168 x 545 x 330
	Technical Documentation	D.DTC-Step-Servo
	CD-ROM	D.DTC-CD
	Programming software	WinPisa EN

The extension kits allow a user with servo or stepper to upgrade to a complete kit for both servo and stepper with no duplication of generic hardware.

The TP 801-E Extension kit servo (D.ERW-SERVO part no. 539017) consists of:

	Description	Type	Qty	Part no.
	Motor	D.DTC-MO-Servo
	Motor Controller	D.DCT-SEC-AC-305
	Cable	D.DSUB-9POL-ST-ST-PAR
	Simubox	D.DCT-BED-SEC
	Systainer GR3	D.SYS.395 x 295 x 210

The TP802-E Extension kit stepper (D.DTC-ERW-STEPPER part no. 539739) consists of:

	Description	Type	Qty	Part no.
	Motor	D.DTC-MO-Step
	Controller	D.DCT-SEC-ST-48-SP200
	Adaptor	D.DSUB-9POLSTST-GEN-CHA
	Cable	D.NULLMOD-BU-BU-9POL-3M
	Systainer GR3	D.SYS.395 x 295 x 210
	Programming software	WinPisa EN

The CD provided with this handbook was designed as a user-friendly interface to the courseware and handbooks and manuals. It lists and organises the courseware into exercises to be conducted on the hardware.

The CD should autostart when inserted into a DVD/CD drive. If it doesn't autostart, then open Windows Explorer and browse the CD. Double click the index.htm file found in the root directory of the CD.

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

The CD will work on any PC with a DVD/CD player but requires the following software to view everything correctly:

Internet Explorer (5 or higher) as browser

Adobe Acrobat Reader

Note: When you select a slideshow from the CD (refer Fig. 3), the slide will open within your browser as shown in Fig. 4. The slides are pdf and to open them in full screen, go View > Full Screen as shown in Fig 4.

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

Fig. 4 Opening the slide in full screen.

To revert back to a normal browser window, select the Restore button on the top right of your window.

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

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

Fig 6. Assembly of servo motor equipment set.

	Item no.	Description
		Axis
		Controller
		Motor

Fig 7. Assembly of servo motor equipment set.

	Item no.	Description
		Power cable
		Encoder cable

Fig 8. Assembly of servo motor equipment set.

	Item no.	Description
		Mains plug
		Test box
		Limit switches
		Power supply 24 V

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

Fig 9. Assembly of stepper motor equipment set.

	Item no.	Description
		Axis
		Controller
		Motor

Fig 10. Assembly of stepper motor equipment set.

	Item no.	Description
		Limit switch
		Motor cable
		Power supply 24 V

Each exercises continues on from the previous one to achieve the overall learning outcomes and therefore maybe considered as "one big exercise". However, they have been organised into outcomes to facilitate learning and integration into a training course. The resources allow the instructor to progressively introduce the key concepts of stepper and servo motor system installation, application and programming.

The outcome defines what the participant is expected to be able to do upon successful completion of the exercise.

The Reason explains why the outcome is important for achieving the overall objectives of the course and most importantly for the participant - "what is in it for me!"

The resources provide the exercise and solution documents as well as courseware to assist in the theory associated with the outcome.

The exercise is designed to achieve the learning outcome. The solution is provided because due to safety and the inherent nature of stepper and servo motors, learning is best done by participants implementing the provided solution.

Note that the exercise is provided on a separate page so the instructor can discuss possible solutions before handing out the actual solution.

To support the practical exercises, slideshows are provided that may be used by the instructor as required. They may be projected in the classroom and discussed or printed and handed out as resources.

At the completion of these exercises, you can:

Assemble a servo motor system

Commission a servo system

Conduct a reference move

Use speed control

Use position control

Set ramps

Use torque control

Use electronic gears/synchronous speed control

Describe the benefits and applications of each feature

The features and benefits of servo motor control need to be understood (and experienced if possible) in order to be able to design, install, commission, maintain and troubleshoot applications in industry.

Assembly of servo motor system

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

The correct and safe assembly of a servo motor system will familiarise you with the various components of a system, the purpose of these components and how they are connected together to form a functioning system.

Commissioning of servo system and introduction to Wmemoc.

You are able to correctly and safely commission a servo system using the main commissioning functions of Wmemoc.

The correct and safe commissioning of a stepper system will familiarise you with the software and associated settings that must be made before using the system.

Speed control in a servo motor system.

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

For safety reasons controllers include the speed control feature. You need to know how to adjust it. When commissioning, it is good practice to test the motor in the directions of rotation with the functions of the speed control.

Initiating a reference move.

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

To work accurately, servo systems need a reference point from which all positions are calculated. This is done after commissioning before normal operation.

Setting system positions, speeds and ramps.

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

The positions, speeds and ramps have to be defined before they can be called in a program. Therefore it is important that you know how these parameters are defined and stored in the system. It is also important to know

Torque control.

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

Torque control is an important feature and benefit that offers safety to man, machine and products. It is important that you are familiar with it and how to make best use of it.

Use of Speed Synchronous Positioning

You are familiar with the electronic gear of the system and can explain the concept of synchronous movement and the electronic gear and know how to use it with Wmemoc.

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

At the completion of these exercises, you can:

Assemble a stepper motor system

Create a simple WinPISA program

Commission a stepper system using WinPISA

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

Conduct a reference move

Use speed control

Use position control

Set ramps

The features and benefits of stepper motor control need to be understood (and experienced if possible) in order to be able to design, install, commission, maintain and troubleshoot applications in industry.

Assembly of stepper motor system

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

The correct and safe assembly of a stepper motor system will familiarise you with the various components of a system, the purpose of these components and how they are connected together to form a functioning system.

Commissioning of stepper system and introduction to WinPISA.

You are able to correctly and safely commission a stepper system using the main commissioning functions of WinPISA.

The correct and safe commissioning of a stepper system will familiarise you with the software and associated settings that must be made before using the system.

Current reduction in a stepper motor system.

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

Current reduction has advantages and disadvantages that you should understand and be able to explain.

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

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

To work accurately, stepper systems need a reference point from which all positions are calculated. This position is reset in the reference move.

The reference move is essential for the system to know the reference point for all the required positions. It must be conducted:

After powering up a stepper system.

Whenever slippage (loss of steps) has occurred.

Setting system speeds (velocity profiles).

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

The speeds and positions have to be defined before they can be called in a program. Therefore it is important that you know how these speeds are defined and stored in the system.

Setting system positions.

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

The speeds and positions have to be defined before they can be called in a program. Therefore it is important that you know how these positions are defined and stored in the system.

Setting ramps (with different profiles).

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

Ramping the speed up and down is an important feature for providing smooth but fast motion. You must know the benefits of ramps and how to set them.

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

Description	Comment	Organiser
Training room
Access  & starting/finish times
Electricity supply	Supply to PC, Beamer, and Training Equipment Electrical power: 230VAC and 24 VDC - 3 plugs / Training place (2 for Training set and 1 for Laptop)
Safety glasses	Safety glasses for all participants if required
Beamer	PC projector - ensure compatibility with your PC e.g. VGA
Spare bulb for beamer	Ensure there is a spare bulb or contingency plan (some bulbs are very expensive)
Whiteboard
Flipchart
Whiteboard markers & eraser
Refreshments & meals	Morning break, lunch, afternoon break
Other:

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

Description	Comment	Qty
PC with e-drives CD
PC software	Internet Explorer or other browser, Adobe Acrobat Reader
Pointer	Overhead type, laser or telescopic pointer
Consumables	Pens, pencils etc for participant	1 per participant
Desk name cards		1 per participant
Industrial catalog/Product CD	As appropriate	1 per participant
Participant handouts		1 per Participant
Supplementary resources	Printed copies of Reference Notes and other files that participants are to receive

Description	Qty

Deliberately blank