1119 a/b - enhancing close loop axis solution with new...

© 2011 Eaton Corporation. All rights reserved.

1119 A/B - Enhancing close loop axis solution with new AxisPro valves

Nalin Shah, Kevin Alstrin, John Blomster

EDM 2011

2 2 © 2011 Eaton Corporation. All rights reserved.

AGENDA

• Introduction of AxisPro Valves and Closed loop modes

• Centralized VS. Distributed Architecture

• Overview of Pro-FX configuration ( Live Demo )

• Overview of DS408 Drive Position Control (DPC)

• Applications review


KBS1-PLC Closed loop position controlled Axis Panel 1

KBS1

New KBS1 (level 1) valve offers:

• M12 CAN-enabled com port

• Configurable command input

+/- 10VDC/4-20,+/-10,+/-15 mA

• Configurable “Enable option”

• Valve diagnostics over M12 port

• Diagnostics LEDs visible through

light port : Power, fault codes

• Backward compatible to existing

KBS series valve

CAN IN

Mach. Controller

Motion controller in PLC


CANopen DS408

• DPC – Drive Position Control – Used for control of cylinder position

• DSC – Drive Speed Control – Used to control the speed of a hydraulic motor or cylinder

• DFPC – Drive Force / Pressure Control – Used to control the force produced by a cylinder or the torque produced by a hydraulic motor.

• DPQ – Drive Pressure / Flow control (Eaton Custom)– Used to control flow (speed) until a threshold is reached then to control pressure.


KBS2-DS408/DSC Distributed Motor Speed Control axis Panel 2


• Hard Coded axis motion

controller per DS408 standard

• Control and CAN-open

communication to Prop valve

• Closed loop (speed) feedback to

the valve

• Parameterize application on PC.

Download to the KBS2 valve via

CAN.

Mach. Controller


KBS3-DS408/DPQ: PQ axis distributed control Panel 3


• Control and CAN open

communication to PROP valve

• Integrated pressure sensors (4

ports) connected to OBE controller.

• Pressure monitoring and/or control

on board - Pressure control hard

coded, configurable per DS 408

• Position control with cylinder

position signal to the valve.

• Parameterize application on PC.

Download to the KBS3 valve via

CAN.

External spring load illustrating

force control.

External spring load

Mach. Controller


KBS4 & KBS3:Two axis synchronized motion control Panel 4

KBS4 KBS3


• White space, freely programmable in CoDeSys

• Local (additional) CAN bus for slave cylinder

• Master-slave and motion control on the valve.

• Master control KBS4 (CoDeSys) and slave KBS3 – DS 408.

External spring load on one cylinder shows parallel motion in

spite of uneven load.

External spring load

CAN IN

Mach. Controller


Moeller PLC & SmartWire-DT Panel 5

Moeller PLC to start motor

SmartWire-DT


Distributed Axis Control Architecture

Machine Control Architecture Centralized Versus Distributed

Axis-Pro supports all machine control architectures

Centralized Axis Control Architecture


On-Board Application Control Synergy with F(x) and IAB Portfolio

Application Software

Pro-FX® Control

Hydraulics

Gen. Purpose Controllers & I/O

High Performance Controllers

Human Machine Interface

Hydraulics

Gen. Purpose Controllers & I/O

High Performance Controllers

Human Machine Interface

Advanced Mobile Valves CC Piston Pumps

EFX Controllers Mobile

I/O

Exte

nders

SFX Controllers

VFX Displays Ultronics / JFX

Directional / Proportional Valves HydroKraft Pumps

Mobile Systems Stationary Systems

Config. Software

Pro-F(x)® Configure

Software

Control F(x)®


Summary of Recent Name Changes

Saturn Valve AxisPro Valve

Valve F(x) Pro-FX Configure

Control F(x) Control F(x)

Pro-FX Control

CoDeSys V2

CoDeSys V3


On-Board Application Control

DS408 Device Profile for

Proportional Valves and

Hydrostatic Transmissions

•Level 2, 3, and 4 Valves

•“Hard coded” motion

control algorithms

•Parameterized using Pro-FX

Configure

•Level 4 Valves

•“White Space”

•Programmable using Pro-

FX Control

DPC – Drive Position Control

DSC – Drive Speed Control

DFPC – Drive Force/Pressure Control

DPQ – Drive Pressure/Flow Control

pQ pump control / pQ cylinder control

Load sensing pump control

Single axis position, flow, or pressure control

Pres and temp compensated flow control

Synchronous axis control (master/slave)

Twin spool Meter in / Meter out control

Machine Prognostics & Diagnostics


Pro-FX Configure Versus Pro-FX Control

Pro-FX

Control

Used to program

the white space in

on Level 4.

Pro-FX

Configure

Used to

configure

Level 1, 2,

3, and 4.


Overview of Pro-FX Configure


Pro-FX Configure: Control Window


Pro-FX Configure: Monitor Window


Pro-FX Configure: Data Plotting


Pro-FX Configure: Diagnostics Window


Hard-Coded, Configurable Controls Drive Position Control (DPC)

Offset

Cylinder Setpoint Spool Setpoint

Cylinder Feedback

Saturation 4-Quadrant

Ramp

x

y

Scale

-1

Sign

Inversion

d

dtDerivative

d

dtDerivative

d

dtDerivative

LPF

Low Pass

Filter

Kv_ff

Velocity

Feed Forward

1

SIntegrator

Kp

Proportional

Gain

Ki

Integral

Gain

Kv

Active

Damping

Ka

Active

Mass

Saturation

-1

Sign

Inversion

Directional

Dependent

Gain

+

-

+

-

+

+

++

++

+

+

Demand

Value

Generator

Feed Forward

Controller

State Feedback

Controller

Actual Value

Conditioning Condition Feedback

Controller Output Conditioning



Offset


Cylinder Feedback


Ramp

x

y

Scale

-1

Sign

Inversion

d

dtDerivative

d

dtDerivative

d

dtDerivative

LPF

Low Pass

Filter

Kv_ff

Velocity

Feed Forward

1

SIntegrator

Kp

Proportional

Gain

Ki

Integral

Gain

Kv

Active

Damping

Ka

Active

Mass

Saturation

-1

Sign

Inversion

Directional

Dependent

Gain

+

-

+

-

+

+

++

++

+

+

Feed Forward

Controller

State Feedback

Controller

Actual Value





Offset


Cylinder Feedback


Ramp

x

y

Scale

-1

Sign

Inversion

d

dtDerivative

d

dtDerivative

d

dtDerivative

LPF

Low Pass

Filter

Kv_ff

Velocity

Feed Forward

1

SIntegrator

Kp

Proportional

Gain

Ki

Integral

Gain

Kv

Active

Damping

Ka

Active

Mass

Saturation

-1

Sign

Inversion

Directional

Dependent

Gain

+

-

+

-

+

+

++

++

+

+

State Feedback

Controller

Actual Value





Offset


Cylinder Feedback


Ramp

x

y

Scale

-1

Sign

Inversion

d

dtDerivative

d

dtDerivative

d

dtDerivative

LPF

Low Pass

Filter

Kv_ff

Velocity

Feed Forward

1

SIntegrator

Kp

Proportional

Gain

Ki

Integral

Gain

Kv

Active

Damping

Ka

Active

Mass

Saturation

-1

Sign

Inversion

Directional

Dependent

Gain

+

-

+

-

+

+

++

++

+

+

State Feedback

Controller

Condition Feedback



Offset


Cylinder Feedback


Ramp

x

y

Scale

-1

Sign

Inversion

d

dtDerivative

d

dtDerivative

d

dtDerivative

LPF

Low Pass

Filter

Kv_ff

Velocity

Feed Forward

1

SIntegrator

Kp

Proportional

Gain

Ki

Integral

Gain

Kv

Active

Damping

Ka

Active

Mass

Saturation

-1

Sign

Inversion

Directional

Dependent

Gain

+

-

+

-

+

+

++

++

+

+

Condition Feedback



Offset


Cylinder Feedback


Ramp

x

y

Scale

-1

Sign

Inversion

d

dtDerivative

d

dtDerivative

d

dtDerivative

LPF

Low Pass

Filter

Kv_ff

Velocity

Feed Forward

1

SIntegrator

Kp

Proportional

Gain

Ki

Integral

Gain

Kv

Active

Damping

Ka

Active

Mass

Saturation

-1

Sign

Inversion

Directional

Dependent

Gain

+

-

+

-

+

+

++

++

+

+


Pro-FX Configure: Graphical Configuration Window


Demand Value Generator Configuring the 4-Quadrant Ramp

Define the 4 ramp rates

in units of um/sec


Testing the 4-Quadrant Ramp Using Data Plotter


Demand Value Generator Configuring the Saturation Limit


Blow Molding: Parison Control

Application: Plastic Blow Molding M / C

• DS408-DPC / Drive Position Control in KBS2

• Position accuracy reqd. with in ~ +/- 0.001 in.

• CAN-open communication to Prop valve

• Closed loop (position) feedback to the valve

KBS2

M/ C Controller


Press Brakes Application

KBS3

Application: Press Brake (200T – 3000T)

• DS408-DPQ: Drive P / Q Control in

KBS3

• Sync. position accuracy reqd. with in ~

+/- 0.0004 “

• Control flow (speed) until a threshold

is reached then switch to pressure

control

Sensor


Wind Turbine: Pitch adjustment of rotor Blades

M/ C Controller

Application: Wind Turbine-Blade

pitch Control

• DS408-DPC: Drive Position Control

in KBS2

• Set point command are generated

as a function of wind speed, wind

dir. And rotor speed and fed to KBS2

• Position sensor output is typ. 4-20

mA


Flattening machines:- Roll Gap Control

P T

KBS4 KBS3 M/ C Controller

Application: Flattening Machine

• Control thickness in manufacturing of foils

or floor coverings

• Synchronized motion control of two

cylinders to maintain accuracy ~ 0.0004 in.

• Control algorithms in white space of KBS4


Hydro forming Press Application

Application: Hydro forming press

• DS408-DPQ: Drive P / Q Control in KBS3

• Pressure on cap end and position of cylinders

maintained to allow no leakage of fluid during

intensified forming pressure

DIE

PART

KBS3 KBS3

Intensified Forming

Pressure


Welding – Steel bands

KBS2 KBS2

KBS2

KBS2

KBS2 KBS2

Controlled

Gap

Application: Welding bands

• DS408-DPC Drive position

control in KBS2

• Bands are aligned in Y dir.

• Bands are positioned in X dir.

to control gap

Y Dir.

X Dir.


Mold Oscillator – Continuous Casting Plant

Application: Mold Oscillator in

Continuous Casting Plant

• DS408-DPC: Drive Position Control

in KBS2

• Mold is oscillated to keep material

in molten state

KBS2

M/ C Controller


Journal Bearing Closed Loop Application - Kirloskar Oil engine Limited, India

•To Check Journal Bearing Half – Dim.

Accuracy

•External motion control in the PLC

• Open Loop Velocity (Q) Mode

• Closed Loop Force (p) Mode

with 400 Kg +/- 18 Kg accuracy

• Total Cycle Time – 0.9 sec

• KBS level 1

KBS 1 KBS 1


Car Sear Belt Assembly Anchorage Test Rig – Calspan, USA

•Test Rig to test Car Seat Head Rest, Seat

Back and Anchoring capacity

•External motion control in the PLC

• Closed Velocity (Q) Mode

• Closed Loop Force (p) Mode

• KBS level 1

1119 a/b - enhancing close loop axis solution with new...

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