4d ship simulator user guide rev1.0(20130225)

7/30/2019 4D Ship Simulator User Guide Rev1.0(20130225)

1/51

4D SHIP SIMULATOR

4D SHIP SIMULATORMaintenance Manual

Document No. : CJI-201302-001-4DSSSRevision : 1.0

Date : Feburary 25, 2013


2/51

4D

Ship

SimulatorMaintenanceManual

2

Table of Contents

Shooting Simulator................................................................................................................................................................................. 3

I. Configuration ................................................................................................................................................................................ 3

II. Connection with the remote computer via UDP ....................................................................................................... 7

III. Library Installation .................................................................................................................................................................. 9

Edge Blending for Projectors .........................................................................................................................................................11

I. Connect to device ....................................................................................................................................................................11

II. Timing and blend-width setting.......................................................................................................................................12

III. Edge-blend parameters setting ......................................................................................................................................13

IV. Keystone settings..................................................................................................................................................................15

V. Curved screen settings ........................................................................................................................................................17

VI. Color correction and pure white correction ...........................................................................................................17

VII. Black level setting ...............................................................................................................................................................19

VIII. Warp table load ....................................................................................................................................................................20

6-axis Driving Device ...........................................................................................................................................................................21

I. Outline ............................................................................................................................................................................................21

II. Product Configuration Details .........................................................................................................................................23

III. Equipment Inspection and Maintenance ..................................................................................................................46

1. Servo Motor........................................................................................................................................................................46

2. Servo Driver........................................................................................................................................................................48

3. Cylinder Assembly ( Servo Motor, etc ) ...................................................................................................................49

4. Other Inspection and Measures .................................................................................................................................51


3/51

4D

Ship


3

Shooting Simulator

I. Configuration

1. Camera Tab

1) Basic UI

- Screen Calibration : Calibration button for the screen

- Laser Threshold

Reference value of the laser detection.Change the value when the laser detection is not good.

Click Apply button to save the reference value.

- 1 Gun Range : Display X and Y coordicate of the Gun number 1 on triggering.

- 2 Gun Range : Display X and Y coordicate of the Gun number 2 on triggering.

- 1 Gun Track : The trace of Gun number 1

- 2 Gun Track : The trace of Gun number 2

- Capture FPS : Capture frame cycle of the cameras. (Standard : 20)


4/51

4D

Ship


4

2) Screen Calibration Mode

- Screen Calibration

Click the Camera 1 or Camera 2 then it split the screen as the picture.

Check the 4 corners of the screen and click the screen for making the corner point.

Click Save Calibration for saving the calibrated corners.

Caution

Before finishing the calibration, dont change the camera bay click the camera tab.


5/51

4D

Ship


5

2. Controller Tab

Controller Tab is for setting the communication with digital gun controller and the camera

- Connect Status

Display the status of the connection

Input : The status of the input control signal(Open, Close)

Camera : The status of the camera control signal(Open, Close)

Boat : Information from the boat, wheel, remote controller(speed and direction control

lever. Open, Close)

Effect : Special effectors for making the environment(wind, light, etc. Open, Close)

- Connect Port : Setting the connection ports

Input : Com 4

Camera : Com 3

Boat : Com 7

Effect : Com 6


6/51

4D

Ship


6

3. UDP Tab

- Address : Setting the address of the server.

When it is used in one computer, use localhost or 127.0.0.1

- Port : Setting the port of the connected server, 27015 default


7/51

4D

Ship


7

II. Connection with the remote computer via UDP

1. Connect two computers via Hub(residential gateway)

1) Connect the host computer and the client computer to the hub using UDP cable

2) Host computer : the computer who runs the main program

Client computer : the computer who runs the Camera3x.exe program

2. Check the IP address of the host computer

1) Check the IP address in the control page of the hub(open 192.168.0.1)

2) If the IP address of the host computer is 192.168.0.6(Kong-PC of the picture), change

the IP address of the UDP tab and click Apply.

3) After changing the Address of the UDP tab, restart the Camera3x.exe again.


8/51

4D

Ship


8


9/51

4D

Ship


9

III. Library Installation

Caution

DO NOT DELETE any file on the main computer.

Some programs need to get the license code again after re-installation.

1. Install the Matrox Mil Lite 9.0.

2. Select the Solios driver on installation.

3. Reboot after the installation.

4. Run Windows Start Button(Start) -> All Program -> Matrox Imaging ->Tools ->

MilConfig.


10/51

4D

Ship


10

5. Select General -> Default Values.

6. Digitizer for current default system

A. Format(DCF) : Select the DCF file(hr50c.dcf).

7. Image

B. Select Band Monochrome(1 Band).

C. Fill the image size 640, 495.


11/51

4D

Ship


11

Edge Blending for Projectors

I. Connect to device

Connect Mviewer device to PC with DVI cable and Serial cable, insert CD, run the

software and a dialogue appears.

Click "OK" to enter the main interface:

If the main interface doesnt appear, right click my PC to open the hardware

manager of PC, select the correct COM port, and click Detect device for PC to detect

Mviewer device and connect to it. After around 10 to 20 seconds, a dialog-box pops up

notifies the device is detected as connected to 3 projectors and connection to PC through

COM port. Also the internal modules for Mviewer MPG203 and projectors is listed.


12/51

4D

Ship


12

MP103 at com1, connected to projector 1, 2 and 3 through 3 units of MG210 If the 30

seconds reading fails to find the device, another notice pops to say no Mviewer device

detected In this case, check the connection between PC and MPG20X and check if

MPG20X is powered on already.

II. Timing and blend-width setting

Afterconnection, click Input Timing to unfold the resolution list, choose one according to

your projectors native resolution. Then enter the screen width and height. Normally, you

can enter the width and height in millimeter, or if you know the ratio, enter the pixels for

width and lines for height. For 3 projectors edge-blending, there are 2 edge-blending

zones, so please also enter the width for BlendWidth0 and BlendWidth1 accordingly. Click

set Timing, the following diagram shows a resolution of 2560x768 , 3x1024x768 edge-

blending with two overlap region all at 256 pixels.


13/51

4D

Ship


13

After setting the total result resolution and blend width, restart your PC and invoke the

NVIDIA/ATI control panel to choose the newly added resolution from list.

III. Edge-blend parameters setting

There are two tabs in the software available for blending effect settings. The first is the

blend set tab and the second is the MG200 blend set tab. The Blend set tab sets the

edge-blending in the MP103 module. The MG200 blend set sets the edge-blending in the

MG200 modules that are connected to MP103s outputs. It is recommended to set the

MP103s edge-blending parameters to bypass mode, and set the MG200s parameters

which is more flexible and fast.

1. Edge-blend parameters setting in MP103

Click blend set tab to set alpha, P, gamma parameters of each blend zone. Select blend1

and blend2 for setting, the blend1 means the overlap zone between left projector and the

center projector, the blend2 means the overlap zone between center projector and right

projector.

Fill the parameters of Alpha/P/Gamma to adjust the effect. Normally, alpha is 0.5, P is 2

and Gamma is 2 to 2.4. The larger the alpha, the brighter the center of blending zone.


14/51

4D

Ship


14

Click test to check the effect; repeat testing until the effect is the best and Click update

to store the parameters. To bypass the MP103s edge -blending feature, set the alpha to 1

and P/Gamma to 0.

2. Edge-blend parameters setting in MG210

Click the MG200 Blend set tab to enter into the edge-blending setting using MG210

modules as Figure 3 on page 9 shows.

In Figure, following operations can be done for each MG210 (Each Projector):

- Enable / disable the MG210 blend, by check / uncheck theMG200 Blend Enable

check box.

- Set the edge-blending parameters for 3 projectors separately by adjusting the

alpha/P/Gamma parameters.

- Set the blend parameters for white level and non-white level. White level can be

defined by user. It is the R/G/B threshold value that defines white. Set to 255 means not

use white level. Set to, say 240, means that all R/G/B value larger than 240 will be treated

as white level, and MG210 will choose the white level blend curve for those pixels in doingblending.

- Set the four corners blending of projector. For horizontal blending, the right blend of

first projector, the left and right for second projector and the left blend of third

projector should be enabled. The blend width can be set in the edit-box.

- Test the edge-blending effect, and fix the parameters into MG210 by click update

button.


15/51

4D

Ship


15

Figure. Edge-blending setting with MG210

IV. Keystone settings

Click "keystone set" Tab to enter into Keystone adjustment for geometry distortion. Click

the "Read device Para" button to get the output resolution and four vertices coordinates of

the projected image appear to be seen.


16/51

4D

Ship


16

The gray part is the projected shape onto a flat screen. We can adjust the quadrilateral

coordinates of the vertices, as in Figure below:

Generally speaking, projectors cant be accurately positioned right opposite the screen, so


17/51

4D

Ship


17

the gray part must be treated with deviation in consideration. When the left of the projected

image is too big and goes outside the screen, adjust the

left upper and left lower coordinates to pull in the gray part. Click Test to apply the

keystone adjustment. If the current resolution is not correct, click reset to get the right

resolution.

V. Curved screen settings

For curved, spherical or cylinder screen, pincushion correction is needed. Click pincusion

tab to enter Pincushion Setting interface as below.

You can set or drag the coordinates of 9-point grid show in the figure to change the

projected image shape, by click the test button. After the settings, click update button to

fix the parameters into MG210.

VI. Color correction and pure white correction

The color correction and pure white correction cannot be used together. If select to do

color correction first, then do white correction, this may overwrite the color correction result,

and vice versa.


18/51

4D

Ship


18

1. Color correction

9 segments of color region, for each R/G/B component, are adjustable. Use one projector

as reference, and adjust another projectors color for each segment / components, click

Test button to show that color to the screen and compare to adjust and match them.

2. Pure white correction

Pure white correction:


19/51

4D

Ship


19

Use one projectors white level as reference, select another projector for adjustment.

When doing adjustment, select one segment for both projector, for example the seg8,

which is the most brighter white level, and fill the values for separated R\G\B value, click

Test button, the MG210 will output a white level according to the parameters set,

compare the level with the reference projectors and adjust accordingly.

VII. Black level setting

In dark scene, although digitally the R/G/B values send to projector are 0, the projector will

still generate a certain brightness to the screen, this is so-called light-leakage due to the

light-path of the projector is not 100% shut-off. The effect to the edge-blending is that the

overlap region will be brighter than the non-overlap region. To overcome this issue, the

edge-blender provides a mechanism of boosting the brightness level of non-blending zone

and blending zone in black scene. This is by defining the black level of non-blending area

and blend-area. If the source brightness level less than the defined level, the blender will

boost the level to the defined level, thus the non-blend zone could be brighter and possibly

compensates the light leak effect. However, due to the non-linearity of projectors light

leakage effect, this could never been perfectly solved. The best solution is to use

projectors with less light leakage.


20/51

4D

Ship


20

Blackness level: enter a number from 0-255 for the level defined as black; normally it

should be less than 100. Light leak width: 0 is invalid here.

VIII. Warp table load

This is advanced functions for geometry correction that is more flexible than pincushion.

Image processing and form load are to be adjusted by a professional mechanic or done

with their help. Dont try adjusting without professional guide at hand.


21/51

4D

Ship


21

6-axis Driving Device

I. Outline

1. Purpose

This User Manual is for the 6-axis Driving Device for the 4D Ship Simulator, and describes the system

construction, specification for main parts, operation and main maintenance procedure.

2. Concept of Composition

This system is composed of hardware such as cylinder assembly, control assembly and software for

operating hardware. Driving computer in the control assembly is linked with user host computer via Ethernet

based network, it get the control command from the host computer and drives 6 electric cylinder assembly

and generates 6 DOF(Degree of Freedom) motion. This 6 DOF motion makes the user(passenger) to feel

the movement.

A. System

1) Hardware

Name Description Unit Qty Remark

6-axis Driving

Device

Cylinder Assembly, Operating, Linear SET 6

Hinge Block Assembly, Upper part SET 3

Hinge Block Assembly, Lower part SET 3Controller Assembly, Driving SET 1

Cable Assembly LOT 1

2) Software

Name Description Unit Qty Remark

Driving Program SmartCue6015.exe LOT 1 Operation Program

B. Main Part List

No. Part Number Description Manufacturer Unit Qty Rem.1 KL1224GEA Pilot Lamp KACON EA 6

2 KF-15A1(include 5A fuse) Fuse Socket KACON EA 1

3 K22-27G-RFON Switch(lighting type,

green)KACON EA 1

4 K22-27G-RFOFF Switch(lighting type,

red)KACON EA 1

5 UF12AM23-H Fan Fulltech EA 2

6 PRW12-2DN2Proximity Switch (B

contact)Autonics EA 12

7 AHN22324 Relay SamwonACT EA 10

8 VG3102 24-22P(3102 VG Connector Daehyun EA 1
http://endic.naver.com/enkrEntry.nhn?entryId=7e5c2c411f154d90962bf86601fea1e1&query=%EA%B7%BC%EC%A0%91%EC%8A%A4%EC%9C%84%EC%B9%98http://endic.naver.com/enkrEntry.nhn?entryId=7e5c2c411f154d90962bf86601fea1e1&query=%EA%B7%BC%EC%A0%91%EC%8A%A4%EC%9C%84%EC%B9%98


22/51

4D

Ship


22

Type) Corporation

9VG3102 20-3P(3102

Type)VG Connector

Daehyun

CorporationEA 1

10 AMP 206430-1 AMP Connector AMP EA 1

11AX60551WB, PEAK-

872VL2Bare bone Case Yoi System SET 1

12 CSDP-20BX2 Servo Driver 2KW Rockwell Samsung SET 6

13 RSMH-20BA1ATK3 Servo Motor 2kW 220V Rockwell Samsung SET 6

14 MMC-BDPV81PNA MMC Board Rockwell Samsung EA 1

15 MMC-LM11 LIMIT Board Rockwell Samsung EA 1

16 MMC-IN11 INPUT Board Rockwell Samsung EA 1

17 MMC-OU11 OUTPUT Board Rockwell Samsung EA 1

18 MMC-CA20LIMIT,I/O Internal

Connection BoardRockwell Samsung EA 1


23/51

4D

Ship


23

II. Product Configuration Details

1. System Composition

A. Hardware/Software Link Structure


24/51

4D

Ship


24

B. 6-axis Driving Device Configuration and Specification

6-axis Driving Device Configuration

6-axis Driving Device Specification


25/51

4D

Ship


25

Driving Device Specification of Motion Platform

Name Dimension Description

Minimum Height 1,056mm Minimum height of Driving Device

Moving Reference Height 1,300mm Neutral height of Driving DeviceMaximum Height 1,544mm Maximum height of Driving Device

Upper Plate Radius 700mmFrom the center of the upper plate to the center of

the upper joint

Lower Plate Radius 1,100mmFrom the center of the lower part of motion platform

to the center of the lower joint

Upper Joint Angle 20 degAngle between two joints near the center of the

upper plate

Lower Joint Angle 14 degAngle between two joints near the center of the

lower part

Performance and other specification of Motion Platform

Displacement Speed Acceleration

Surge -356/362 mm 600 mm/s > 0.6 g

Sway -324/324 mm 540 mm/s > 0.6 g

Heave -244/244 mm 400 mm/s > 0.6 g

Roll -20/20 deg 33 deg/s >200 deg /s2

Pitch -20/20 deg 33 deg/s >200 deg /s2

Yaw -26/26 deg 43 deg/s >200 deg /s2

Payload

Operation Payload 1,500 kgf

Momentary Maximum Payload 3,500 kgf

Power Consumption

Power Requirement 3 phase 220VAC, 50/60Hz

Consumption Average 6kW, Peak 15kW


26/51

4D

Ship


26

2. Hardware

Configuration and Functions of the Hardware

Part Description RemarkCylinder Assembly, Operating,

Linear

Composed of 6 Cylinders. Each cylinder has electric

servo motor for realizing the 6 DOF motion

Hinge Block Assembly, Upper part Supporting the upper 6 cylinder assembly

Hinge Block Assembly, Lower part Supporting the lower 6 cylinder assembly

Controller Assembly, Driving Control the 6 cylinder assembly

Cable Assembly Interface the electric signals between cylinder assembly

and the controller assembly

A. Cylinder Assembly

This cylinder assembly uses ball screw type brush-less AC servo motor with good performance and highmaintainability. And the design is for high safety and reliability, it is simple to install and easy to maintain in

comparison with the hydraulic or pneumatic type.

Specification of the Cylinder Assembly

Name Description Remark

Length 1.144mm(the shortest distance between the upper hinge joint and the

lower hinge joint

Stroke 400mm(the maximum length of piston operation

Maximum Speed 333 mm/s

Rated (Max.) Thrust 600(1,700) kgf (maximum thrust 0.2 sec)

Ball screw Lead 10 mm

Weight 60 kg(for each cylinder assembly, including servo motor)

Driving Motor

Coupling Housing

Cylinder/Piston

Upper Hinge JointUp/down Limit Sensor &

Air Outlet

Lower Hinge Joint


27/51

4D

Ship


27

Servo Motor Configuration and Torque

Specification of the Servo Motor


Model Name RSMH-20BA1ATK3

Rated Power 2 kW

Rated Torque 9.55 Nm

Max. Torque 28.5 Nm

Rated Rotation Speed 2,000 RPM

Max. Rotation Speed 3,000 RPM

Rated/Max. Current 12.3/51.9 Amp

Rated Voltage 220VAC 3 PHASE

Brake O

Brake Control DC 24 V

Brake Pull Time 160 ms

Brake Release Time 75 ms

Brake Rated Current 1.287 A

Weight 19.5 Kg


28/51

4D

Ship


28

B. Cylinder Assembly Connection Part (Hinge Blocks)

This connection part attached the upper/lower part of the cylinder assembly, realize the smoothing

movement and proper angle, and provide the stability of the system.

Cylinder Assembly Connection Part (Lower) Cylinder Assembly Connection Part (Upper)

C. Cable Assembly

Cable Assembly is composed of the interface cable between the driving controller and cylinder assembly,

main/sub power supply, LAN, KVM(keyboard, Video, Mouse), and emergency stop cable.

Cable Connection Diagram


29/51

4D

Ship


29

D. Controller Assembly

Controller assembly makes the 6 DOF movements using 6 electric actuators, it receives the control

commands from the host computer linked with Ethernet based network.

Controller Assembly

Power control and status indicator assembly : check the power control status

Circuit breaker : break the main power and the motor power Driving control computer : control the servo driver using embedded motion control board

External interface assembly : interface between external servo motors and controller

Servo driver assembly : control servo motors using the signal from the driving control computer

Top

FrontRight


30/51

4D

Ship


30

1) Power Control and Status Display Assembly

Motor Power : Using the push switch with signal light, check the ON/OFF status of the motor power

Operation : Check the 1~6 axis motion operating status

Power Control and Status Display Assembly

2) Circuit Breaker

Circuit breaker : break the main power and the motor power

Circuit breaker

Motor Power ON(220VAC 3 Phase)

Motor Power OFF

(220VAC 3 Phase)

1~6 axis operating status(When operation, green

light on)

Control Power Breaker(Computer & Servo Control

Power,220VAC Single Phase)


31/51

4D

Ship


31

3) External Interface Assembly

A. Emergency Stop Input : the emergency stop signal input

B. KVM : KVM signal output

C. LAN : Ethernet communication port

D. Upper Limit Sensor : Upper limit sensor input of 1~6 axis actuator

E. Lower Limit Sensor : Lower limit sensor input of 1~6 axis actuator

F. Control Power Input : Computer & Controller power input (220VAC Single Phase)

G. Motor Encoder : Motor encoder signal input

H. Motor Power Input : Motor power input(220VAC 3 Phase)

I. Motor Power : Motor power output

External Interface Assembly

A

B

C

D E

F

G

H

I


32/51

4D

Ship


32

4) Controller Assembly Internals

Controller Assembly Internals

A. Servo Driver, 6 sets

Servo Driver

RegenerativeBrake Resistor

Brake RelayServo Driver Fuse

Input Module

Output ModuleElectric Outlet

Fan

Interface TerminalBlock

DC Power Supply

Limit module Driving ControlComputer

KVM Extender


33/51

4D

Ship


33

Specification of the Servo Driver(CSDP-20BX2)


Main Supply Voltage 3-phase 200 to 230V, 5%, 50/60 Hz

Control Voltage Single Phase 200 to 230V, 5%, 50/60 HzEncoder Type 2500 P/R, 9-wire type Inc.

Output Signal Type Differential Line Driver Output

Control Method PWM Control by IPM

Speed Control Range Internal Speed command 5,000

Output Voltage 200Vrms

Rated Output Current 13Arms

Peak Output Current 39Arms

Rated Input Current 10.3Arms

Speed Response Frequency 400Hz

Speed/Torque Command Input Signal 0~10 V DC, Can be controlled by parameter

Ambient Temperature in Operation 0 to 55C/

Ambient Humidity in Operation 90% RH or less

Ambient Temperature in Storage -25 to 80C

Ambient Humidity in Storage 90% RH or less

Weight 4.6kg

(1) Regenerative Brake Resistor 6 sets : consume the regenerative power when brake the motor

(2) Brake Relay 9 sets : brake for prevent the vertical falling

(3) Fan 2 sets : internal circulation

(4) Interface Terminal Block 15 sets

(5) Fuse 1 set : protect the sequence circuit

(6) Input Module 1 set : input data gathering device(emergency switch, main power status)

(7) Output Module 1 set : control signals for the device from the computer(motor brake, main power

on/off)

(8) Limit Module 1 set : actuator(1~6 axis), upper/lower sensor input

(9) Electric Outlet 1 set : external power output(computer, KVM extender)

(10) Driving Control Computer 1 set

Driving Control Computer


34/51

4D

Ship


34

Specification of the Driving Control Computer

(11) KVM Extender 1 set : external monitor, keyboard, mouse connection

(12) DC Power Supply 1 set : power supply for the motor brake


35/51

4D

Ship


35

3. Software

A. User Interface(GUI)

Motion Control Software Main Window

Composition of the control button

Number Description Remark

1 Title

2 Lamp of the system status

3 Operation mode selection radio button

4 System time information

5 Sub menu window activation push button

6 System monitoring sub menu window7 System operation information

8 System control button


36/51

4D

Ship


36

4. Motion Platform Start-up Process

Caution!

Before operating the motion platform, please keep people away from the motion platform.

For the abnormal operation of the motion platform, keep the emergency stop switch at hand when

operation the motion platform.

Check Power On status of the motion driving control computer, control box and servo driver again.

Double-click the SmartCUE6015" icon to run the motion control software.

After running the software, check the followings,- System Status : check the limit is ON

- System Operation Information : Check the message as the picture

Before the operation of the motion platform, test the communication between the motion computer and

the other controllers.

At first, click the NEUTRAL button.


37/51

4D

Ship


37

If the communication is normal, the CL(mm) value of the each 6 actuator increases together in

actuator status and,

In the system status, MOV light on.

After reaching to the neutral position, the following messages come out.


38/51

4D

Ship


38

5. Motion Platform Operation Process

Caution!




In the Sinusoid Motion mode, the motion platform plays the damping motion with the programmed

motion data.

A. Replay Motion

Replay operation mode is drive the motion platform using preset motion data file.

Follow the procedure,

Run the motion system and move to the NEUTRAL position.

Click the Replay button in the Operation mode selection radio button.

In the pop-up file selection window, select the file to load and click the Open(O) button.


39/51

4D

Ship


39

If the loading file is normal, the following message will pop-up, then click the Check button.

Click RUN button to start the motion.

When operation, the system status and replay information can be check the following GUI window,

- System Status Lamp

MOV. lamp flicker on and off.

- System Monitoring Information

The file name in operation, progress and frame information can be checked

File name Progress bar for checking Frame/Total Frame

After playing, the system moves to the NEUTRAL position. To stop when playing, press STOP

button of the system control button, then the system stop the playing and move to the NEUTRAL

position.


40/51

4D

Ship


40

B. Sinusoid Motion

Sinusoid motion waveform

Sinusoid operation mode is driving the motion platform according to the sinusoidal parameter

input(amplitude, frequency) by the user.

Follow the procedure,

Run the motion system and move to the NEUTRAL position.

Click the Sinusoid button in the Operation mode selection radio button.

In the pop-up parameter input window, fill up the amplitude, frequency value and the running time.

Click APPLY button to set the sinusoid mode data.


41/51

4D

Ship


41

If the input data exceed the normal range, the following error message comes out, on click Check

button, the input data will be reset.

Enter the digit from 0 to 320.

If the input data in the normal range by the step 4 , click the EXIT button to return to the main

window.

Click RUN button to start the motion.

When operation, the system status and replay information can be check the following GUI window,


MOV. lamp flicker on and off.

- Actuator Status

Actuator Status window displays the length, error, motor speed and otherstatus information.

Select the display item Activate the motion data recording Display pause and resume

- Motion Command/Feedback

Motion Command/Feedback window displays the position or the angle of each DOF.

Graph Display

Status of

Servo Amp.

Status of

Limit Sensor

Control Len th

Feedback Length

Length Control Error

Total Deviation

Motor Speed


42/51

4D

Ship


42

After playing, the system moves to the NEUTRAL position. To stop when playing, press STOP

button of the system control button, then the system stop the playing and move to the NEUTRAL

position.

Control commandInfo.

Feedback info.


43/51

4D

Ship


43

6. Motion Platform Shutdown Process

Caution!




Motion should be in the NEUTRAL position.

Click the Bottom button in the System control button.

On click the Bottom button, the actuators start to fall down. The actuators reach the lower limit, the

motion platform turned to bottom status and stop. At that time, tick sound occurs and it is the brake

operation sound of the motors.

On the normal bottom status, check the following status,


Check the Limit : ON status.

- System Operation Information

Check the messages as the picture.


44/51

4D

Ship


44

Click the Exit button in the System control button or Click the right click at MCM Tray of the system

tray and click the Exit button to end the software.

Push the Motor power OFF button to disconnect the servo driver power.

Push the motion driving control computer power button to shut down the computer.

Motor Power ON(220VAC 3 Phase)

Motor Power OFF(220VAC 3 Phase)

1~6 axis operating status(When operation, green

light on)


45/51

4D

Ship


45

7. Shape


46/51

4D

Ship


46

III. Equipment Inspection and Maintenance

Caution!

Servo driver is very dangerous because it has the high-voltage terminal. DO NOT TOUCH the terminal

of the servo driver.(Electric Shock)

For a while after power off, the internal circuits is kept charged at higher voltage. Inspections should be

done a while (about 10 minutes)

Only the trained engineer can do the maintenance, inspection and parts replacement. In addition,

before working, remove all the metallic items (watch, rings, etc.).

Do not disassemble, repair, or alter the device arbitrarily. It can cause fire, electric shock or injury.

1. Servo Motor

Inspection and maintenance should be done according to the following table. However, do not

disassemble the motor.

Never contact the servo motor with water directly.

Servo motors can be operated normally less than 90% of relative humidity. High humidity can affect the

performance of servo motors.

Servo motors can be operated normally less than 40 of temperature. Do not apply shock to servo motors. Especially, the encoder on the servo motor is very sensitive to the

vibration and the shock and can be damaged by the shock.

Servo Motor Check

Inspection Item Cycle Description Remark

Vibration and Noise Everyday Adjust it to not be bigger than usual occasions. Abnormal

Foreign BodiesInstantly

when foundVacuum clean.

Insulation resistance1 Year Checking with the insulation resistance

measuring instrument. It should be higher than

500V 10M.

Contact thecompany if it is

lower than 10M

Oil Seal 5,000 Hours Replace with a new oil seal.

Overall Inspection 2,000 Hours Check with the manufacturer.

Disassembly and

worn-out part

replacement

In the event of disassemble the servo motor for repair or inspection, a care shall be taken for A/S not

available.


47/51

4D

Ship


47

Servo Motor Error Cause and Inspection/Action

Error Cause Inspection Action

The motor

does not run

Motor error

Measure the resistance

between U - V, U - W, V W.

Replace the motor if they are

unbalanced.

Overload No load test.

Reduce the load or replace the

motor with the higher capacity

motor.

Loosened connections

Check if the U/V/W connector

pins are firmly secured with

screws.

Loosened pins should be fixed

firmly. Replace the damaged

parts.

Wiring errorCheck the wirings are made

correctly.

Refer the System Configuration

and Wiring

Motor is

overheated

The ambient

temperature is high.

Lower the ambient

temperature(under 40C)Keep the proper temperature.

Overload No load test.Reduce the load or replace themotor with the higher capacity

motor.

Foreign BodiesCheck foreign bodies on the

motor surface.Clean the surface.

Abnormal

sound and/or

vibration.

Loosened connections

Check if the U/V/W connector

pins are firmly secured with

screws.

Loosened pins should be fixed

firmly. Replace the damaged

parts.

Mechanical installation

condition is bad.

Loosened for mismatched

coupling.

Confirm the installation

condition (coupling, nut

tightening) and adjust.

Motor bearingOperate the motor without loadin order to check the sound and

vibration near the bearing.

Replace the motor and operate

it to do the same checks.

Mechanical noise and

vibration of the load

Check the mechanical part of

the load if it has been damaged.

Contact the manufacturer of the

mechanical part of the load.


48/51

4D

Ship


48

2. Servo Driver

The servo drive has an embedded electronic circuit. Dust and other foreign bodies may cause malfunction.

Please keep the system cleaned and serviced periodically.(1 Year)

Never disassemble the servo driver.

Never contact the servo motor with water directly.

Servo motors can be operated normally less than 90% of relative humidity. High humidity can affect the

performance of servo motors.

Servo motors can be operated normally less than 55 of temperature. Do not apply shock to servo motors.

Refer the attached CSDP Plus Servo Drive User Manual for the further inspection and maintenance.

Servo Driver Check


Main Body 1 YearRemove the dust and grease with compressed

air and cloth.

Socket, Connector,

Screw1 Year Tighten.

Circuit Board 1 YearContact the company in the case of

discoloration, breakage or a broken wire.

Servo Driver Part Replacement Cycle(20 hours running a day)Item Cycle Remark

Capacitor 3 Year

Cable 3 Year(Traveling Cable)

Power Element 3 Year

Regenerative Brake Resistor 2 Year

Dynamic Brake Resistor 2 Year

Fan 2 Year

Cooling Fan 4~5 Year

Fuse 10 Year

In the event of disassemble the servo driver for repair or inspection, a care shall be taken for A/S not

available.


49/51

4D

Ship


49

3. Cylinder Assembly ( Servo Motor, etc )

Check the cylinder assembly before operating and driving of the motion platform always. Check the

coupling status of each mechanical part and the lubrication condition.

Grease Feeding Point of the Cylinder Assembly

DO NOT USE WD40 or similar with WD40 instead of grease. It can damage the cylinder assembly

inside. USE ONLY Grease (At least every 3 month).

Coupling Housing

Air Outlet

End point of theCylinder

Lower Hinge Block

(Inside the Cover)

Upper Hinge Block(Inside the Cover)

End point of theCylinder


50/51

4D

Ship


50

Cylinder Assembly Check List

No. ItemResult Cycle

RemarkNormal Bad Daily Weekly Cycle

1The upper limit switch is working correctly.

(The operation of the lever on stopping)O

2The lower limit switch is working correctly.

(The operation of the lever on stopping)O

3The coating of the wire of limit switch is

normal.O

4 The bolt for securing the limit is fastened. O

5 The cable of servo motor is connected exactly. O

6 All of the hinge caps are fixed exactly. O

7 Air outlet is not blocked by contaminants. O

8 Lock-nut for fix the cylinder and the bearinghousing is fastened.

O

9Coupling bolt for securing the motor shaft and

the ball screw is fastened.O 3 month

10Coupling bolt for securing the bearing housing

and the coupling housing is fastened.O

11Bolt for securing the motor post and the

coupling housing is fastened.O

12Bolt for securing the upper and lower joint

block is fastened.O

13Anchor bolt for lower frame of the motion

platform is fastened. O 6 month

14After motion operation, it does not generator

higher heat than usual.O 3 month

15In motion operation, it does not make the

louder noise than usual.O 3 month

16 Joint block rotation is smooth. O 3 month

17 Joint block axis rotation is smooth. O 3 month

Note

Inspection should be done just before the operation or driving of the motion platform or weekly.

Coupling bolts of every part of the motion platform should be inspected every day.

They are can be loosen because of the vibration of the motion platform.

Inspect the anchoring status of the lower frame of the motion platform before the operation or driving,

and fasten if it is loosened.


51/51

atorMaintenanceManual

4. Other Inspection and Measures

Other Inspection and Measures


Cable Connection Every time

Check the cable connection with the

motor power, encoder, and limit

sensor.

Foreign bodies on the

equipment and the room

Instantly when

foundVacuum clean.

Lubricant 3 Month USE Grease ONLYDO NOT USE

WD40

Overall 6 Month -

4d ship simulator user guide rev1.0(20130225)

Documents