Digital controller RK 4004 5.1.2 P a r a m e t e r list "Extended DCS" (only on RK 4 0 0 4 - 8 0 0 3 ) No. ..0. ..1. ..2.

Name edit device edit group reset settings Default 5 0 0 Min. 1 0 0 T h e following p a r a m e t e r s can only be edited using a CANMON program, Max. F 7 2 Unit hex Description

..4. ..5.

Add. DCS Config. >function config

4.X 0000

4.0 0000

5.5 FFFF

..6. ..7. ..8.

mid target limit auto offset limit target change speed

0.0 0.0 0

-3250.0 3250.0 -3250.0 3250.0 0 120

Select device number See block diagram for device number hex Select group number See block diagram for group number Works settings 0 = no function 1 = restore customer settings 2 = restore internal basic settings Software version hex Configuration [ ] check workspace 0x0001 [ ] emergency guide 0x0002 mm Limit for reference variable during lamination mm Limit for web offset mm/s Rate of change of reference variable

0.3(FE5002) Search Range Mode . >Ho R e s t r i c t i o n ( !>Always R e s t r i c t i o n ( > R e s t r . Auto & Time ( * > R e s t r . d u r i n g Time

If the following sign ">" is s e t in front of the p a r a m e t e r it may be edited with t h e help of a p a r a m e t e r value list (selection list) in CANMON or DO 2 0 0 . . Editing with C a n m o n : Select the "Value" field a n d o p e n the p a r a m e t e r list via the enter key. Select the required p a r a m e t e r value with the cursor keys, to mark the p a r a m e t e r value p r e s s the s p a c e b a r . Editing with c o m m a n d station DO 200.: Select the required p a r a m e t e r value via the "increase value"/ " d e c r e a s e value" keys, to mark the p a r a m e t e r value p r e s s the a c knowledge key.

Parameter value list (selection list)

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Digital controller RK 4 0 0 4 5.2 E x p l a n a t i o n of p a r a m e t e r s 5.2.1 E x p l a n a t i o n of p a r a m e t e r s "Standard"

..0. e d i t d e v i c e . . 1 . edit g r o u p T h e device a d d r e s s consists of the device a n d group n u m b e r s . Each device with a CAN connection (serial or parallel) p o s s e s s e s its own device a d d r e s s that may only be a s s i g n e d o n c e in the entire CAN network . In order for a specific device to be a d d r e s s e d in the control loop the device n u m b e r must be s e t in p a r a m e t e r "..0. edit device" and the group n u m b e r in p a r a m e t e r " . . 1 . edit group". T h e device and group n u m b e r s a r e specified in the block diagram for e a c h device with a CAN a d d r e s s .

..2. r e s e t s e t t i n g s In the event of incorrect functioning or p a r a m e t e r entries, the E+L basic settings or default v a l u e s may be reloaded. The following settings a r e possible: 1 = perform c u s t o m e r settings. This c u s t o m e r setting is only p o s sible on c o m p a c t s y s t e m s s e t by E+L prior to delivery w h e r e all p a r a m e t e r settings w e r e s a v e d in a b a c k u p list. T h e setting valu e s a r e t h u s reloaded. 2 = perform basic settings. T h e default v a l u e s specified in the par a m e t e r list a r e loaded. T h e default v a l u e s a r e however only loaded for the currently s e l e c t e d device. No p a r a m e t e r values a r e c h a n g e d on the remaining devices.

..3. start service U s e this p a r a m e t e r to start various p r o c e s s e s that a r e particularly required on commissioning the s y s t e m . T h e following functions a r e possible: 1 = Reset guider In this reset all p a r a m e t e r v a l u e s for the selected device a r e s a v e d and a restart performed. Every time p a r a m e t e r values a r e c h a n g e d s e t u p m o d e should always be quit via 1 to a s s u r e that all c h a n g e d p a r a m e t e r v a l u e s a r e s a v e d . Save parameters Function 2 is identical to function 1, the only difference is that no restart is performed for the selected device. A c t u a t o r initialisation r u n (with s p e c i f i c a t i o n of t h e m o t i o n path) Prior to the initialization run t h e actual positioning path must be established a n d entered in p a r a m e t e r ".2.5. total motion range". T h e actuator initialization run is started by entering the value 10. Prior to starting the actuator should be located in its center position for this start position is s a v e d as the new center position. T h e latter may also be corrected manually at any time via p a r a m e t e r " . 3 . 1 . c e n t e r offset".

2 =

10 =

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Digital controller RK 4004 11 = Initialisation run s u p p o r t b e a m By entering value 11 the initialization run for all support b e a m s featured in this group is performed. Initialisation run a c t u a t o r (with s p e c i f i c a t i o n o f m o t o r a n d gear data) In this initialization run by first entering the motor and g e a r data ( p a r a m e t e r .3.47.3.57.3.6. and .3.7.) the maximum positioning path is established and e n t e r e d in p a r a m e t e r ".2.5. total motion range". C a p t u r e of guiding criterion p h o t o On follow-up control s y s t e m s the position of the actuator/tool is controlled according to the d e t e c t e d w e b position. In order to calibrate the offset, a guiding criterion photo of the actuator must be taken. To this end, t h e actuator is moved to the required location manually. While t h e actuator guiding criterion photo is being taken, t h e offset is calculated on the basis of the current actuator position and the w e b position and entered in p a r a m e t e r ".4.6. foto auto offset". C a l i b r a t e s y s t e m offset (only with data protocol PR 2) If the control card is u s e d for a support b e a m , the system offset must be calibrated. During the calibration of the s y s t e m offset, the support b e a m position is calibrated to the middle of the machine (reference line). T h e p a r a m e t e r "1.1.1. template position" must be set before the calibration can be performed. C a l i b r a t e t h e z e r o p o i n t for t h e m o t o r c u r r e n t m e a s u r e ment A z e r o calibration for the motor current m e a s u r e m e n t is performed. T h e offset determined during this p r o c e s s is s a v e d in p a r a m e t e r 1.0.9. Save system parameters T h e p a r a m e t e r v a l u e s of certain p a r a m e t e r s a r e additionally stored a n d not deleted in the c a s e of possible data memory d e letion. T h e following p a r a m e t e r s a r e s a v e d : .8.2. / .8.3. / .8.4. / .8.5. / .8.6. / .9.2. / .9.7. / .9.8. a n d .9.9. . S a v e t h e c a l i b r a t i o n d a t a for t h e c o n t r o l l e r c a r d R K 4 0 0 4 T h e v a l u e s s a v e d a r e displayed in p a r a m e t e r 1.0.8. to 1.1.0. . 30 = general w e b guider basic parameter setting 31 = VS 35 .. s u p p o r t b e a m b a s i c p a r a m e t e r setting 32 = 3 p o s i t i o n c o n t r o l l e r b a s i c p a r a m e t e r s e t t i n g 33= 34= B a s i c p a r a m e t e r s e t t i n g for DR 1 1 . . / DR 12.. V S 50.. s u p p o r t b e a m b a s i c p a r a m e t e r s e t t i n g T h e device-specific p a r a m e t e r s a r e preset for the specified devices by entering the appropriate value.

12=

13=

15=

20 =

22=

23=

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Digital controller RK 4 0 0 4 42= Expanded setup-mode In s e t u p m o d e all existing p a r a m e t e r s may be selected and t h e p a r a m e t e r v a l u e s viewed. S o m e of the p a r a m e t e r values may be c h a n g e d immediately. T h e protected p a r a m e t e r s may only be c h a n g e d o n c e value 42 h a s b e e n entered. This entry furnishes a c c e s s to what is known as " e x p a n d e d setup-mode". In e x p a n d e d s e t u p m o d e all p a r a m e t e r s that can be c h a n g e d , may be changed. Save customer settings In this form of saving all p a r a m e t e r settings a r e stored in a b a c k u p list. If n e c e s s a r y , all customer-specific settings may be reloaded using p a r a m e t e r "..2. reset s e t t i n g s " . Delete reset c o u n t e r a n d running h o u r s meter T h e internal r e s e t counter and running hours meter a r e reset to zero. Delete maximum t e m p e r a t u r e T h e maximum heat sink t e m p e r a t u r e s a v e d is deleted. S e t calibration v a l u e s to default T h e calibration v a l u e s a r e reset to the default values. Delete error m e m o r y This c o m m a n d should only be u s e d by E+L service personnel. T h e controller card can store up to 100 errors that h a v e occurred. If the n u m b e r of errors e x c e e d s the 100 mark, the error m e s s a g e s a r e p u s h e d out at the back of the error memory and a r e t h u s deleted. Delete data m e m o r y This c o m m a n d should be u s e d by E+L service personnel. T h e entire d a t a m e m o r y of t h e controller card is deleted. O n c e the controller card is switched on the default v a l u e s a r e automatically loaded.

44 =

55 =

56 = 57 = 98 =

99 =

N o c o m m a n d s a r e p e r f o r m e d until a p a r a m e t e r c h a n g e h a s been executed!

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Digital controller RK 4004 Number 1.X to 3.X 4.X to 6.X 7.X to 9.X Number 1.0 1.1 etc. 1.9 2.0 2.1 etc. CAN data protocol PR 1 PR 2 PR 1 + PR 2 Software version A B etc. J K L etc. ..4. RK 4 0 0 4 T h e actual CAN data protocol and the software version a r e displayed. T h e n u m b e r before the point indicates the CAN data protocol used by the software. T h e n u m b e r after the point indicates the software version.

. . 5 . w e b e d g e offset P a r a m e t e r block for setting the w e b offset.

..6. w e b o f f s e t Sensor zero point T h e w e b offset permits the d i s p l a c e m e n t of the set w e b position to the left or right during automatic m o d e . T h e offset is set directly in this p a r a m e t e r by a c o m m a n d station or via a digital interface. T h e s t e p width for w e b offsetting may be set in p a r a m e t e r "..7. step width". T h e offsetting of the set position is displayed on the c o m m a n d station in mm. A set w e b offset is p r e s e r v e d , e v e n when the operating voltage is switched off, until a new entry is s a v e d . In the c a s e of fixed s e n s o r s or a single motor support b e a m with two positioning c a r r i a g e s the w e b offset is limited to 75 % of the s e n s o r m e a s u r i n g range. For the remaining applications with s u p port b e a m s a n d c a m e r a s the w e b offset may be increased to the maximum p a r a m e t e r value .

Web offset to the right in the direction of web travel

..7. s t e p w i d t h T h e s t e p width of the w e b offset per key push may be set in V mm. T h e w e b offset is c h a n g e d by this set value by pressing a key on the c o m m a n d station.
1 0 0

..8. o s c . a m p l i t u d e During the oscillation stroke it is determined by how far to the left and right the actuator will swing in oscillation m o d e . T h e oscillation stroke may be e n t e r e d directly in this p a r a m e t e r or via a c o m m a n d station with oscillation feature. Entering is performed in V mm.
10

Oscillation stroke ?

In the c a s e of fixed s e n s o r s or a single motor support b e a m with two positioning c a r r i a g e s the oscillation stroke is limited to 75 % of the s e n s o r m e a s u r i n g r a n g e .

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Digital controller RK 4 0 0 4 ..9. o s c . c y c l . t i m e Cycle-dependent: T h e cycle time (oscillation time t ) for an oscillation period is e s t a b lished here. T h e longer the period, the slower the actuator oscillates. Entry may be directly in the p a r a m e t e r or via a c o m m a n d station with oscillation function.
c

Oscillation time t Path-dependent: In p a t h - d e p e n d e n t oscillation the oscillation period is determined by p a t h - d e p e n d e n t , external p u l s e s . T h e oscillation period is divided up into n-sections. T h e maximum n u m b e r of p u l s e s must not e x c e e d 20 p u l s e s per s e c o n d . T h e n u m b e r of p u l s e s to be set may be calculated as follows: 1. Establish path length per oscillation period

s = w e b length per oscillation period

2. Establish maximum oscillation frequency V f c max g 60

x

f V s

cmax

m a x

= maximum oscillation frequency (1/s) = maximum w e b s p e e d (m/min) = w e b length per oscillation period (m)

3. Establish no. of p u l s e s T h e maximum n u m b e r of p u l s e s per period is limited by the maximum input frequency off 20 Hz. f = maximum input frequency 20 Hz f max oscillation frequency (Hz) n = no. of p u l s e s per period
emax = C

max
P =

1 c max T h e no. of p u l s e s n is e n t e r e d in the parameter.

Dimensioning of the external pulse g e n e r a t o r may be determined as follows: f s n

a m a x

f =- 1 a max s

= maximum pulse g e n e r a t o r output frequency (Hz) = w e b length per oscillation period (m) = no. of p u l s e s per period

T h e external pulse g e n e r a t o r must emit the calculated no. of p u l s e s L =vat maximum w e b s p e e d . a max ~
m

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Digital controller RK 4004 .1.0. o s c . w a v e form Oscillation m o d e d e t e r m i n e s the oscillation c o u r s e . By entering a value of b e t w e e n 5 a n d 95 oscillation progression may be c h a n g e d from s q u a r e to delta w a v e . 5 \ s "95" ] .1.1. >osc. triggermode Depending on the c o m m a n d station featured, oscillation may be started in different m a n n e r s . In addition, the differentiation must be m a d e of w h e t h e r cycle or p a t h - d e p e n d e n t oscillation is concerned. In t h e c a s e of c y c l e - d e p e n d e n t oscillation the duration of an oscillation cycle d e p e n d s on the set time and in the c a s e of p a t h - d e p e n d e n t oscillation on the external p u l s e s ( s e e p a r a m e t e r "..9. o s c . cycl. time"). On switching-off oscillation the cycle in p r o g r e s s is continued to the next z e r o p a s s . In the c a s e of p a t h - d e p e n d e n t oscillation the corresponding p u l s e s m u s t be supplied up to the zero p a s s . For p a t h - d e p e n d e n t oscillation the digital input X 3.2 must be prog r a m m e d to "web s p e e d measuring" ( s e e p a r a m e t e r .8.6.). T h e following table illustrated the various setting options: Parameter value: Path Cycle dependent dependent 4 0 1 5 Explanation: r 95 = = S q u a r e - w a v e ( s t e e p rise/drop of the oscillation signal, long dwelling period in t h e oscillation e n d position D e l t a - w a v e (shallow rise/drop of the oscillation signal, short dwelling period in the oscillation end position

"5"

2 3

6 7

Oscillation is switched on together with automatic mode or off via a command station with oscillation key or digital interface (command code), independently of the automatic key. If no command station with oscillation key is featured, oscillation may in this case be switched on or off via the automatic key. After starting automatic mode, by pressing the automatic key oscillation is started or stopped while the actuator always remains in "automatic" mode. Oscillation is generally switched off. Even if an oscillation key is featured, oscillation cannot be started. Oscillation is always active. Automatic mode without oscillation is not possible. Oscillation is started together with automatic mode!

.1.2. w e b e d g e c o n t r o l l e r P a r a m e t e r block for setting the w e b guider.

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Digital controller RK 4 0 0 4 . 1 . 3 . p r o p r a n g e +/On p r o p o r t i o n a l a c t u a t o r s t h e amplification of the position controller is s e t via t h e two p a r a m e t e r s ".1.3. Prop r a n g e " and ".1.6. velocity auto". On i n t e g r a l a c t u a t o r s amplification is set via the two p a r a m e t e r s ".1.3. Prop r a n g e " a n d ".4.5. prop stroke". With regard to t h e following considerations p l e a s e always take into a c c o u n t that a c h a n g e to o n e of the two p a r a m e t e r s will alw a y s influence amplification. ^Amplification too high iff, / / r, Amplification right Amplification too low Amplification is correctly set if, after brief overshooting the error is corrected. If t h e position controller is s e t with too great a d e g r e e of sensitivity, t h e guider will o v e r s h o o t as well. In the c a s e of too little amplification the control loop will be too slow. Optimum amplification may be determined with a characteristic curve tracer. In practice, a m plification may also be determined by trial and error.

Proportional actuator: T h e smaller t h e s e t proportional r a n g e at a c o n s t a n t maximum positioning velocity ( P a r a m e t e r ".1.6. velocity auto") is, the greater the amplification of t h e w e b guider will be. A negative proportional r a n g e c a u s e s negative amplification, the effective direction is t h u s inverted in automatic m o d e . Proportional range .1.3. prop range 2,0 3,5

Velocity correction established correction velocity depending on proportional range

Positioning velocity .1.6. velocity auto 20 mm/s

Set position (sensor measuring range center)

Control deviation of 1.5 mm

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Digital controller RK 4004 By reducing the proportional r a n g e the characteristic curve ( s e e fig.) will b e c o m e steeper. T h e s t e e p e r the characteristic curve the greater the positioning velocity will be in the c a s e of a control deviation and the s y s t e m t h u s more sensitive. T h e positioning velocity of the actuator may be determined on the b a s i s of the characteristic curve reg a r d l e s s of the control deviation.

In this e x a m p l e a proportional r a n g e of 2 mm or 3.5 mm h a s been a s s u m e d at a maximum motion s p e e d of 20 m m / s . Given a control deviation of 1.5 mm the positioning velocity is 15 m m / s for a proportional r a n g e of 2 mm and 8.0 m m / s for a proportional r a n g e of 3.5 mm. T h e v a l u e s may also be calculated arithmetically: Amplification (G) = p a r a m e t e r .1.6. / P a r a m e t e r .1.3. Correction velocity (VK) = control deviation * amplification (G) Example 1: G = 20/2 = 10 V, VK = 1.5 mm * 10 V, VK = 15 m m / s Example 2: G = 20/3.5 = 5.71 V, VK = 1.5 mm * 5.71 V, VK = 8.6 m m / s

Proportional actuator optimisation: R e d u c e the proportional r a n g e by small s t e p s only. Following e a c h c h a n g e of t h e p a r a m e t e r value a w e b deviation should be produced manually in automatic m o d e so that oscillation may be detected immediately. R e d u c e the proportional r a n g e until the guider starts to oscillate. The i n c r e a s e the proportional r a n g e again until no more oscillation may be observed.

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Digital controller RK 4 0 0 4 Integral a c t u a t o r : T h e smaller t h e s e t proportional r a n g e is for the maximum correction path of t h e actuator ( p a r a m e t e r ".4.5. prop stroke "), the greater the amplification of the w e b guider. A negative proportional r a n g e c a u s e s negative amplification, the effective direction in automatic m o d e is t h u s inverted. Correction positioning path established correction path depending on proportional range Proportional range .1.3. prop range 2.0 3.5

Set position (Sensor measuring range center)

Control deviation of 1.5 mm

By reducing the proportional r a n g e the characteristic curve ( s e e fig.) b e c o m e s s t e e p e r . T h e s t e e p e r the characteristic curve the greater the positioning path of t h e actuator given a control deviation and the more sensitive t h e s y s t e m b e c o m e s . T h e correction path of the actuator may be established on the b a s i s of the characteristic curve independently of the control deviation. In this e x a m p l e a proportional r a n g e of 2 mm or 3.5 mm h a s b e e n a s s u m e d with a correction path of 25 mm. Given a control deviation of 1.5 mm the correction path a m o u n t s to approx. 18 mm with a proportional r a n g e of 2 mm a n d with a proportional r a n g e of 3.5 mm approx. 10.5 mm .

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Digital controller RK 4004 T h e v a l u e s may also be calculated arithmetically: Amplification (G) = p a r a m e t e r .4.5. / p a r a m e t e r .1.3. Correction path (SK) = control deviation * amplification (G) Example 1: G = 25/2 = 12.5 SK = 1.5 mm * 12.5 VK = 18.75 m m Integral a c t u a t o r o p t i m i s a t i o n : R e d u c e the proportional r a n g e by small s t e p s only. Following e a c h c h a n g e of the p a r a m e t e r value the a w e b deviation should be prod u c e d manually in automatic m o d e so that oscillation may be d e tected immediately. R e d u c e the proportional r a n g e until the guider starts to oscillate. The i n c r e a s e the proportional r a n g e again until no more oscillation may be observed. Example 2: G = 25/3.5 = 7.14 SK = 1.5 mm * 7.14 VK = 10.71 m m

.1.4. d u a l - r a t e w i d t h .1.5. d u a l - r a t e level If the w e b e d g e is subject to certain fluctuations (uneven e d g e s ) t h e s e two p a r a m e t e r s may be u s e d to determine a r a n g e in which, given a deviation from the s e t position, the correction velocity of the actuator is reduced in the c a s e of proportional guiders. Given a w e b e d g e progression as illustrated opposite, the actuator would normally try to correct the deviation according to the broken line. T h e actuator would only oscillate a n d the control result would not be satisfactory. T h e broken line r e p r e s e n t s the controller amplification ( p a r a m e t e r .1.3./.1.6.). Within the set window width ".1.4. dual-rate width" the positioning velocity is reduced in the c a s e of a control deviation. T h e positioning velocity reduction is s e t in p a r a m e t e r ".1.5. dual-rate level". Potential oscillation d u e to e d g e errors may t h u s be reduced. If the e d g e error e x c e e d s the set window width r a n g e the positioning velocity is inc r e a s e d ( s e e fig. on left). Both p a r a m e t e r v a l u e s a r e % entries and a r e related to the set valu e s of p a r a m e t e r ".1.3. prop r a n g e " a n d ".1.6. velocity auto" Example: T h e following v a l u e s a r e set in t h e p a r a m e t e r s . .1.3. prop r a n g e .1.6. velocity auto 10.0 mm 20 m m / s

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Digital controller RK 4 0 0 4 .1.4. dual-rate width .1.5. dual-rate level : 50% 70% = 5 mm = 1 4 mm/s

Window width = 10.0 mm * 50 % / 1 0 0 R e d u c e d pos. velocity = 20 m m / s * 70 % / 1 0 0

Within 5 mm of t h e s e t w e b position a w e b error is corrected at a maximum motion s p e e d of 14 mm/s.

This function is being deactivated w h e n value "100" is entered into p a r a m e t e r ".1.5. dual-rate level".

.1.6. v e l o c i t y a u t o T h e g r e a t e r the s e t maximum positioning velocity is given a constant proportional r a n g e ( p a r a m e t e r ".1.3. prop r a n g e "), the greater the amplification of the w e b guider will be in automatic m o d e . Correction velocity established correction velocity depending on the positioning velocity Proportional range .1.3. prop range 2.0

3 4 Positioning velocity .1.6. velocity auto 15 mm/s 20 mm/s

Set position (Sensor measuring range center)

C o n { r o | d e v j a t j o n of

1.5 mm By increasing t h e maximum positioning velocity the characteristic curve b e c o m e s s t e e p e r ( s e e fig.). T h e s t e e p e r the characteristic curve the g r e a t e r t h e positioning velocity will be given a control d e viation a n d the m o r e sensitive the s y s t e m will b e c o m e . T h e positioning velocity with which t h e actuator tries to correct the error may be d e d u c e d from t h e characteristic curve.

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Digital controller RK 4004 In this e x a m p l e a maximum positioning velocity of 15 mm/s or 20 m m / s h a s b e e n a s s u m e d with a proportional r a n g e of 2 mm. Given a maximum positioning velocity of 15 mm/s the positioning velocity a m o u n t s to approx. 11 m m / s with a control deviation of 1.5 mm a n d approx. 15 m m / s with a maximum positioning velocity of 20 m m / s . T h e v a l u e s may also be calculated arithmetically: Amplification (G) = p a r a m e t e r .1.6. / p a r a m e t e r .1.3. Correction velocity (VK) = control deviation * amplification (G) Example 1: G = 15/2 = 7.5 V
s

Example 2: G = 20/2 = 10.0 V s

s 1

VK=1.5mm*7.5 V VK = 11.25 m m / s

VK = 1.5 mm * 10.0 / VK = 15.0 m m / s

If the positioning velocity is too high the w e b guider will begin to o s cillate. T h e maximum positioning velocity must be set higher than the maximum error velocity, yet m u s t not e x c e e d the nominal positioning velocity the DC actuator.

.1.7. v e l o c i t y p o s T h e positioning velocity is determined in this p a r a m e t e r for the following operating m o d e s : actuator "center position" support b e a m "park s e n s o r " actuator / support b e a m "positioning c o m m a n d s "

T h e s t e p width of the s p e e d setting is 1 mm/s.

.1.8. v e l o c i t y j o g T h e positioning velocity with which the actuator or support b e a m is positioned in "manual" m o d e may be s e t in this p a r a m e t e r with a step width of 1 m m / s .

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Digital controller RK 4 0 0 4 .1.9. v e l o c i t y d e f e c t ".2.2. defect range " Switching threshold for reducing the positioning velocity So that, in the e v e n t of a w e b d i s p l a c e m e n t (e.g. s e a m joint) the actuator no longer follows up at maximum positioning velocity in "automatic" m o d e , the positioning velocity may be reduced to a required value. From which d e g r e e of control deviation (web offset) o n w a r d s the reduction is activated, must be s e t in p a r a m e t e r ".2.2. defect r a n g e " . In t h e c a s e of a support b e a m this velocity setting is determined in "search for e d g e " m o d e . I This p a r a m e t e r is only active if "defect detection" is selected in par a m e t e r .9.7..

".1.9. velocity emergence" Value of the reduced positioning velocity

.2.0. d e r a t e d v e l o c i t y Not a s s i g n e d at present.

.2.1. reserved 21 Not a s s i g n e d at present.

.2.2. d e f e c t r a n g e If t h e set value is e x c e e d e d , the positioning velocity will be reduced to t h e value s e t in p a r a m e t e r ".1 .-9. velocity defect". In the event of a s u d d e n w e b d i s p l a c e m e n t ( s e a m joint) this prevents the actuator following up at maximum positioning velocity which might lead to a w e b tear. This p a r a m e t e r is only active if "defect detection" is selected in par a m e t e r .9.7. .

.2.3. s e r v o configuration P a r a m e t e r block for setting t h e motor data.

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Digital controller RK 4004 .2.4. m o t i o n d i r e c t i o n T h e positioning direction of t h e DC actuator drive may be inverted via this parameter.

Following inversion of the positioning direction an initialization run must be performed.

.2.5. m o t i o n r a n g e total T h e actual positioning path (dimension K) covered by the actuator at the outfeed (transfer roller) m u s t be e n t e r e d in this parameter. As on certain a c t u a t o r s (e.g. pivoting frames) the actuator positioning path is not identical to that of t h e DC actuator drive, the exact value must be entered. T h e mechanical ratio (".3.7. m e c h . g e a r factor") is determined via this setting during the initialization run a n d the motor g e a r constant calculated. T h e latter effects the normalization of the positioning s p e e d and path.

.2.6. p o s i t i o n r a n g e + .2.7. p o s i t i o n r a n g e Via t h e position r a n g e limit the DC actuator drive is prevented from reaching its mechanical spindle s t o p or the actuator its mechanical stop. On c o m p a c t s y s t e m s the maximum actuator positioning path ( s e e p a r a m e t e r ".2.5. total motion range") is s h o r t e n e d at the factory by approx. 2 mm. In the c a s e of on-site mounting of the DC actuator drive the position r a n g e limit m u s t be s e t by the customer. Especially in the c a s e of large moved m a s s e s , p l e a s e e n s u r e that the actuator d o e s not c o m e to a standstill at o n c e . The positioning range must be r e d u c e d accordingly. T h e s e t v a l u e s a r e always in relation to the set center. T h e positioning path must e n t e r e d for both s i d e s (right/left) of the center position in p a r a m e t e r .2.6. a n d .2.7. of the positioning range. T h e s e position r a n g e limits must not be u s e d as s a f e g u a r d s for p e r s o n s or a p p l i a n c e s . For the safety of p e r s o n s or appliances the e n d position limits must be fitted with additional limit switches or a suitable mechanical stop.

.2.8. a l a r m limit % If n e c e s s a r y a r a n g e may be defined that, o n c e e x c e e d e d , triggers the output of a limit alarm. T h e value is entered in % and is in relation to the two p a r a m e t e r s ".2.6. positionrange +" and ".2.7. positionr a n g e -". If the actuator e x c e e d s this calculated value the "End position early warning" m e s s a g e is output. T h e "End position reached" m e s s a g e is only output at t h e two e n d positions. The limit for "End position early warning" always relates to the center of the actuating r a n g e set. T h e warning is output for both s i d e s (positive and n e g a tive). BEA-250482-EN-23 J Page 35

Digital controller RK 4 0 0 4 Example: \ I i l i i\ f |L .2.7 = 15 mm Entered value in parameter .2.8. 75% 15 mm

Entered value in parameter .2.6. / .2.7. 15 mm * 75/100 = 11.25 mm

.2.6. = 15 mm

11.25 mm end position early warning in relation to theoretical center 1 S

:

If the actuating range of 11.25 mm is exceeded, the "End position early warning" message is output. If the actuating range of 15 mm is reached, the "End position reached" message is output.

1I 1 i H\ . .2.7. = 10 mm

If the v a l u e s differ in p a r a m e t e r s .2.6. / .2.7. a theoretical center will be d e d u c e d from the s u m of t h e two values. T h e e n d position early warning is in relation to this center. Example: Entered value in parameter .2.8. Entered value in parameter .2.6. Entered value i n parameter .2.7. (15mm + 10 mm) /2 * 75/100 = 9.375 mm = = = 1 0 75% 15 mm mm

ti 2.6. = 15 mm

9.375 mm end position early warning in relation to theoretical center

.2.9. h y b r i d offset If a support b e a m is o p e r a t e d with two drives in w h a t is termed hybrid m o d e the two positioning c a r r i a g e s move symmetrically to the support b e a m center. This support b e a m center (center of the guided w e b ) should match t h e m a c h i n e center. The support b e a m center may be m a t c h e d to the m a c h i n e c e n t e r via this p a r a m e t e r (.2.9. hybrid offset). In the c a s e of mechanically coupled support b e a m s (one drive, two positioning carriages) this offset is not possible. This p a r a m e t e r is only n e c e s s a r y on a two-motor support b e a m in device X.7.

.3.0. r e f e r e n c e offset In this p a r a m e t e r the d i s t a n c e b e t w e e n the reference switch switching point a n d the center of the DC actuator drive is set. To calibrate the internal position counter the actuator m o v e s first to the reference switch, their c e n t e r position (neutral position) in "center position" operating m o d e . To a s s u r e that the positioning m o v e m e n t is as slight as possible in "center position" m o d e the reference switch switching point should be the s a m e a s neutral position. This p a r a m e t e r is automatically determined and entered during the actuator initialization run.

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Digital controller RK 4004 DC actuator drive center . 3 . 1 . c e n t e r offset Center offset What is termed the "center offset" is the difference between the DC actuator drive c e n t e r a n d the actuator neutral position. If this neutral position d e v i a t e s from the positioning path center the former may be c h a n g e d by entering the "center offset". In the c a s e of a pivoting frame, neutral position m e a n s that the positioning roller is parallel to the guide roller. If the guider is in "center position" m o d e while the "center offset" is c h a n g e d , t h e c h a n g e of p a r a m e t e r value will be performed immediately by the DC actuator drive. Checking of the actuator neutral position is possible at o n c e .

Actuator neutral position

.3.2. s y s t e m offset If the DC actuator is located in the c e n t e r of its positioning range the actual position value "0" will be transmitted via the CAN bus. For s p e cial applications an offset value may be set in this p a r a m e t e r which is a d d e d to the transmitted actual position value.

.3.3. total resolution T h e motor g e a r c o n s t a n t is displayed in this parameter. It is calculated on the b a s i s of the following four p a r a m e t e r s : .3.4. e n c o d e r resolution, .3.5. rotation gear, .3.6. linear gear, .3.7. m e c h . g e a r factor;

.3.4. e n c o d e r r e s o l u t i o n .3.5. r o t a t i o n g e a r .3.6. l i n e a r g e a r .3.7. m e c h . g e a r f a c t o r T h e motor g e a r c o n s t a n t is calculated via t h e s e p a r a m e t e r s .

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Digital controller RK 4 0 0 4 T h e v a l u e s for the three p a r a m e t e r s .3.47.3.5./.3.6. must be determined using t h e table in c h a p t e r 6.

T h e mechanical ratio is specified in p a r a m e t e r ".3.7. m e c h . g e a r factor". T h e ratio may be established as follows: M e a s u r e d i s t a n c e S 1 b e t w e e n the c e n t e r of rotation a n d DC actuator drive securing point. Equally, m e a s u r e distance S 2 between the c e n t e r of rotation a n d the outfeed point. T h e s e two v a l u e s a r e set in relation to o n e a n o t h e r a n d the value calculated p r o d u c e s the m e chanical ratio ( p a r a m e t e r .3.7.). Example: measured distance S 1 measured distance S 2 850 mm / 450 mm = 1.89 In this example the entry in parameter .3.7. is 1.89. 450 850 mm mm

During the initialization run ( p a r a m e t e r . . 3 . / value 10) p a r a m e t e r ".3.7. m e c h . gearfactor" is established automatically.

.3.8. e n c o d e r filter For a d y n a m i c s p e e d control the e n c o d e r impulses should be filtered as little as possible. Too small a filter value will c a u s e an u n s t e a d y motor s p e e d .

.3.9. p o s . c o n t r o l l e r P a r a m e t e r block for setting t h e positioning control loop.

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Digital controller RK 4 0 0 4 .4.0. d e a t h z o n e s (mm) Set position Actual position without 25 + dead zone 20 J\ A / \ 15 + / \i \ / \ 10 5 1 r t(3) H h 2 3 4 5 6 7 If, in applications with a stiff m e c h a n i s m or large moved m a s s e s , t h e r e a r e problems with the position control loop (e.g. oscillation around the set position), a d e a d z o n e can be set taking into account the n e c e s s a r y positioning accuracy. T h e r e is no actuating movement within t h e r a n g e set.

s (mm) ^ Set position 25 20 15 + TcT 5+ 1 Actual position with dead zone 3 4.0. death zone H 1 1 1 h 2 3 4 5 6 7 t(s)

.4.1. p o s prop Positioning velocity If the position error is g r e a t e r than the s e t "position controller proportional range" the correction velocity will t h u s correspond to the maximum positioning velocity. If the position error is within the set "position controller proportional range" a l e s s e r positioning velocity according to the o n e of the characteristic c u r v e s is produced. Via this p a r a m e t e r the P c o m p o n e n t of the actuator drive position controller is indirectly set. Example: Maximum positioning velocity in automatic (parameter .1.6.) Position controller proportional range (Parameter .4.1.) A w e b set position deviation of 1 mm p r o d u c e s an actuator set position of 15 mm b a s e d on the s e t v a l u e s ( p a r a m e t e r .1.3. and .4.5.). T h e DC actuator drive c o v e r s the first 10 mm at maximum positioning velocity as t h e s e v a l u e s a r e outwith the grey range. O n c e the 10 mm a r e p a s s e d , only 5 mm remain. T h e s e 5 mm lie within the grey range a n d the velocity is tfius r e d u c e d linearly to 0 until the 15 mm position r a n g e is r e a c h e d . In the c a s e of uneven e d g e s (textile) this p a r a m e t e r may be inc r e a s e d to d a m p e n t h e DC actuator drive position controller. The static precision of the w e b guider is hereby preserved. T h e value of p a r a m e t e r . 4 . 1 . should a m o u n t at most to half of the s e n s o r scanning range.

^ Position e a IT
e r r o r

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Digital controller RK 4 0 0 4 .4.2. a c t p o s i t i o n T h e actual position of the actuator at the outfeed, in relation to the s e t center, is displayed.

.4.3. s e t position T h e s e t position of the actuator at the outfeed, in relation to the set center, is displayed.

.4.4. p o s s o u r c e a d r e s s In the c a s e of follow-up controlling (master/slave) a s e c o n d actuator (slave) without s e n s o r s c a n n i n g precisely follows up a freely selectable actuator (master). T h e device a d d r e s s of the m a s t e r ' s guider must be e n t e r e d on the controller card of the s e c o n d actuator (slave). Example: T h e m a s t e r ' s a d d r e s s is T h e s l a v e ' s a d d r e s s is 1.5 2.5

Value 15 ( a d d r e s s 1.5) must be e n t e r e d in p a r a m e t e r .4.4. of the slave controller card ( a d d r e s s 2.5).

.4.5. p r o p s t r o k e In t h e c a s e of integral a c t u a t o r s the correction path is set in relation to t h e set proportional r a n g e ( p a r a m e t e r ".1.3. prop r a n g e "). This p a r a m e t e r h a s no function for proportional actuators. T h e g r e a t e r the s e t correction path is for a c o n s t a n t proportional r a n g e ( p a r a m e t e r ".1.3. prop r a n g e "), the g r e a t e r the amplification ( s t e e p characteristic curve) of the w e b guider in automatic m o d e . T h e s t e e p e r the characteristic curve the longer the correction path in the e v e n t of a control deviation a n d t h u s the more sensitive the s y s tem will b e c o m e . T h e correction path u s e d by the actuator to try to correct an error may be s e e n in the characteristic curve.

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