Motion Analyzer Software User Manual PDF

User Manual
Motion Analyzer Software

Version 7.00
Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Kinetix, MP-Series, ProposalWorks, Rockwell Automation, Rockwell Software, RSLogix, TechConnect, TL-Series, and Ultra are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Summary of Changes
This manual contains new and updated information.
New and Updated This table contains the changes made to this revision.
Information Topic Page
Removed the Activation Wizard section. N/A
Added Group/Ungroup and Add Drive Group descriptions to the Home Tab section. 16
Updated Power Data, Shunt, and Energy tab examples for the 46
Power Supply/Accessories - Single-axis Drive Systems section.
Added Power Supply/Accessories AC/DC Power Sharing Systems (Kinetix 5500 drives) section. 51
Updated the Output Format Selection dialog boxes in the Export to RSLogix 5000 Wizard section. 65
Added new Explorer View examples and updated the Drives Group Node description. 78
Updated the Solution List dialog box example. 209
Added Preferred Product section. 210
Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012 3

Summary of Changes
Notes:
4 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Preface
About This Publication The versatility of Motion Analyzer software lets users of various application
complexities and experience levels use one software package to size their systems.
This manual is designed to accommodate basic users, advanced users, and
everyone in between.
Who Should Use This Manual This manual is intended for engineers directly involved in the selecting, sizing,
and optimizing of drives and motors or actuators for a motion control system.
Conventions Used in This The following conventions are used throughout this manual:
Manual Bulleted lists such as this one provide information, not procedural steps.
Numbered lists provide sequential steps or hierarchical information.
Hyperlinks are embedded throughout this document so that you can easily
navigate to and obtain information that is relevant to your particular
application.
System Requirements Motion Analyzer software requires the following operating conditions.
Attribute Description
Pentium IV processor 500 MB free space in the
Computer hardware requirements 1 GB RAM minimum installation directory
1280x800 screen resolution .NET Framework 2.0
Windows XP - 32 Bit (SP2) Windows Vista - 64 Bit
Operating systems supported Windows XP - 64 Bit (SP2) Windows 7 - 32 Bit
Windows Vista - 32 Bit Windows 7 - 64 Bit
Office 2007
Microsoft Office software supported Office 2010
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
Download Motion Analyzer software from: Comprehensive motion application sizing tool used for analysis, optimization,
http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software selection, and validation of your Kinetix Motion Control system.
Overview of Kinetix servo drives, motors, actuators, and motion accessories designed to
Kinetix Motion Control Selection Guide, publication GMC-SG001 help make initial decisions for the motion control products best suited for your system
requirements.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and other certification details.
You can view or download publications at

http:/www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.

Preface
Notes:

Chapter 1
Welcome to Motion Analyzer Software
Topic Page
Before You Begin Sizing 8
Database Updater Program 8
Welcome to Motion Analyzer 13
Menu Bar and Quick Access Toolbar 14
File Tab 15
Home Tab 16
Graphical View 17
Group View 22
Multiple Profile View 26
Power Supply/Accessories View 29
Preferences Tab 62
Export Import Tab 65
Export to RSLogix 5000 Wizard 65
Bill of Materials (BOM) Tab 76
Help Tab 76
Explorer View 78

Chapter 1 Welcome to Motion Analyzer Software
After downloading and starting Motion Analyzer software, youll want to update
1.1. Before You Begin Sizing the Motion Analyzer database with the latest Allen-Bradley products available for
motion control applications. This section steps you through that process.
TIP Download Motion Analyzer software from

http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software.
1.1.1. Database Updater Program
The Motion Analyzer Database Updater program updates your Motion Analyzer
software with the latest database available for the version currently installed on
your personal computer.
1. To start the Motion Analyzer database updater program, go to

Start>All Programs>Rockwell Automation>Motion Analyzer 7.00>
Database Updater.
TIP To update the software version, download Motion Analyzer software from
http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software.
The Motion Analyzer Database Updater wizard opens.
Table 1 - Database Updater Analysis

Installed Motion Indicates the version of Motion Analyzer software currently installed.
Analyzer version
Installed database Indicates the database version currently installed.
version
2. Click Next.

Welcome to Motion Analyzer Software Chapter 1
The program checks for database updates.
If the program finds that you already have the current database installed,
the following dialog box opens.
3. Click Finish.

4. If the program finds that a database update is available, a dialog box opens
with the following information:
Installed software and database versions
Available database version
Database download file size
Summary of new features and products in the new database
5. Click Update.

6. If the database updater program detects that your current version of

Motion Analyzer software is running, a dialog box opens with the
following instructions.
7. If the program finds that a new software version is available, a dialog box
opens with the following options:
Click the link to download the new version of Motion Analyzer
software
Click Next to skip the download and just update your current database

8. When the database updater program begins the update, this dialog box
opens.
9. When the database updater program completes the update, this dialog box
opens.
10. Click Finish.

1.1.2. Welcome to Motion Analyzer
The Welcome to Motion Analyzer dialog box opens when the software
application is launched. Two modes of operation are possible.
Figure 1 - Welcome to Motion Analyzer Dialog Box
Table 2 - Motion Analyzer Modes of Operation

Mode Description
Intuitive workflow to help size, select, and optimize the motion control system. This mode also
Size and Select creates a bill of materials.
Just Quote Creates only a bill of materials so no sizing input is required.
Click either of the New option modes to start a new application or click Browse
to open a previously configured application.

1.2. Menu Bar and Quick Your Motion Analyzer application file opens and the menu bar appears across the
top of the dialog box. Above the menu bar is the Quick Access toolbar.
Access Toolbar
Figure 2 - Size and Select Dialog Box
Quick Access Toolbar
Menu Bar
The Quick Access toolbar provides shortcuts to commonly used functions.

These functions include New, Open, Save, and Print.
Table 3 - Menu Bar Tab Descriptions

Options Description Page
File Tab Standard File menu options. 15
Most commonly used actions across different views in Motion Analyzer
Home Tab 16
software.
Preferences Tab Setting /View user preference option. 62
Export Import Tab All data Export Import functionality. 65
Bill of Materials (BOM) Tab Useful shortcuts for navigating through the Bill of Materials view. 76
Help Tab Standard Help menu options. 76

1.2.1. File Tab
The File tab is similar to the file menu in many computer applications.
Figure 3 - File Tab Options
Table 4 - File Tab Descriptions (refer to Figure 3)

Options Description
New Click New to go to the Welcome dialog box in Motion Analyzer software.
Click Open to browse folders and open Motion Analyzer applications. Standard Open
Open functionality.
Save Click to save the running Motion Analyzer application. Standard Save functionality.
Click to launch a dialog box, browse to the path on your computer, and save the current
Save As application to an.mba file.
Click for the list of recently opened applications. You can open one of these applications
Recent Files directly from this shortcut.
Lets you open Motion Analyzer sample applications present in the Motion Analyzer
Sample Applications installation.
Print Click to print the application data.
Print
Print Preview Click to see a preview of printable application data.
Help This is similar to the Help Tab on page 76.
Exit Click to close the running application.

1.2.2. Home Tab
The Home tab contains five sections.
Figure 4 - Home Tab Options
Table 5 - Home Tab Descriptions

Option Description
Used to access the different views available in Motion Analyzer software.
Graphical View Click to open the Graphical view on page 17.
Group View Click to open the Group view on page 22.
Multiple Profile View Click to open the Multiple Profile view on page 26.
Views
(label 1 in Figure 4) Power Supply/ Click to open the Power Supply/Accessories view on page 29.
Accessories View
Identify Your Load
Click to open the Axis view on page 82.
Axis View
System Bill of
Click to open the BOM view on page 36.
Materials (BOM) View
Clipboard Used to access the Cut, Copy, and Paste functions. Click to perform these functions that are
(label 2 in Figure 4) common to many software programs.
Used to access these editing functions. Each one works on the entity selected in Explorer
hierarchy view.
Rename Click to rename the selected entity.
Delete Click to delete the selected entity from the application.
Click to sort the axes in Drives group for Multi Axis Family application
Sort by Power by Axis Power. Sort is valid at the Rack, Group, or IPIM level.
Edit
(label 3 in Figure 4) Allocate Allocate the axis from Un-allocate Axes Group to Drives Group.
Unallocate Un-allocate the axis from Drives Group to un-allocate Axes Group.
Select multiple axes in Explorer view and click Group to create a Power
Sharing Drive Group. This feature is available only for families that
Group/Ungroup support AC and DC power sharing (Kinetix 5500 drives).
Select Power Sharing Drive Group in the Explorer view and click
Ungroup to ungroup the axes of the selected group.
Used to access these add functions. Each one works on the entity selected in Explorer hierarchy
view.
Add a new IPIM module in the selected Drives Group in Explorer
Add IPIM hierarchy view.
Add
(label 4 in Figure 4) Add a new axis in the Drives Group/Unallocated Group or IPIM based
Add Axis on users current selection in Explorer hierarchy view.
Add a new Drives Group under the Project node in the Explorer
Add Drive Group hierarchy view. This feature is available only for families that support
AC and DC sharing (Kinetix 5500 drives).
Tools
(label 5 in Figure 4) Motion Analyzer/SolidWorks Integration is used to launch the SolidWorks Integration wizard.

1.2.2.1. Graphical View
The Graphical view applies to multi-axis drive families and provides graphical
representation of the current (Bulletin 2093 and 2094) power rail and
Kinetix 6000M integrated drive-motor system configurations.
Figure 5 - Graphical View Example
Table 6 - Graphical View Options (refer to Figure 5)

Displays the graphical representation of the current Bulletin 2093 or 2094
Power Rail View 18
power rail configuration.
Power Interface Displays the graphical representation of the Kinetix 6000M integrated drive- 20
Module View motor system on the Bulletin 2094 power rail.

1.2.2.1.1. Power Rail View
The Power Rail view displays the graphical representation of the current Bulletin
2093 or 2094 power rail configuration.
Figure 6 - Power Rail View Example
Table 7 - Power Rail View Options

Options Description
Part Number Displays the selected power rail catalog number.
Product Rack
Summary Total No. of Slots Displays the total number of slots available in the selected power rail.
(label 1 in Figure 6)
Slots Occupied Displays the number of slots currently occupied in the selected power rail.
Graphical representation of the power rail with the drive modules and empty slots are
Image view displayed along with the selected catalog numbers. Power rail configurations like Axis Slot
(label 2 in Figure 6) mapping can be configured using options available in this view.
Right-click the modules and choose operations to perform from the menu (refer to Figure 7).
Refers to the type of the module that is currently selected in the power
Selected Slot rail. For example, axis module (AM), integrated axis module (IAM), power
Module interface module (IPIM), or empty slot.
Module Information
(label 3 in Figure 6) Part Number Catalog number of the selected drive module.
Slot Number Power rail slot number occupied by the selected drive module.
Axis Name Name you assigned to the axis associated with the selected drive module.
Click to launch the Axis view of the axis associated with the selected drive
View Axis module.
Additional Un- allocate Un-allocates the axis associated with the selected drive modules.
Module Information
(inside red box) Click to open the Kinetix Motion Control Selection Guide. The page
View Product displayed from the selection guide corresponds to the selected drive
Guide module.

Figure 7 - Operations to Perform Example
Additionally, you can click, drag, and drop a module to reposition that module
on the power rail (refer to Figure 8).
Figure 8 - Drag and Drop Modules to Reposition on Power Rail

1.2.2.1.2. Power Interface Module View
The integrated drive-motor power interface module (IPIM) mounts to the

Bulletin 2094 power rail and connects (daisy-chains) with up to sixteen
integrated drive-motor (IDM) units.
Figure 9 - Power Rail View Example (Kinetix 6000M integrated drive-motor system)
Table 8 - Power Rail View Options (Kinetix 6000M integrated drive-motor system)
Options Description
Slot Number Power rail slot number occupied by the selected IPIM module.
Number of Displays the number of axes currently associated with the selected IPIM
IPIM Summary Associated Axis module.
Number of Displays the additional number of axis that can be added in this IPIM
Additional Axis module.
Allowed
Graphical representation of the Kinetix 6000M integrated drive-motor system are displayed
Image view with the selected catalog numbers. Power rail configurations, like the order of IDM axes, can
(label 2 in Figure 9) be configured using options available in this view.
Right-click an IDM unit and choose operations to perform from the menu (refer to Figure 10).
Refers to the type of the module that is currently selected in the power
Selected Slot rail. For example, integrated drive-motor unit (IDM) or power interface
Module module (IPIM).
Selected Slot Module Part Number Catalog number of the selected unit or module.
The position of the selected unit or module, assuming the IDM unit
IDM Position closest to the IPIM module is identified as 1.
Axis Name Name you assigned to the axis associated with the selected IDM unit.
Click to launch the Axis view of the axis associated with the selected IDM
View Axis unit.
Additional Un- allocate Un-allocates the axis associated with the selected IDM unit.
Module Information
(inside red boxes) View Product Click to open the Kinetix Motion Control Selection Guide. The page
Guide displayed from the selection guide corresponds to the selected IDM unit.
Back to Rack Click to switch back to the power rail view.

Figure 10 - Operations to Perform Example
Additionally, you can click, drag, and drop an IDM unit to reposition that unit in
the daisy-chain configuration (refer to Figure 11).
Figure 11 - Drag and Drop to Reposition IDM Units

1.2.2.2. Group View
The Group view provides a summary of all the axes associated with the drive
group. Additionally, the Group view gives a visual representation of the axis
mapping in the power rail for multi-axes drive families. Group view varies
depending on the Application mode selected. Refer to Figure 12 and Figure 13
for examples of each.
Figure 12 - Group View Example (Select and Size mode)
Figure 13 - Group View Example (Just Quote mode)

There are two areas of interest in the Group view, as illustrated in Figure 14.
Figure 14 - Group View Example
Table 9 - Power Rail View Options

Power Rail Image Power rail image based on the current system configuration. This graphic only 24
(label 1 in Figure 14) applies to multi-axis drive families.
Axis Summary Image Displays a summary of the current axis configurations including drive module 25
(label 2 in Figure 14) and motor/actuator catalog numbers.

1.2.2.2.1. Power Rail Image
The power rail image only applies to multi-axis drive families. In this example,
the current configuration of Kinetix 6000 servo drives is shown on an eight-axis
Bulletin 2094 power rail.
Figure 15 - Bulletin 2094 Power Rail Image
Table 10 - Power Rail Slot Example (refer to Figure 15)

Option Description
IAM Module (slots 1 and 2) Integrated axis module (IAM) is always the first drive module on the power rail. In this
case, the IAM module is a double-wide module, so it occupies two slots.
AM Modules (slots 35) Axis modules (AM) are always right of the IAM module.
Empty slots are always to the far right on the power rail and must be occupied by slot-
Empty Slots (slots 68) filler modules.

1.2.2.2.2. Axis Summary Image
The axis summary images apply to all drive families. In this example, the current
configuration of Kinetix 6000 servo drives includes the drive/motor
combination featured below.
Figure 16 - Axis Summary Bar (servo drive)
Table 11 - Axis Summary Example

Option Description
Axis Solution Status icon indicates the status of the selected
Axis Solution solution. Axis solution status is defined in Solution on page
Status Icon 208.
Title Band
(label 1 in Figure 16) A warning triangle icon indicates a warning with this axis,
Warning Icon which requires your attention.
Axis Name Name of the Axis.
Displays information about the selected drive/motor axis or IPIM module.
Motor (1) Selected motor catalog number.
Axis Bar
(label 2 in Figure 16) Drive Selected drive module catalog number.
Gearbox Selected gearbox catalog number.
RBM Selected RBM module catalog number.
Short-cuts to Axis view Icons are a graphical representation of the selected axis components. Click icons to switch
(label 3 in Figure 16) to the corresponding data page in the Axis view.
(1) Configure Motor BOM is available for the selected motor. Click to launch the Configure Motor dialog box.
In this example, the current configuration includes a Kinetix 6000M power

interface module (IPIM).
Figure 17 - Kinetix 6000M Power Interface Module
IPIM module icon along with the catalog number of the selected IPIM module is
displayed in this bar. Click + to access the IPIM child nodes (IDM units).

1.2.2.3. Multiple Profile View
The Multiple Profile view permits viewing profiles of multiple axes

simultaneously and defining axes synchronization and offsets among the axes.
Figure 18 - Multiple Profile View Example
Table 12 - Multiple Profile View Options

Top Band Lets you define the Time Span to which all graphs should be scaled. 27
(label 1 in Figure 18) Additionally, this view lets you select a subset of the available axes to view.
Graph View Profiles of all axes are displayed in this section with the shorter profiles being 28
(label 2 in Figure 18) repeated to fit the length of the longest profile.

1.2.2.3.1. Top Band
This area lets you define the Time Span to which all graphs should be scaled.
Additionally, this view lets you select a subset of the available axes to view.
Figure 19 - Top Band of Multiple Profile View
Table 13 - Top Band Example

Option Description
Time span is the length of x-axis on which all the profiles are plotted. Use this option to zoom-
Modify Time Span in or zoom-out on the time scale. Enter the minimum and maximum value of the time scale of
(label 1 in Figure 19) interest and click Apply to re-plot all graphs to this scale.
Select All to display all axes.
Show Axis
(label 2 in Figure 19) Select Selected (Change) to choose the axis of interest (refer to Figure 20 for typical dialog
box).
Sort By
(label 3 in Figure 19) This option lets you sort the axes in the graph area according to the Slot Number or Axis Name.
Figure 20 - Selected Axis Example

1.2.2.3.2. Graph View
The Graph view displays profiles of all axes with the shorter profiles being
repeated to fit the length of the longest profile.
Figure 21 - Graph View Example
Table 14 - Graph View Options (refer to Figure 21)

Option Description
The phase relationship between the various axis profiles in a common DC bus system affects
the peak bus current requirement. For example, if all axes accelerate simultaneously, the bus
current demand is much greater than if each axis accelerates in turn.
From the Synchronized with pull-down menu, choose the random or synchronized operation
for each axis.
Set at least one axis to Random as the reference axis. Set other axes to be synchronized with
Synchronized with the reference axis or Random.
The safe setting for system sizing is all Random. In this case the worst case current demand for
each axis is automatically lined up by adjusting the phase relationship of the axis profiles.
If the phase relationship is known and will not change, the Cycle Profiles should be set up in
the correct relationship and Synchronized with set. This relationship is maintained by the
system sizing algorithm and may result in a smaller drive being selected.
If all axis profiles are the same length and start at their correct respective positions, then the
Offset offsets will be zero. Otherwise, the offset may be used to align the profiles correctly.

1.2.2.4. Power Supply/Accessories View
In Axis view, you matched a drive with your motor. However, if there are power
components needed for your application, youll select them in Power Supply/
Accessories view.
1.2.2.4.1. Power Supply/Accessories - Multi-axis Drive Systems
If your drive family is Kinetix 2000, Kinetix 6000, or Kinetix 6200/6500, youll
also need to configure the IAM module and select the appropriate power rail.
Figure 22 - Power Supply/Accessories Dialog Box
Table 15 - Power Supply/Accessories Tabs (refer to Figure 22)

Parameters Description Page
Power Data Tab View regeneration and motoring data for each axis. 30
IAM and Shunt Tab Select drive modules and external shunt resistors for multi -axis systems. 31
Displays total auxiliary input power, input VA, input current, and power
IAM Control Power Tab distribution across the axes. These are the installation ratings for the IAM 32
module.
Analyze the drive module activity in terms of bus voltage and system
Analysis Tab current. With this tab, you can also simulate changes to the system 33
parameters.
Energy Tab View Input Current values, System Power values, Shunt Power, and Energy 34
Savings Estimates.
Configure Power Supply Configure the bill of materials (BOM) for the power supply after fully sizing 35
BOM Tab the application.

1.2.2.4.1.1. Power Data Tab
Use the Power Data tab to view regeneration and motoring data for each axis.
Table 16 - Power Data Tab Properties (refer to Figure 22)

Parameters Description
The axis histograms show a multi-axis representation of axis currents including Peak
Axis Histograms Motoring, Average Motoring, Peak Regenerating, and Average Regenerating.
The phase relationship between the various axis motion profiles in a common DC bus
system affects the peak bus-current requirement. For example, if all axes accelerate
simultaneously (for example, synchronous operation), the bus current demand is much
greater than if each accelerates in turn. The pull-down menu lets you choose Random or
Synchronized mode for axes operation. At least one axis should be set to Random as the
Random/Sync reference axis. Other axes may be set to Synchronized or Random relative to the reference
Relationship axis. The safe setting for system sizing is all Random. In this case, the worst case current
demand for each axis is automatically lined up by adjusting the phase relationship of the
axis motion profiles. If the phase relationship is known and will not change, the Cycle
Profiles should be set up in the correct relationship and appropriate synchronized set. This
relationship is maintained by the system sizing algorithm and may result in a smaller
drive being selected.
If all axis motion profiles are the same length and start at their correct respective
Offset positions at the default time, then the offsets will be zero. Otherwise, a specified time
offset may be used to align the motion profiles correctly.

1.2.2.4.1.2. IAM and Shunt Tab
Click Search to automatically configure the IAM and/or shunt module catalog
number.
Figure 23 - IAM and Shunt Tab
Table 17 - IAM and Shunt Tab Properties

Click Search to configure the IAM module (Kinetix 2000, Kinetix 6000, and Kinetix 6200/6500
drives) based on the selection made in Axis view, and/or an external shunt module, should
an existing internal shunt for a given drive be outside its rating. Where multiple external
IAM & Shunt Selection shunts exist, these can be readily chosen by searching for a shunt.
(label 1 in Figure 23) Both the drive module and shunt module have automatic and manual selection options.
You can manually select a drive or IAM module and the compatible shunt. The manual
selection of only one of the two components is also provided. This means that you can have
manual drive and automatic shunt selection or vice versa.
The drive continuous and peak current utilizations and the shunt continuous current
Utilizations utilization histograms are displayed. Use the forward or backward arrows to scroll through
(label 2 in Figure 23) other drive and shunt options. Click the drive module or shunt module catalog number to
view their product specifications.
This window is available only for the Kinetix multi-axis drive families after a valid IAM
module and shunt solution is found. This window displays the shunt resistance, power, and
Component Listings of capacitance values for all the components involved in the IAM and shunt module solution.
Kinetix Shunts The components may include converter (IAM), all the inverters (AM), shunt module and
(label 3 in Figure 23) shunt resistor. The Shunt Protect limit is also shown in order to reflect the shunt power
utilization of the component.

1.2.2.4.1.3. IAM Control Power Tab
The IAM Control Power tab displays total auxiliary input power, input VA,
input current, and power distribution across the axes. These are the installation
ratings for the IAM module.
Figure 24 - IAM Control Power Tab
Table 18 - IAM Control Power Tab Properties

Auxiliary AC Voltage is a user input value. The value can lie within the IAM Control Voltage
Auxiliary AC Voltage Range. Refer to the Kinetix Servo Drives Technical Data, publication GMC-TD003, for servo
(label 1 in Figure 24) drive power specifications.
Power Rail Summary This view shows the total auxiliary input power, input VA, and input current in a tabular
(label 2 in Figure 24) format.
Power Rail Details This view contains the slots occupied, slot number, drive module, and continuous output
(label 3 in Figure 24) power distribution details in tabular format. The IPIM module is available as line item (axis
level item) in this view.

1.2.2.4.1.4. Analysis Tab
Click Analysis to conduct detailed analysis of the drive module activity in terms
of bus volts and system current, along with the capability of simulating changes to
the system parameters.
Figure 25 - Analysis Tab Dialog Box
Table 19 - Analysis Tab Properties

Simulation Parameters Adjust these parameters to observe how changes to the parameters impact the bus voltage and current.
(refer to Figure 25)
Time From/ Check these boxes to adjust the X- and Y-axis values for the plot.
Voltage From
Zoom Window The Time Slice variable sets the time interval for the Analysis display. Because the shunt switching action is
(refer to Figure 25) modeled during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for
Time Slice example). However, if the total cycle time is more than a few seconds, the calculation time may become excessive.
The time is equal to the longest axis cycle. In the case of a very long length of time, it is suggested that a longer time
slice be used for early checks, but a time slice of less 0.1 ms should be used for the final selection.
If the time is increased, this error message often appears.
This time slice message may also appear as soon as you click Solution on the main
taskbar. In this case, clicking Yes or No still takes you to the Solution tab, but if
you click No, some pre-calculations are not performed.
This time slice message often appears if one of the motion cycles is a cam, which
often has very short time segments. In this case, click No to ignore the message.

1.2.2.4.1.5. Energy Tab
Click Energy to display the main power supply parameters including Input
Current, System Power, Shunt Power and Energy Savings Estimates.

1.2.2.4.1.6. Configure Power Supply BOM Tab
Click the Configure Power Supply BOM tab to complete the bill of materials
(BOM) for the Power Supply after fully sizing the application. In this tab, you
select options for the power rail, shunt module, filters, circuit breakers, and fuses.

1.2.2.4.1.7. System Bill of Materials (BOM) View
Click BOM view to review the entire BOM (bill of materials) for the system and
add any additional parts that may be needed.
Table 20 - BOM View Tabs

Configuration Summary Tab Shows all the axis components in axis order. 37
Software and Accessories Tab Contains the Controllers, Software, and other Accessories to complete 38
your system.
Additional Parts Tab Select any additional components. 39
BOM Tab Displays the full bill of materials (BOM). 40

1.2.2.4.1.7.1. Configuration Summary Tab
Click Configuration Summary to display all the axis components and

descriptions in axis order. Scroll down to see all the axes.

1.2.2.4.1.7.2. Software and Accessories Tab
Click Software and Accessories to complete your system.
To assist in selecting the Sercos cables, click Auto Select to automatically build a
set of these cables with the required lengths to link the axes according to their slot
configuration.
Break-out boards, cables, kits, and various connectors are available to complete
cabling from drive to motor.
Other components such as connectors, safe-off headers, and line filters for
example, are available.

1.2.2.4.1.7.3. Additional Parts Tab
Click Additional Parts to add any additional components you may need.
From the Product Family pull-down menu, choose the Family, Motor Series, and
then by component category to reduce the time required to search for motion
control components. If you know the catalog number, entering that is the
quickest way to find your part.

1.2.2.4.1.7.4. BOM Tab
Click BOM to display the full bill of materials (BOM) in the same section
headings as the other tabs.
This BOM can be exported to Microsoft Word or Microsoft Excel software by

clicking the appropriate button.

1.2.2.4.2. Power Supply/Accessories - Integrated Drive-Motor (IDM) Systems
The integrated drive-motor (IDM) power interface module (IPIM) is effectively

a power management module for the DC link to a group of individual IDM
units, but to the 2094 power rail it looks like an axis module. Each IPIM module
can handle up to 16 axes, with certain limitations.
Table 21 - IPIM Module Configuration

Power Data Tab View regeneration and motoring data for each IDM unit. 41
IPIM Module Selection Tab Lets you select the IPIM module. 42
Cable selection for connecting IPIM module-to-IDM unit and
Cable Length Tab 43
IDM unit-to-IDM unit.
Bar graph for control power
Control Power Tab Summary view 44
Details view
Configure IPIM Module Configure the bill of materials (BOM) for the power supply after fully sizing 45
Click the Power Data tab to view regeneration and motoring data for each IDM
unit.
Figure 26 - Power Data Tab

Table 22 - Power Data Tab Descriptions

Options Description
Name of the power rail and selected IPIM module slot is displayed here. Click the power rail
Label 1 in Figure 26 name label switches the view from IPIM view to Power Rail - Power Supply view.
IDM Axis view Summary of the all IDM units associated with the selected IPIM module along with the Axis
(label 2 in Figure 26) Motoring Bus Current and Axis Regenerating Bus Current values of each IDM unit.
Back to Power Rail Click to switch the view from IPIM view to Power Rail - Power Supply view.
1.2.2.4.2.2. IPIM Module Selection Tab
Click the IPIM Module Selection tab to select an IPIM module.
Figure 27 - IPIM Selection Tab
Table 23 - IPIM Selection Tab Descriptions

Options Description
Select Automatic for Motion Analyzer software to search for the best IPIM
Automatic module solution for the selected slot.
Selection mode Manual Select Manual to manually select the IPIM module.
(label 1 in Figure 27 Current Displays the selected IPIM module catalog number.
Selection
Search Search button is disabled because only one catalog number is available.
Arrows provide the means to scroll forward/backward to smaller/larger
IPIM IPIM module catalog numbers.
Utilizations DC Bus Current Graphical representation of DC bus current rms limit for the selected IPIM
(label 2 in Figure 27) RMS Limit module.
DC Bus Current Graphical representation of DC bus current instantaneous limit for the
Instantaneous selected IPIM module.
Limit

1.2.2.4.2.3. Cable Length Tab
Click the Cable Length tab to select cables for connecting IPIM module-to-IDM
unit and IDM unit-to-IDM unit.
Figure 28 - Cable Length Tab
Table 24 - Cable Length Tab Descriptions

Options Description
From the Cable Length pull-down menus, choose the appropriate cable length for connecting
IPIM module-to-IDM unit and IDM unit-to-unit. The maximum cable lengths in an IDM system
are specified as 25 m (82 ft) IDM unit-to-IDM unit and 100 m (328 ft) total cable length.
IDM Cables
(label 1 in Figure 28 Cable For Specifies the modules the cables will join.
Cable Length Specifies the cable length.
Total Length Specifies the total length of the cables.
IDM System Graphic Graphical representation of IPIM module, associated IDM units and joining cables. Cable length
(label 2 in Figure 28) is displayed over the cables.

1.2.2.4.2.4. Control Power Tab
Click the Control Power tab for utilization views and to select the number of
sensor inputs and outputs.
Figure 29 - Control Power Tab
Table 25 - Control Power Tab Descriptions

Options Description
Control This bar graph displays the percentage of power utilized by all IDM units to the
Power maximum power that can be supplied by IPIM module.
Utilizations
(label 1 in Figure 29 Total Displays the sum of power utilized by all the IDM units.
IPIM Displays the maximum power that can be supplied by the selected IPIM module.
Selection for Control
Power Usage Summary From the pull-down menu, choose the quantity of each of I/O Sensor. Summary
(label 2 in Figure 29) view view displays the control power usage and control voltage for each IDM unit.
Detailed View Click the Details arrow (refer to Figure 30) to display complete information for each IDM unit.
(label 3 in Figure 29) This table is hidden by default.
Figure 30 - Control Power Tab (details arrow)

Figure 31 - Control Power Tab (details revealed)
1.2.2.4.2.5. Configure IPIM Module BOM Tab
Click the Configure IPIM Module BOM tab to select hybrid and network
cables, and other IDM system accessory items.
Figure 32 - Configure IPIM Module BOM Tab
Table 26 - Configure IPIM Module BOM Tab Descriptions

Options Description
Step 1 (Figure 32) IPIM module IPIM module selected on the IPIM Module tab is displayed here.
Step 2 (Figure 32) Hybrid cables Hybrid cable lengths selected on the Cable Lengths tab are displayed here.
Network cables can be routed with the hybrid cables, so network cable lengths
Step 3 (Figure 32) Network cables should be the same as the hybrid cable. The IPIM-to-IDM1 cable must have a
straight connector to the IPIM module.
Step 4 (Figure 32) Hybrid coupler The hybrid coupler connects between two hybrid cables, to bypass an IDM unit.
Step 5 (Figure 33) Network Use the network bulkhead adapter for securing network cables as they pass
bulkhead adapter through the cabinet.

1.2.2.4.3. Power Supply/Accessories - Single-axis Drive Systems
If your drive family is single axis, for example, Kinetix 300, Kinetix 350,
Kinetix 3, or Ultra3000, Ultra5000, and Ultra1500, you must configure a shunt
or specify no shunt required.
Figure 34 - Power Supply/Accessories Dialog Box

Power Data Tab View the regeneration and motoring data for each axis. 47
Shunt Tab Select the external shunt resistors for single-axis systems. 47
Analyze the drive module activity in terms of bus voltage and system current.
Analysis Tab 48
With this tab, you can also simulate changes to the system parameters.
Energy Tab View input current values and energy savings estimates for each axis. 49
Configure Power Supply Configure the bill of materials (BOM) for the power supply after fully sizing 50


The axis histograms show a multi-axis representation of axis currents including Peak
Axis Histograms Motoring, Average Motoring, Peak Regenerating, and Average Regenerating.
1.2.2.4.3.2. Shunt Tab
Click Search to automatically configure the shunt module catalog number for
each axis.
Figure 35 - Shunt Tab
Table 29 - Shunt Tab Properties

Shunt selection Click Search to configure external shunts if an existing internal shunt for a given drive is
(refer to Figure 23) outside its rating. If you need more than one external shunt, click search to select multiple
shunt modules. You can also select a compatible shunt manually.
Continuous Current The drive continuous and peak current utilizations and the shunt continuous current
utilization bar utilization histograms are displayed in percentage form. Click the drive module or shunt
(refer to Figure 23) catalog number to view its product specification.

1.2.2.4.3.3. Analysis Tab
Click Analysis to display plots of drive module activity in terms of the DC bus
voltage and DC bus current:
The red line is the bus voltage trip point.
The green line is the DC bus voltage.
The grey line is the bus current.
Figure 36 - Analysis Tab Dialog Box
Table 30 - Analysis Tab Properties

Shunt On The voltage level where the shunt enables.
Shunt Off The voltage level where the shunt turns off.
Simulation Parameters (1) Trip The voltage level where the drive trips on an overvoltage fault by changing the trip volts.
(refer to Figure 25) Resistance The shunt resistance level in ohms.
Power Changing the power value modifies how much energy the shunt resistor can dissipate continuously.
Capacitance Changing the capacitance value changes the DC bus capacitance.
Time From/ Check these boxes to adjust the X- and Y-axis values for the plot. Click Plot to implement these changes.
Voltage From
Zoom The Time Slice variable sets the time interval for the Analysis tab. Because the shunt switching action is modeled
(refer to Figure 25) during selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example).
Time Slice However, if the total cycle time is more than a few seconds, the calculation time may become excessive. The time is
equal to the longest axis cycle.
(1) Click Apply to implement these changes.

If the time slice variable is increased, this error message often appears.
1.2.2.4.3.4. Energy Tab
Click the Energy tab to display the main power supply parameters including
input current, cost of system energy, and cost of shunt energy.

1.2.2.4.3.5. Configure Power Supply BOM Tab
(BOM) for the Power Supply after fully sizing the application. In this tab, you
select options for the shunt module, filters, circuit breakers, and fuses.

1.2.2.4.4. Power Supply/Accessories AC/DC Power Sharing Systems (Kinetix 5500 drives)
If your drive family is Kinetix 5500, you must define a valid power sharing
configuration and then configure a shunt and capacitor, or specify if no shunt or
capacitor are required.
Figure 37 - Power Supply/Accessories
Table 31 - Power Configuration Options (refer to label 1 in Figure 37)

Use this option for shared AC/DC or common bus configuration. The following restrictions are imposed on the
number of drives allowed in common bus, or shared AC/DC configuration, based on the converter capacity and/or
connectors:
Single phase operation is not allowed.
The bus master drive or drives with an AC connection should have the same power rating (catalog number).
The bus master drive or drives should always have a rating equal to, or greater than, the followers.
DC Sharing The number of bus master drives cannot exceed the following rule: Frame 3 = two drives; Frame 2 = four drives;
Frame 1 = eight drives.
The number of follower drives is driven by the frame of the master drive or drives, and cannot exceed this rule:
Frame 1 drive = only four more bus followers can be added; Frame 2 drive = only six more bus followers can be
added.
Power Configuration options Converter power output should be reduced by 30% of the sum of the individual converter power capacities of
(label 1 in Figure 37) drives configured for shared AC/DC.
The maximum number of drives in a bus power sharing group is eight drives.
3-phase AC input power can be shared among drives with the same power rating. No DC bus connections are
allowed in this configuration. AC power sharing allows you to minimize the system components, such as circuit
breakers and fuses. The following limitations apply when drives are configured for sharing AC input power:
Single-phase operation is not allowed.
All drives must be configured for the same converter voltage rating.
AC Sharing Only
Drives with the same power rating (catalog number) can be used for this configuration.
The maximum number of drives that can be configured for shared AC operation is limited by the amp capacity of
the AC input connector. The following rules apply: Frame 1 drives can share AC with up to five drives of the same
rating; Frame 2 drives can share AC with up to three drives of the same rating; Frame 3 drives can share AC with
up to two drives of the same rating.
Axes sharing AC/DC Select the AC and DC sharing option for each axis individually.
(label 2 in Figure 37

1.2.2.4.4.1. DC Sharing
Use the DC Sharing configuration to group axes to share a common DC bus and
input AC supply (optional).

Power Data Tab View regeneration and motoring data for each axis.
Converter and Shunt Tab Select the shunts and capacitor for your system.
Analyze the drive module activity in terms of bus voltage and system
Analysis Tab current. With this tab, you can also simulate changes to the system
parameters.
Energy Tab View input current values and energy savings estimates for each axis.
Configure the bill of materials (BOM) for the power supply after fully sizing
Configure Power Supply BOM Tab the application.
1.2.2.4.4.1.1. Power Data Tab
Click the Power Data tab to view regeneration and motoring data for each axis.

The axis histograms show a multi-axis representation of axis currents including peak motoring, average motoring, peak regenerating, and average
Axis histograms regenerating.
The phase relationship between the various axis motion profiles in a common DC bus system affects the peak bus-current requirement. For example, if all axes
accelerate simultaneously (for example, synchronous operation), the bus current demand is much greater than if each accelerates in turn. The pull-down menu
lets you choose Random or Synchronized mode for axes operation. At least one axis should be set to random as the reference axis. Other axes may be set to
Random/Sync synchronized or random relative to the reference axis.
relationship The safe setting for system sizing is all Random mode. In this case, the worst case current demand for each axis is automatically lined up by adjusting the phase
relationship of the axis motion profiles. If the phase relationship is known and will not change, the cycle profiles should be set up in the correct relationship and
appropriate synchronized set. This relationship is maintained by the system sizing algorithm and may result in a smaller drive being selected.
If all axis motion profiles are the same length and start at their correct respective positions at the default time, then the offsets will be zero. Otherwise, a
Offset specified time offset may be used to align the motion profiles correctly.

1.2.2.4.4.1.2. Converter and Shunt Tab
Select shunt and capacitor modules for your system.
Figure 39 - Converter and Shunt Tab
Table 34 - Converter and Shunt Tab Properties (refer to Figure 39)

Shunt Selection and Component
Listing In this section you select a shunt for each axis, and a capacitor module for the
system.
Click Calculate Utilizations to analyze the behavior of the bus, and to calculate
Calculation Utilizations the drive and shunt utilizations.
Utilization The drive continuous and peak current utilizations and the shunt continuous
current utilization histograms are displayed in this area. Click the drive module
(label 2 in Figure 39) catalog number to view the drive specifications.

1.2.2.4.4.1.3. Analysis Tab
Click the Analysis tab to conduct detailed analysis of the drive module activity in
terms of bus volts and system current, along with the capability of simulating
changes to the system parameters. The analysis activities are described as follows:
Figure 40 - Analysis Tab
Table 35 - Analysis Tab Properties (refer to Figure 40)

Simulation Parameters
Adjust these parameters to observe how changes to the parameters impact the bus voltage and current.
(refer to Figure 40)
Time From/
Check these boxes to adjust the X- and Y-axis values for the plot.
Voltage From
Zoom window The Time Slice variable sets the time interval for the analysis display. Because the shunt switching action is modeled during
(refer to Figure 40) selection, this value needs to be very short to obtain an accurate shunt selection (0.1 ms, for example). However, if the total cycle
Time Slice time is more than a few seconds, the calculation time may become excessive.
The time is equal to the longest axis cycle. In the case of a very long length of time, we suggest that a longer time slice be used
for early checks, but a time slice of less than 0.1 ms should be used for the final selection.

If the time is increased, the time slice error message often appears.
1.2.2.4.4.1.4. Energy Tab
Input Current, System Power, Shunt Power, and Energy Savings Estimates.
Figure 41 - Energy Tab

1.2.2.4.4.1.5. Configure Power Supply BOM Tab
(BOM) for the power supply after fully sizing the application. In this tab, you
Figure 42 - Configure Power Supply BOM Tab
1.2.2.4.4.2. AC Sharing Only
Use the AC Sharing Only configuration to group axes to share input AC supply
only, with no DC bus sharing.
Figure 43 - Power Configuration Tab for AC Sharing Only Mode

Table 36 - Power Supply/Accessories (refer to Figure 43)

Power Data Tab View regeneration and motoring data for each axis.
Converter and Shunt Tab Select the shunt and capacitor for your system.
Analyze the drive module activity in terms of bus voltage and system current. With this
Analysis Tab tab, you can also simulate changes to the system parameters.
Energy Tab View input current values and energy savings estimates for each axis.
Configure Power Supply BOM Configure the bill of materials (BOM) for the power supply after fully sizing the
Tab application.
1.2.2.4.4.2.1. Power Data Tab

The axis histograms show a multi-axis representation of axis currents including peak motoring,
Axis histograms
average motoring, peak regenerating, and average regenerating.

1.2.2.4.4.2.2. Shunt Tab
Select the shunt and capacitor module for your system.
Figure 45 - Shunt Tab
Table 38 - Shunt Tab Properties (refer to Figure 45)

Click Search to configure external shunts if an existing internal shunt for a given
Shunt selection drive is outside its rating. If you need more than one external shunt, click search
(refer to Figure 45) to select multiple shunt modules. You can also select a compatible shunt
manually.
Continuous Current utilization bar The drive continuous and peak current utilizations and the shunt continuous
current utilization histograms are displayed in percentage form. Click the drive
(refer to Figure 45) module or shunt catalog number to view its product specification.

1.2.2.4.4.2.3. Analysis Tab
Click the Analysis tab to display plots of drive module activity in terms of the DC
bus voltage and DC bus current. The analysis activities are described as follows:
Figure 46 - Analysis Tab
Table 39 - Analysis Tab Properties (refer to Figure 46)

Shunt On The voltage level where the shunt enables.
Shunt Off The voltage level where the shunt turns off.
The voltage level where the drive trips on an overvoltage fault by
Simulation Trip changing the trip volts.
Parameters (1)
(refer to Figure 46) Resistance The shunt resistance level in ohms.
Changing the power value modifies how much energy the shunt
Power resistor can dissipate continuously.
Capacitance Changing the capacitance value changes the DC bus capacitance.
Time From/ Check these boxes to adjust the X- and Y-axis values for the plot.
Voltage From Click Plot to implement these changes.
The Time Slice variable sets the time interval for the Analysis tab.
Zoom window Because the shunt switching action is modeled during selection,
(refer to Figure 46) this value needs to be very short to obtain an accurate shunt
Time Slice selection (0.1 ms, for example).
However, if the total cycle time is more than a few seconds, the
calculation time may become excessive. The time is equal to the
longest axis cycle.
(1) Click Apply to implement these changes.

If the time is increased, the time slice error message often appears.
1.2.2.4.4.2.4. Energy Tab
input current, cost of system energy, and cost of shunt energy.
Figure 47 - Energy Tab

1.2.2.4.4.2.5. Configure Power Supply BOM Tab
(BOM) for the power supply after fully sizing the application. In this tab, you
Figure 48 - Configure Power Supply BOM Tab

1.2.3. Preferences Tab
The Preferences tab contains three sections.
Figure 49 - Preferences Tab Options
Table 40 - Preferences Tab Descriptions

Options Description
The product databases may be modified to restrict selections to those
My Preferred Database items marked by you. This may be used, for example, by a distributor
(refer to Figure 50) to select from a range of popular stock items. Drives, Motors, and
Database Gearboxes may all be marked.
(label 1 in User Defined Database Creates a database of custom motors with your own specifications that
Figure 49) (refer to Figure 51) can be sized and analyzed.
Updates the Motion Analyzer database on your personal computer to
Check for Updates the latest database available from the Motion Analyzer server.
User Information
Settings (refer to Figure 52) Enter details about the end-user. Entries appear on printouts.
(label 2 in
Figure 49) Lets privileged users select the electronic keys to provide additional
Key Status features and functions.
Units of Measure Lets you set default units for all data entry. Choice includes a user
(refer to Figure 53) Custom set.
Options
(label 3 in Operating Conditions Lets you set the operating conditions used to calculate Life
Figure 49) (refer to Figure 54) calculations of Bearing Life, Ball Screw Life, Roller Screw Life, and Strip
Seal Life in Motion Analyzer software.
Notes Launches system notes for the application.
Figure 50 - Preferred Data Dialog Box

Figure 51 - User Defined Motors Dialog Box
Figure 52 - Options - User Information Dialog Box

Figure 53 - Options - Units of Measure Dialog Box
Figure 54 - Options - Operating Conditions Dialog Box

1.2.4. Export Import Tab
The Export - Import tab contains two sections.
Figure 55 - Export - Import Tab Options
Table 41 - Export - Import Tab Descriptions

Options Description
Project Data to Word Exports the application data to a Microsoft Word document.
Launches the export wizard to let you export the profile data of the
Profile Data selected axis. Refer to More Options Profile Editor Mode on page 142.
Export
(label 1 in Figure 55) BOM to Word Exports Bill of Material to Microsoft Word document.
BOM to Excel Exports Bill of Material to Microsoft Excel file.
Exports motion system information to RSLogix 5000 software to
Export To RSLogix 5000 use it in the next step of your design process.
Imports the axis data from another axis either of current application
Axis Data
Import or from any other Motion Analyzer application.
(label 2 in Figure 55) Imports the Profile data for selected axis. Imported Profile Data must
Profile Data have been previously exported by Motion Analyzer software.
1.2.4.1. Export to RSLogix 5000 Wizard
Once you have selected a motor and drive in Motion Analyzer software, you can
export motion system information to RSLogix 5000 software and use it in the
next step of your design process. You can generate an RSLogix 5000 file (.L5X),
version 18.00, 19.00, 20.00, or 21.00. Applications can be exported to
RSLogix 5000 software as new .L5X files or as updates to existing .L5X files.

1.2.4.1.1. Export Options - Create a New .L5X File
1. From the Export-Import menu, click Export To RSLogix 5000.
The Output Format Selection dialog box opens.
2. Select Create a New L5X and from the pull-down menu and choose the
RSLogix 5000 software version you intend to use.
3. Click Next.
The Axis Mapping dialog box opens.

1.2.4.1.1.1. Axis Mapping
Information about .L5X file that Motion Analyzer generates is displayed at the
top of the screen as read only information.
Table 42 - Axis Mapping Properties

Motion Analyzer software assigns a default name for the controller. You can edit this once
Controller Name the file has been loaded.
Motion Analyzer software creates a file with a default controller type. You can edit this
Controller Type once the file has been loaded.
Motion Analyzer software creates a file with a default Logix chassis. You may change your
Chassis Type chassis type once the file has been loaded.
The name you define for each axis in Motion Analyzer software is used to create a
RSLogix 5000 axis tag. Underscore characters replace spaces in the name defined
in Motion Analyzer software. To change these names you must exit the Export to
RSLogix 5000 wizard and change the names by right-clicking each axis in the
Motion Analyzer explorer tree.
All axes in your Motion Analyzer (.mba) file appear in the table. If they will
export without trouble, a green status check is displayed.

Table 43 - Axis Mapping Symbols

Axes will export without errors.
Axes with warning icon only partially export to RSLogix 5000 software. A note at the
bottom of the screen indicates what is wrong.
Not recommended icon. A note at the bottom of the screen indicates what is wrong.
If problems occur with selected catalog numbers, a warning icon and a note at the
bottom of the dialog box appears.
Figure 56 - Axis with Warning Icon
If export isnt possible, a note at the bottom of the dialog box indicates what the
problem is. This axis is not exported to RSLogix 5000 software.
Figure 57 - Axis with Not Recommended Icon
If the number of axes a sercos module can support is exceeded, a new sercos
module is added into the pull-down menu in the third column. This is selectable
for the rest of the axes. This new module is also exported to the .L5X file.
4. Click Next.

The Target Location dialog box opens.
1.2.4.1.1.2. Save and Import the L5X File
1. Click Browse to select a target location and save the .L5X file.
IMPORTANT Do not use spaces or special characters in the name, or RSLogix 5000
software will not open the file.
2. Click Finish.

3. Open RSLogix 5000 software.
4. Browse to your .L5X file and open it.

5. Browse to the location where you would like to store your .acd file.
6. Click Import.

Your motion system information imports from Motion Analyzer software.

Exceptions include warnings noted on the Axis Mapping dialog box.

1.2.4.1.2. Export Options - Update an Existing L5X File
1. From the Export-Import menu, click Export To RSLogix 5000.
The Output Format Selection dialog box opens.
2. Select Update an Existing L5X and click browse to find the file you wish to
update.
3. Click Next.

The Axis Mapping dialog box opens.
4. Make changes as needed to the existing file.

5. Click Next.

The Target Location dialog box opens.
Table 44 - Export Output Target Properties

Save Select Save to replace the old L5X file with the updated file.
Save As Select Save As to create an updated L5X file in a new location and/or with a new name.
6. Open the file in RSLogix 5000 software as described earlier and notice
that the motion system information from your Motion Analyzer software
file has been included.
7. Click Finish.

1.2.5. Bill of Materials (BOM) Tab
The Bill of Materials (BOM) tab contains two sections.
Figure 58 - Bill of Materials (BOM) Tab Options
Table 45 - Bill of Materials (BOM) Tab Descriptions

Options Description
This is a combo item and contains the axis names of all the axes in the
Drives Group that have a solution. It lets you navigate to the
Axis Configure Axis BOM tab of Axis view where you can configure the
BOM for the axis chosen.
This is a combo item for single-axis drive family and a button item for
multi-axis drive family. For single-axis drive family, it contains the
axis names of all the axes in Drives Group that have a solution. It lets
System Module
Configure you navigate to Configure Power Supply BOM tab of the Power Supply
(label 1 in Figure 58) & Accessories view where you can configure the Power Supply BOM
for the system.
Software and Navigate to the Software & Accessories tab of System BOM view on
Accessories Tab page 38.
Additional Parts Tab Navigate to the Additional Parts tab of System BOM view on page 39.
Configuration Navigate to the BOM tab of System BOM view on page 37.
Summary Tab
Export BOM to Word Exports Bill of Material to Microsoft Word document.

(label 2 in Figure 58) BOM to Excel Exports Bill of Material to Microsoft Excel file.
1.2.6. Help Tab

The Help tab contains one section.
Figure 59 - Help Tab Options
Table 46 - Help Tab Descriptions (refer to Figure 59)

Options Description
Motion Analyzer Help Launches Motion Analyzer help.
Activate Motion Launches the Motion Analyzer Activation wizard. You can Purchase License or Activate their
Analyzer Motion Analyzer installation (refer to Figure 60).
Send Feedback Provides contact information for Motion Analyzer software support.
Release Notes Launches the Release Notes for the installed Motion Analyzer software revision.
About Motion Analyzer Launches the About Motion Analyzer dialog box that displays details of the installed copy of
Motion Analyzer software (refer to Figure 61).

Figure 60 - Motion Analyzer Activation Wizard
Figure 61 - About Motion Analyzer

1.3. Explorer View The Explorer view provides a Windows Explorer style graphical user interface for
accessing components in your Motion Analyzer software application.
For multi-axis drive systems, the axes are added under the Power Rail node in the
Explorer hierarchy view.
Figure 62 - Typical Multi-axis Drive Explorer View
For single-axis drive systems, the axes are added under the Project node in the
Explorer hierarchy view.
Figure 63 - Typical Single-axis Drive Explorer View
For drive families that allow stand alone as well as power sharing group (Kinetix
5500 drives), a mix of drive group and stand alone axes can be added under the
Project Node.

Figure 64 - Typical AC/DC Power Sharing System (Kinetix 5500) Explorer View
Table 47 - Explorer View Structure (refer to Figure 62)

Options Description
The project node contains two types of groups. The Power Rail/Drive Group (of the selected product family) and an unallocated group.
Applies to multi-axis drive families. Shown is the power rail icon, drive family name, and power rail catalog
number. The default name for this node is Drives Group 1, however, it is renamed when a solution for any
Power Rail Node axis under this group is defined.
For single-axis family, the default name is Drives Group 1. For multi-axes family, the default name is Power
Rail 1. Also, for multi-axis family, after the drive family is defined, the power rail displays many empty slots
until each slot is allocated a module.
Drives Group Node Applies to drive families that allow AC and DC power sharing (Kinetix 5500). Shown is the drive group icon
and drive name.
Axis Module Node Axis node consists of two levels. First level displays the slot number of the power rail (available only for
multi-axis families), axis name, drive catalog number, and the solution status of the axis. Second level
Project Node displays the motor catalog number for the selected solution. Additionally, if there is a warning in the axis,
then a warning triangle is also displayed beside the solution status.
Axis Module Node When the solution is not yet selected, then only the axis node is displayed and instead of drive catalog
number, Incomplete is displayed.
IPIM Module Node
This node displays the slot number that the IPIM module is assigned to on the power rail along with the
name of the IPIM module, catalog number of the selected IPIM module, and the IPIM module status.
IDM Unit Node

IDM unit node is similar to axis module node except that the IDM unit node consists of only a single node
representing the axis solution.
Empty Slot Node

Applies to multi-axis drive families. It is visible after a multi-axis drive family is selected.
Unallocated Axis Node The Unallocated Axes Node is where axes independent of other axes can be created. An unallocated axis can be allocated to a Drive Group using the allocate
button located in the Home Tab on the menu bar or by dragging and dropping the axis.
Additionally, if the power supply solution is present, then the status of the selected power supply solution is also displayed, as described below.
Indicates that the selected power supply solution and all children support the application requirement.
Status Symbols
Indicates that the selected power supply solution or any one of the children marginally support the application requirement.
Indicates that the selected power supply solution or any one of the children is not recommended for the application. Additionally, this icon is
also displayed when the IAM module for the power rail has not been sized.

Notes:

Chapter 2
Sizing Your System
Topic Page
Identify Your Load 82
Linear Loads 83
Rotary Loads 86
Rotary Complex Loads 87
Application Template Loads 96
From SolidWorks 120
Define Your Profile 139
Less Options Profile Editor Mode 140
More Options Profile Editor Mode 142
Specify Your Linear Load Mechanism 178
Belt Drive 180
Lead Screw 181
Chain and Sprocket 182
Rack and Pinion 183
Linear Motor 184
Electric Cylinders 186
Linear Stages 187
Linear Thrusters 189
Specify Your Transmission 191
Compute Using Inertia and Ratio 193
Compute Using Pitch Circle Diameter 194
Compute Using Number of Teeth 195
Choose Your Motor Series 196
Choose Your Electric Cylinder Series 199
Choose Your Drive Family 201

Chapter 2 Sizing Your System
A load is a device that transfers the actuator output to the desired end effectors.
2.1. Identify Your Load Loads do not affect the motion type.
Figure 65 - Load Type Tab
Table 48 - Load Type Options

Load Type Description Page
Linear Loads Load moves in a straight line. 83
Rotary Loads Load rotates and the system has no translation to linear motion. 86
Rotary Complex Loads Rotary motion can be translated to linear motion, and vise versa. Inertia, 87
friction, and/or torque values for the system change with time.
Simplify data entry dramatically where the application is appropriate. The
Application Template Application Templates include Press Roll Feed (Constant Time or Angle), 96
Loads Carriage Cut Off, Cutter Knife Drive, Advanced Templates, and Power Speed.
From SolidWorks Used to obtain load data to aid in sizing your application for the appropriate 120
motors, drives, and accessories.

Sizing Your System Chapter 2
2.1.1. Linear Loads
For a Linear application, the load moves in a straight line.
Figure 66 - Linear Load Type
Table 49 - Linear Load Parameters

Parameter Description
Load Mass Mass of the linear load.
Any external force (+/-) acting on the load. Positive force acts to oppose positive
Applied Force movement; down the inclination surface if inclination is non-zero. The arrow on the
graphic indicates the force direction.
Coefficient of friction (). It is a unitless value, which is used to calculate the force of
friction. It is largely dependent on the nature of the surfaces in contact with each other.
Typical values for the coefficient of friction can be found in engineering tables. This value,
Coeff of Friction along with the load mass (for example, Load weight + Table/Slide/Carriage weight),
determines the amount of motor force or torque necessary to move a slide or table, for
example.
Angle of inclination from the horizontal. The limits for this value are 0 and 90. In the
horizontal case (0 inclination), the Table Mass, Belt/Chain Mass, and/or Slide Mass are
not affected by gravity, whereas in the vertical case (90 inclination), only the table mass
is affected by gravity. Values for Table Mass, Belt/Chain Mass, and/or Slide Mass may be
entered on the Mechanism tab (a future step in the workflow) if a Belt Drive, Lead Screw,
Inclination Chain and Sprocket, or Rack and Pinion are selected.
If the Inclination angle is between 0 and -90, you must enter the angle as a positive
number and invert the motion profile. For example, enter a 45 angle value on the Load
tab and a negative velocity in More Options Profile Editor Mode on page 142. Failure to do
this will result in an under-calculation of the regenerative energy.

2.1.1.1. Advanced Considerations - Counterbalances
In a counterbalanced system, unbalanced mass should be entered as Table Mass

and balanced mass as Belt/Chain Mass. Values for Table Mass, Belt/Chain Mass,
and/or Slide Mass may be entered on the Mechanism tab (a future step in the
workflow) if a Belt Drive, Lead Screw, Chain and Sprocket, or Rack and Pinion
are selected.
There are two main types of counterbalance.
Table 50 - Counterbalance Types

Type Description
A 100% counterbalance doubles the load mass entered on the Load tab. Friction is usually
Mass negligible and the net force is zero. Accelerations are normally limited to less than gravity
Counterbalance (9.81 m/s2) to maintain the suspension tension.
A 100% counterbalance means there is zero net force, but usually adds significant friction,
Force especially hydraulic types. For example, pneumatic, hydraulic, or spring. The increase in load
Counterbalance mass is usually negligible.
Figure 67 - Counterbalance Types
Mass Counterbalance Force Counterbalance
Drive Belt
Counterbalance Mass
Load Mass
Weight
Weight
Drive Belt
Force
Load Mass
Counterbalance
Cylinder
Weight Motor
Air Pressure
Motor

2.1.1.1.1. Mass Counterbalance

Vertical load with a 100% mass counterbalance
Set the Inclination field to zero and enter a load mass two times greater
than the load into the Load Mass field.
Vertical load with less than 100% mass counterbalance.

Set the Inclination field to zero and enter the load mass plus the
counterbalance mass into the Load Mass field. Add an external positive
force equal to the following into the Applied Force field:
F = (Mload - Mcounterbalance) a
where a = acceleration due to gravity = 9.81 m/s2
2.1.1.1.2. Force Counterbalance
For a vertical load with a 100% force counterbalance, you have two choices:
Set the Inclination field to zero and enter the load mass into the Load Mass
field.
Set the Inclination field to 90, and enter the load mass into the Load Mass
field. Add an external negative force equal to the load weight into the
Applied Force field.
For a vertical load with less than 100% force counterbalance, set the Inclination
field to 90 and put the load mass into the Load Mass field. Add an external
negative force equal to the counterbalance force into the Applied Force field.
Be sure to add some allowance for friction. Hydraulic type counterbalances are
notorious for high friction, which is usually speed-dependent. Because a mass
counterbalance cannot easily handle this directly, take the friction force at the
maximum speed, convert the friction force to torque at the drive shaft and add
this torque to the Losses field in the Actuator tab.

2.1.2. Rotary Loads
For a rotary application, the load rotates and the system has no translation to
linear motion.
Figure 68 - Rotary Load Type
Table 51 - Rotary Load Parameters

This is the inertia of any balanced load about the axis of rotation. For example, if the main
Primary Inertia (1) mass is a circular table which is driven about its own axis of symmetry, then primary
inertia is equal to the table inertia.
Friction This is the force resisting the relative motion of two surfaces against each other.
(1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily
available.

2.1.3. Rotary Complex Loads
A complex rotary load is non-linear, which means that the load position is not
directly proportional to the input shaft position as it is with standard actuator
types. A simple example is a crank, where the load velocity is sinusoidal with a
constant shaft speed. The Crank and Four Bar Linkage templates are available for
these applications.
The main challenge with non-linear mechanisms is that the inertia value varies
with shaft angle. This means that even at constant shaft speed, a torque that varies
with the rate of change of inertia is required to maintain that speed. The same is
true of an unbalanced load in which external forces, such as gravity, induce torque
values that depend only on shaft angle, not velocity or acceleration.
The Rotary Complex load separates the dynamic inertia values from the motion
profile so that, having calculated inertia for a range of shaft positions, the motion
profile can be varied without having to re-calculate inertia at each shaft position.
Figure 69 - Rotary Complex Load Type

Table 52 - Complex Load Data Options

Option Description
User Defined Import load data from an external file into the Complex Load Data table on
Complex Load Data page 90.
(label 1 in Figure 69) Use the Unbalanced Load and Crank templates to calculate load data and
Templates
enter it in the Complex Load Data table on page 90.
With this option, the first and last points should be identical so that the
motion profile can be repeated (for example, zero and 360 ). Motion
Repeating Analyzer software assumes that rotation may continue indefinitely in
either direction.
With this option, the first and last points indicate the maximum and
Limited Range minimum positions permitted.
Motion (1) # Data point number; this number is arbitrary.
Position Driving shaft angle with reference to the starting angle.
Inertia Load inertia for the given shaft angle.
Applied Torque Torque applied at the given position.
Friction Torque Torque loss due to friction.
Description Available for you to enter optional notes.
Graph tab The Graph tab of the display window shows the inertia, applied torque, and friction torque
(label 3 in Figure 69) values as a function of shaft position based on the data entered in the table on the left (label 2
in Figure 69).
(1) The complex load data (position, inertia, and torque, for example) is entered manually, imported, or calculated in the available
Rotary Complex Templates.
It is important to start with the mechanism in the appropriate position. Click

Start Condition on the toolbar at the top of the More Options Profile Editor
Mode dialog box to input the motion profile start condition.
Figure 70 - Graph Tab

In this Crank application, the green applied torque curve shows a sharp peak
around 180 when a high force is encountered near the end of the linear stroke.
Figure 71 - Crank Application Example

2.1.3.1. User Defined
For the User Defined data entry option, calculations are typically made with a
spreadsheet. Once the data is arranged in columns to match the Complex Load
Data table, you can copy the data to the clipboard and paste it into the table. The
columns are tab delimited, which is the default format for Microsoft Excel
software. Alternatively, you can create and import a text file.
IMPORTANT Before pasting data make sure that the column units match those of the data.
2.1.3.2. Templates
The Rotary Complex templates can be used to calculate Complex Load Data for
Unbalanced Load and Crank application types.
Figure 72 - Rotary Complex Loads
There are two Rotary Complex templates available to assist in calculating data for
the Complex Load Data table (label 2 in Figure 72).
Table 53 - Template Options (label 1 in Figure 72)

Template Description Page
Unbalanced Load Lets you enter parameters for an Unbalanced Load application. 91
Template
Crank Template Lets you enter parameters for Crank applications. 93

2.1.3.2.1. Unbalanced Load Template
This template lets you enter parameters for an unbalanced load application.
Figure 73 - Unbalanced Load Template
Motion Analyzer software assumes that the axis of rotation is parallel to the
ground if no axis angle is entered and that unbalanced masses create a gravity
related torque. Secondary Inertia, Secondary Mass and Axis Separation
parameters are required to take into account gravity induced torque values.
Figure 74 - Axis of Rotation Parallel to Ground with No Axis Angle Defined

If the gravity torque (Secondary Mass * 9.81 m/s2 * Axis separation2) is known to
be small as compared to the acceleration torque or motor nominal torque, then it
may not be necessary to include the unbalanced mass effects.
ATTENTION: If the angle of movement in any profile segment is such that the
gravity torque changes significantly during that segment (a common
occurrence) then break the segment into smaller portions.
Table 54 - Unbalanced Load Parameters (refer to Figure 73)

The inertia of any balanced load about its own axis of rotation. For example, if the main
Primary Inertia (1) mass is a circular table which is driven about its own axis of symmetry, then Primary
Inertia is equal to the table inertia.
Losses The losses consist of the torque lost in the system due to friction.
Secondary Inertia (1) The moment of inertia of the unbalanced mass about its own center of gravity.
Secondary Mass The unbalanced mass.
Axis Separation The distance between the secondary mass center of gravity and the axis of rotation.
The starting angle of rotation. Zero indicates that at the start of the motion profile, the
Axis Angle center of gravity lies vertically below the center of rotation. This is the position of the load
if it is allowed to swing freely. Positive rotation is clockwise.
available.

2.1.3.2.2. Crank Template
The Crank template is used to calculate the load profile for a given application,
based on either input shaft velocity or linear load velocity.
IMPORTANT This template should only be used for constant inertia. Do not set secondary
mass or secondary inertia when using this template.
Figure 75 - Crank Template
Figure 76 - Animated Display (for reference)
TIP Parameter entry descriptions are displayed when the cursor is held over an
entry field for several seconds.

Table 55 - Crank Template Parameters

For reference to make sure that entered data is accurate and particularly that the orientation of the crank is correct. The animation rotates the crank so that
the system can be better visualized. The X/Y plane is horizontal.
Sets the crankshaft inclination. Set this parameter before starting the animation. The 0y button sets the angle to 90. The
Vertical Slider (Left) current angle is displayed in the Mechanical Data window.
Sets the linear slide inclination. The 0z button sets the angle to 0. The current angle is displayed in the Mechanical Data
Horizontal Slider (Top) window. The true angle to the horizontal is dependent on both slider positions since it is a compound angle.
Animated Display
(label 1 in Figure 75) Horizontal Slider (Scale) Sets the display scale.
Horizontal Slider (Speed) Sets the animation speed.
Black Arrow Represents the external force and the arrow length is proportional to the applied force.
2D/3D Toggles between two and three-dimensional representations of the crank.
Thick Lines Check this box if you would like the graphical displays to be shown with a thicker line.
Animate Click to run the simulated crank image through the specified motion profile.
Template Options
(inside red box Stop Click to stop the animation.
in Figure 75)
Calculate Click to calculate the external torque and reflected inertia values.
Crank Radius The distance between crank shaft and crank pin.
(1)
Crank Inertia The inertia of the crank alone, when the connecting rod is disconnected.
Connecting Rod Length (2) The distance from the crank pin center to the gudgeon (wrist) pin center.
Connecting Rod Mass The total mass of the connecting rod.
Conrod C of G from Crankpin The distance between the crank pin and the connecting rod center of gravity.
Conrod Inertia about C of G (1) The inertia of the connecting rod about its own center of gravity.
Linear (Load) Mass The mass of the load attached to the connecting rod at the gudgeon pin.
Linear (Load) Offset The distance from the linear motion center line to the crankshaft axis.
Force Start Position The distance between gudgeon (wrist) pin and crank shaft center when force is applied.
Mechanical Data
(label 2 in Figure 75) Force End Position The distance between the gudgeon (wrist) pin and crank shaft center when force stops.
Force at End (3) The magnitude of the force at the ending point.
Force v Angle Box When this box is checked, the force varies according to shaft angle rather than linear position.
Draw Click this button to show the geometry at the start angle/position.
Click this button to transfer the geometrical data to the clipboard for pasting into the RSLogix 5000 Cam Editor. The
master axis is a virtual axis and the slave axis is the crank axis. A trapezoidal move of the virtual axis produces a
Logix Cam trapezoidal load profile at the gudgeon pin. The master data must increase positively so only that part of the cam that
satisfies this requirement is exported.
This displayed value is the angle of the crank shaft with respect to the XY (horizontal) plane. 90 indicates vertical and
Crankshaft Inclination gravity has no effect.
This displayed value is the angle with respect to the horizontal plane along which the linear mass moves. Zero degrees
Crank Plane Inclination indicates horizontal and gravity has no effect.
Start Angle The starting angle for the Crank load profile.
Export to Complex Load
(label 3 in Figure 75) End Angle The ending angle for the Crank load profile.
Points The number of points you would like to divide the load profile into.

Table 55 - Crank Template Parameters (continued)

Peak Inertia The calculated maximum reflected inertia at the crankshaft.
The Peak External Force + Gravity Torque is the calculated peak torque, generated from the external linear force and
Results Peak Ext. + Grav. Torque gravity.
Apply Click to apply the load profile data and close the window.
Cancel Click to close the window without applying any data.
Chart Display The Chart Display displays the crank velocity, the inertia that is reflected to the crankshaft, and the crank torque due to external influences such as gravity
(label 5 in Figure 75) and applied force. These are the parameters which will be applied.
(1) Use the Inertia Calculator Template on page 105 to calculate the inertia value for your application, if the value is not readily available.
(2) Setting this length to zero configures the mechanism as a Scotch Yoke, where the linear load follows a simple harmonic motion.
(3) If the Force at Start is different from the Force at End, the force varies between these two limits according to gudgeon pin position or crank angle. If the values are equal, a constant force is applied.

2.1.4. Application Template Loads
The application templates let you enter pre-configured mechanism application

data.
Figure 77 - Application Template Load Type
Table 56 - Application Template Options

Template Type Description Page
This application is typically cutting strip material into pre-set lengths with a
Press Roll Feed (constant Press Shear (heavy-duty knife). The material must be stationary when the 97
time/constant angle) cut is made and the cut takes place over a fixed amount of time or a fixed
angle of the driving crank whose speed is varied to match the cut rate.
Carriage Cut Off Flying Shear (heavy-duty knife on a moving carriage). The shear must be 100
stationary relative to the material (for example, moving at line speed) when
the cut is made and the cut takes a fixed time.
Rotary Knife (heavy-duty knife blades mounted on a pair of rotating
Cutter Knife Drive drums). The blades must be stationary relative to the material (for example, 102
moving at line speed) when the cut is made and the cut takes place over a
fixed drum angle.
These templates let you enter data for complex mechanisms. Advanced
Advanced Templates Templates include the Inertia Calculator, Crank, Winder/Unwinder, and Four 104
Bar Linkage.
Power/Speed Templates These templates let you enter torque and speed values that are used to 118
calculate the power requirement for the application.

2.1.4.1. Press Roll Feed (constant time/constant angle)
This application is typically cutting strip material such as steel into pre-set lengths
by means of a press shear (heavy-duty knife). The material must be stationary
when the cut is made and the cut takes place over a fixed amount of time or a
fixed angle of the driving crank whose speed is varied to match the cut rate.
Strip material is unwound from a reel at constant surface speed and fed via
separately driven leveler rolls into one end of a looping pit (a free-hanging loop of
material providing storage). On the other side of the loop, a pair of feeder rolls
grips the material and moves it forward the required cut length and then stops.
After the cut is complete, the material is moved again. The average velocity of the
nip/feeder rolls must be equal to the constant velocity of the unwinder and
leveler rolls.
Figure 78 - Press Roll Feed - Constant Time
Figure 79 - Press Roll Feed - Constant Angle

Table 57 - Press Roll Feed Parameters

Moving Material Mass The mass of the material in the loop and on the flat before the Nip/Feed rolls. (3)
Bias Force The force required to overcome the force of gravity on the loop. (3)
Drive Roll Diameter The diameter of the roll in direct contact with the strip, driven from the motor.
Load (2)
(label 1 in Figure 78 or Total Roll Inertia The total inertia of the strip material at the drive shaft.
Figure 79)
The time during which the material must be stationary in an accurate position. This value is only required for Press Roll Feed -
Cut (Waiting) Time Constant Time applications (refer to the red boxes in images above).
The crank angle during which the material must be stationary in an accurate position. This value is only required for Press Roll
Cut (Waiting) Angle Feed - Constant Angle applications (refer to the red boxes in images above).
Select this option for data entry when the maximum design speed of the constant-speed sections of the line is known. This
speed does not refer to the peak velocity of the feeder section, which is determined by Motion Analyzer software.
Max Average Line Speed When you select the option to enter data based on Max Average Line Speed, this data is required. This is
Min. Cut length at
Critical Preferences (1) the critical condition on which the sizing process is performed. To cut shorter lengths than this critical
Max line speed
(label 2 in Figure 78 or length, the line speed must be reduced.
Figure 79) Select this option for data entry when the number of cuts made by the system per minute is known.
Cuts/min When you select the option to enter data based on Cuts/min, this data is required. This is the critical
Max. Cut length at condition on which the sizing process is performed. To cut longer lengths than this critical length, the
Cuts/min line speed must be reduced.
This is the time required for the system to achieve the required position accuracy before the cut commences. The finer the
Settling Time
System Properties required accuracy, the longer the settling time value. This time is typically 20 to 75 ms for an A servo system.
(label 3 in Figure 78 or This option is only required for Press Cutter Knife Drive applications. The Cosine Compensation is used to make sure that while
Figure 79) Cosine Compensation the press cutter knife is in contact with the material being cut, the horizontal component of the knifes velocity matches the
material speed.
Linear Select this option for standard linear acceleration and deceleration ramps.
Motion Type Properties Select this option for S shaped acceleration and deceleration ramps that are used to produce smoother motion. You need to
(label 4 in Figure 78 or S-Curve enter the percent jerk value for this option.
Figure 79)
Select this option for a triangular load profile. This option is only required for Press Roll Feed - Constant Angle applications (see
Triangular Move red box in Figure 79).
(1) At very long cut lengths, the limiting factor, determined by the design speed of the leveler rolls and unwinder, is the maximum line speed. As cut length is reduced, the servo has to index more and more
rapidly until the peak or RMS (root mean squared) torque limit is reached. To cut shorter lengths than this critical length, the line speed must be reduced. Sizing is based on this critical length, maximum
line speed and cut time, which are typically specified.
(3) You can enter this data manually or use the Loop Calculator on page 99, to determine the value.

Click in Figure 78 or Figure 79 to determine the Moving Mass and Bias

Force parameters by using the Loop Calculator.
Figure 80 - Loop Calculator
Table 58 - Loop Calculator Parameters

Choose strip material from the pull-down menu or enter the density value
Density manually.
Material
(label 1 in Figure 80) Thickness Strip material thickness.
Width Strip material width.
Flat Length Strip material flat length as defined in the Press Roll Feed Diagram.
Loop
(label 2 in Figure 80) Loop Length Strip material loop length as defined in the Press Roll Feed Diagram.
Loop Depth Strip material max loop depth as defined in the Press Roll Feed Diagram.
Moving Mass When you click Compute, the Loop Calculator displays the Moving Mass
Computed Parameters and Bias Force values based on the values you entered for the parameters
(label 3 in Figure 80) Bias Force above. These values are entered in the Application Template when you click
OK.

2.1.4.2. Carriage Cut Off
by means of a Flying Shear (heavy-duty knife mounted on a moving carriage).
The shear must be stationary relative to the material (for example, moving at line
speed) when the cut is made and the cut takes a fixed time.
separately driven leveler rolls. After the cut is complete, the shear is stopped then
moved back to its start position. It must accelerate to match the line speed at the
correct position to cut the required length of material.
Figure 81 - Carriage Cut Off Template

Table 59 - Carriage Cut Off Parameters

Mass of Carriage Total mass of the linear moving parts.
Load Drive Roll Diameter Diameter of the roll, driven from the motor.
(label 1 in Figure 81) Friction Coefficient Coefficient of friction of the sliding bearing.
Cut Time Time the carriage must be synchronized accurately with the material.
Min Cut length at the critical condition on which the sizing process is performed. To cut shorter lengths than this critical
Critical Preferences (1) Max line speed length, the line speed must be reduced.
Select this option for data entry when the number of cuts made by the system per minute is known.
Max Cut length at condition on which the sizing process is performed. To cut longer lengths than this critical length, the
System Properties This is the time required for the system to achieve the required position accuracy before the cut commences. The finer the
(label 3 in Figure 81) Settling Time required accuracy, the longer the settling time value. This time is typically 20 to 75 ms for an A servo system.
Motion Type Properties
(label 4 in Figure 81) Select this option for S shaped acceleration and deceleration ramps that are used to produce smoother motion. You need to
S-Curve enter the percent jerk value for this option.

2.1.4.3. Cutter Knife Drive
by means of a rotary knife (heavy-duty knife blades mounted on a pair of rotating
drums). The blades must be stationary relative to the material (for example,
moving at line speed) when the cut is made and the cut takes place over a fixed
drum angle.
separately driven leveler rolls. After the cut is complete, the drum is adjusted
forward or backward relative to the material in order to cut the required length. It
must return to line speed at the position required to cut the required length of
material.
When the cut-length is equal to the circumference of the locus of the knife blade
tip, it is said to be the synchronous cut length. In this special case, the knife drums
rotate at a steady speed.
Figure 82 - Cutter Knife Drive Template

Table 60 - Cutter Knife Drive Parameters

Total Knife Inertia (2) Inertia of the knife assembly at the drive shaft.
As illustrated in the Cutter Knife Drive (Rotary Knife) diagram, this is the diameter of the circle passing through the cutting
Effective Diameter edge.
Load Contact Angle (Before Time the material must be stationary in an accurate position.
(label 1 in Figure 82) BDC)
Number of Blades/Knife Number of blades around the circumference of the knife.
Maximum force required to cut through the material. Cutting force is essentially constant while maximum torque occurs at the
Cutting Force first point of knife contact.
Min Cut length at the critical condition on which the sizing process is performed. To cut shorter lengths than this critical
Critical Preferences (1) Max line speed length, the line speed must be reduced.
Select this option for data entry when the number of cuts made by the system per minute is known.
Max Cut length at condition on which the sizing process is performed. To cut longer lengths than this critical length, the
This is the time required for the system to achieve the required position accuracy before the cut commences. The finer the
Settling Time required accuracy, the longer the settling time value. This time is typically 20 to 75 ms for an A servo system.
System Properties
(label 3 in Figure 82) This option is only required for Press Cutter Knife Drive applications. The Cosine Compensation is used to make sure that while
Cosine Compensation the press cutter knife is in contact with the material being cut, the horizontal component of the knifes velocity matches the
material speed.
Motion Type Properties
(label 4 in Figure 82) Select this option for S shaped acceleration and deceleration ramps that are used to produce smoother motion. You need to
S-Curve enter the percent jerk value for this option.

2.1.4.4. Advanced Templates
The Advanced Templates tab let you enter data for complex mechanisms. The
templates convert the complex mechanisms into Motion Analyzer mechanism
data and load profiles with additional inertia and loads.
Figure 83 - Advanced Templates Dialog Box
Table 61 - Advanced Template Options

Inertia Calculator Calculates the inertia for your application. 105
Crank Template Lets you enter parameters for Crank applications. 93
Enter required inputs to calculate the load profile for Winder or Unwinder
Winder/Unwinder 112
applications.
Four Bar Linkage Enter required inputs to calculate the load profile for Four Bar Linkage 114
applications.

2.1.4.4.1. Inertia Calculator
The Inertia Calculator has several options for inputting parameters to calculate
inertia for an application.
Figure 84 - Inertia Calculator Template
Table 62 - Inertia Calculator Template Options

This is the default mode when you open the Inertia Calculator. You can also
enter this mode by clicking Less Options in the lower left corner of the
Less Options Inertia Mode calculator in More Options Inertia Mode. Use this mode to calculate inertia 106
for a single cylindrical component. The center of mass/center of gravity of
the cylinder must coincide with the axis of rotation.
Enter this mode by clicking More Options in the lower left corner of the
More Options Inertia Mode calculator in Less Options Inertia mode. Use this mode to enter data for more 107
complex shaped components. By assembling cylinders, cuboids, and prisms,
any largely three dimensional shape can be constructed.
Use this mode to directly import inertia data from SolidWorks. Enter
SolidWorks Import SolidWorks mode by choosing SolidWorks from the Type pull-down menu in 109
the Element Properties window.

2.1.4.4.1.1. Less Options Inertia Mode
The Less Options Inertia mode is the default mode when you open the Inertia
Calculator. Use this mode to calculate inertia for a single cylindrical component.
The center of mass/center of gravity of the cylinder must coincide with the axis of
rotation.
Figure 85 - Less Options Inertia Mode
Table 63 - Less Options Inertia Mode Properties

Type Choose the type of cylinder (solid or hollow) you would like to calculate the inertia for.
Name Enter a meaningful name for the item you are calculating inertia for.
Calculate Using Select the type of data (mass or density) you would like to use to calculate inertia.
This is the diameter of the cylinder. When calculating inertia for a hollow cylinder, you also need to enter inner and outer
Diameter diameter as defined in the Element Image window.
Element Properties
(label 1 in Figure 85) Length This is the length of the cylinder. This parameter is not required when calculating based on mass.
Mass This is the cylinder mass. This parameter is not required when calculating based on density.
Choose the material of the cylinder from the pull-down menu. If Other is selected as the material type, the density value
Material also needs to be entered. This parameter is not required when calculating based on mass.
When the cylinder material is not available in the Material pull-down menu, the density value must be entered here. This
Density parameter is not required when calculating based on mass or when the material is selected from the pull-down menu.
Element Properties Element Mass

(label 2 in Figure 85) Element Inertia Once the element properties are entered, the Element Mass and Element Inertia properties are displayed (see label 2) and
in the Results window (see label 3).
Total Inertia The Element Mass and Element Inertia, and the Total Mass and Total Inertia are equivalent in Less Options Inertia mode,
Results because data is only entered for a single cylindrical element.
(label 3 in Figure 85) Mass
Because the Less Options Inertia mode is used to calculate the inertia of a single
cylindrical component, the options in the Add Element toolbar are not available.

2.1.4.4.1.2. More Options Inertia Mode
In More Options Inertia mode you can calculate the mass and inertia of complex
shapes. By assembling cylinders, cuboids and prisms, you can construct any
largely three dimensional shape.
Figure 86 - More Options Inertia Mode
Table 64 - More Options Inertia Mode Properties

Pull-down menu that lets you add an inertia element at the bottom of the Element List. You have the option of adding a solid cylinder,
Add Element hollow cylinder, cuboid, or prism.
Insert Pull-down menu that lets you insert an inertia element above the selected inertia element in the Element List.
Delete Deletes the selected inertia element in the Element List.
Add Element Toolbar
(label 1 in Figure 86) Cut Removes the selected inertia element in order to place it in another location in the Element List.
Copy Create a copy of the selected inertia element in order to replicate the element in another location in the Element List.
Paste This button lets you replace the selected inertia element with a cut or copied inertia element.
Use the Inertia Element Selector arrows (red box in Figure 86) to navigate through the various inertia elements in the Element List. As
Segment Selector
you navigate to an inertia element, the associated Element Properties window and Element Image tab are displayed.

Table 64 - More Options Inertia Mode Properties (continued)

Once the Element Properties are entered, the Element Mass and Element Inertia values are displayed at the bottom of the Element Properties window (label 4
in Figure 86).
Type Select the type of element (solid cylinder, hollow cylinder, cuboid, or prism) you would like to add to the Element List.
Name Enter a meaningful name for the element you are editing.
Calculate Using Select the type of data (mass or density) you would like to use to calculate inertia.
X This is the position for the inertia element in the X (horizontal) direction. For a prism you will need to enter X1, X2 and X3 positions.
Y This is the position for the inertia element in the Y (vertical) direction. For a prism you will need to enter Y1, Y2 and Y3 positions.
Element Properties Diameter This is the diameter of the inertia element if it is cylindrical. For a cuboid you will need to enter width and height.
Inner Diameter This is the inner diameter of the inertia element if it is a hollow cylinder.
Length This is the length of the inertia element. This parameter is not required when calculating based on mass.
Quantity This is the number of identical elements.
Mass This is the mass of the inertia element. This parameter is not required when calculating based on density.
Select the material of the cylinder from the pull-down menu. If Other is selected as the material type, the density value also needs to be
Material entered. This parameter is not required when calculating based on mass.
When the inertia element material is not available in the Material pull-down menu, the density value must be entered here. This
Density parameter is not required when calculating based on mass or when the material is selected from the pull-down menu.
Element List
(label 5 in Figure 86) Summary list of the elements that make up the component with the current element highlighted in blue.
Results Motion Analyzer software takes gravity into account only if an unbalanced load is entered as secondary inertia. Gravity is taken to act from top to bottom of the
(label 6 in Figure 86) Component Plot window.
Error List In the event of incorrect input data, a list of errors is displayed.
Figure 87 - Element Image Tab (label 3 in Figure 86)
Use this tab to verify the correct placement of the various inertia elements.

2.1.4.4.1.3. SolidWorks Import
You can use the SolidWorks Inertia Calculator to import inertia data directly
from SolidWorks software when the part geometry is complex and a SolidWorks
model is readily available. The part must be balanced about the axis of rotation.
For unbalanced loads, a SolidWorks Motion Study must be completed and users
must interface with SolidWorks, using the resulting torque data to appropriately
size a motor. Refer to From SolidWorks on page 120 for more information on the
SolidWorks Interface Wizard.
Figure 88 - SolidWorks Inertia Calculator
The density, volume, and surface area of the element (label 1 in Figure 88) are
displayed in the middle. The mass and inertia (label 2 in Figure 88) are displayed
at the bottom of the Element Properties window and in the Results window at
the bottom right (label 3 in Figure 88).
Receive inertia data from SolidWorks software by selecting SolidWorks from the
Type pull-down menu in the Element Properties window.

Click Import to open the SolidWorks - Data Import dialog box.
Figure 89 - Import SolidWorks Data
Table 65 - SolidWorks - Data Import (refer to Figure 89)

Load/Change Load or change the SolidWorks model.
Update the data returned to Motion Analyzer software if changes are made to the model while
Refresh the part is open in SolidWorks software.
Click the radio button corresponding to the models axis of rotation in the Inertia Details section.
Select Axis (1) This step is critical to determining the inertia since the model needs to be balanced about the
correct axis.
(1) The axis of rotation corresponds to the inertia value that is different from the other two values. Since the model is balanced about
the axis of rotation, the inertia is the same about two axes, and different about one.
Click OK to import the data from SolidWorks into Motion Analyzer software.

The SolidWorks Data Import window closes and returns to the Inertia
Calculator window and the imported element image.
Figure 90 - Imported Element Image

2.1.4.4.2. Winder/Unwinder
Use this template to enter required inputs to calculate the load profile for Winder
or Unwinder applications.
Figure 91 - Winder/Unwinder Template
For a Winder or Unwinder application, two index moves are created:

Maximum diameter, minimum rotation speed
(= maximum torque for center driven)
Minimum diameter, maximum rotation speed
(= minimum torque for center driven)
The maximum torque condition is the worst case for winding temperature so the
move time for this index is made large enough to dominate the temperature
calculations.
The maximum speed case is included to check that the specified speed can be
reached. If the application requires a different acceleration for the full roll
compared to the core, this can be done in Define Your Profile on page 139 after
you click Apply.

Table 66 - Input Data (label 1 in Figure 91)

The roll is driven directly via a shaft at its center of rotation. For a Center Driven application,
Center Driven Rotary Load is selected and the roll is modeled as Inertia and Torque in a Multi-segment profile.
No further load information needs be added.
The roll is driven by the friction of rollers pressing onto the circumference of the web. For a
Surface Driven application, Linear Load and Belt Drive are selected and the roll is modeled as
Mass and Force in a Multi-segment profile.
IMPORTANT The driving roll/rolls data should be added as Drive Roll and
Surface Driven
Idler Roll.
You will be asked if you want to reset the Actuator parameters to zero. Click Yes, if this is the first
time you applied this Winder. If you already applied it and added the drive roll data in the Belt
Actuator, the drive roll data will be deleted.
Empty Diameter Minimum reel diameter, when the roll is completely unwound.
Empty Inertia Inertia of the reel when it is completely unwound.
Full Diameter Maximum reel diameter, when the roll is completely wound.
Material Inertia (1) Inertia of the reel when it is at full diameter or completely wound.
Maximum Web Maximum allowable web tension for the material. The value is used for sizing purposes.
Tension
Minimum Web Minimum web tension for the application. It is used to calculate the Tension Ratio.
Tension
Maximum Web Design speed of the material running through the machine.
Speed
Acceleration Time Shortest required acceleration time from zero to maximum web speed.
Deceleration Time Shortest required deceleration time from maximum web speed to zero.
Check this box if the acceleration and deceleration follow a smooth S-curve. If this box is not
S-curve checked, acceleration is considered trapezoidal.
Select either Wind or Unwind for your application. This setting determines the direction of pull
Wind/Unwind from the web tension.
This option is used only when a Wind and Unwind axis share a DC power rail. The two axes are
first sized as normal (for example, Profile Mirror is set to Off). The Winder is then set to Profile
Profile Mirror Mirror. This matches the two axis motion profiles as if they were connected by the web. This is
necessary only to check the system sizing. In this mode the motor winding temperature of the
Winder axis will be underestimated.
available.
Click Calculate to display the following values in the Results portion of the
window (label 2 in Figure 91).
Table 67 - Calculated Parameters (label 2 in Figure 91)

Buildup Ratio Ratio of the Maximum/ Minimum diameter of the roll.
Ratio of Maximum/Minimum inertia values. A large inertia range value is more difficult to
Inertia Range control.
Tension Ratio Ratio of the Maximum/Minimum tension values.
Maximum web tension multiplied by the maximum web speed. This power is regenerated
Maximum Web continuously during unwind and should be catered for by suitably rated dump resistors or a
Power regenerative power supply. Motion Analyzer software underestimates this rating by
approximately 10%.

2.1.4.4.3. Four Bar Linkage
You can use this template to enter required inputs to calculate the load profile for
Four Bar Linkage applications.
Figure 92 - Four Bar Linkage Template
Figure 93 - Animated Diagram (for reference)
TIP Parameter entry descriptions are displayed when the cursor is held over an
entry field for several seconds.

Table 68 - Four Bar Linkage Properties

Vertical Slider This slider sets the crankshaft inclination and should be set before starting the animation. Click 0y to set the angle to 90. The current
(left) angle is displayed in the Mechanical Data window.
Horizontal Slider This slider sets the linear slide inclination. Click 0z to set the angle to 0. The current angle is displayed in the Mechanical Data window.
(top) The true angle to the horizontal is dependent on both slider positions because it is a compound angle.
Horizontal Slider This slider sets the display scale.
(scale)
Animated Display (1)
(label 1 in Figure 92) Horizontal Slider This slider sets the animation speed. The black arrow in the plot represents the external force, and the arrow length is proportional to
(Speed) the applied force.
Animate Click to run the simulated crank image through the specified motion profile.
Stop Click to stop the animation.
Analyze Click to display the bar graphs that show the contribution of each mechanical component to the inertia and torque values.
Calculate Click to calculate the external torque and reflected inertia values that will be applied.
Link 1 Length Distance between Pivot 1 and Pivot 2.
Link 1 Inertia (2) Inertia of Link 1.
Link 1 Start Angle Initial angle between Link 1 and X Axis. Angular load profile only.
Link 2 Length Distance between Pivot 2 and Pivot 3.
Link 2 Mass Mass of Link 2.
Link 2 CG Link 2 Center of Gravity with respect to Pivot 2.
Link 2 Inertia (1) Inertia of Link 2 about its own center of gravity.
Load Pivot X X distance between Pivot 1 and Pivot 4.
Load Pivot Y Y distance between Pivot 1 and Pivot 4.
Load Link Length Distance between Pivot 3 and Pivot 4.
Load Inertia Inertia of the load (Link 3) about its own center of gravity.
Mechanical Data Load Mass Mass of the load (Link 3.)
Load G of G Radius Distance between Pivot 4 and center of gravity of the load (Link 3.)
Load G of G Angle Angle between the lines that make up the center of gravity of the load (Link 3), Pivot 4, and Pivot 3.
Link 1 Start Angle Link 1 angle when force is applied.
Force at Start Magnitude of the force at the starting point.
Magnitude of the force at the ending point. If the Force at Start is different from the Force at End, the force varies between these two
Force at End limits according to gudgeon pin position or crank angle. If the values are equal, a constant force is applied.
Force Orientation Force orientation from the X axis.
Draw Start Click to show the geometry at the start angle/position.
Position
Click to transfer the geometrical data to the clipboard for pasting into the RSLogix 5000 Cam Editor. The master axis is a virtual axis
Export Logix Cam while the slave axis is the crank axis. A trapezoidal move of the virtual axis then produces a trapezoidal profile at the gudgeon pin. The
master data must increase positive so only that part of the cam that satisfies this requirement is exported.
Pivot 1 Axis Displayed value is the angle of the crank shaft with respect to the XY (horizontal) plane. 90 indicates vertical, and gravity has no
Inclination effect.

Table 68 - Four Bar Linkage Properties (continued)

Coarse Data Select this option if the size of the profile segments is sufficient to detect significant changes to force or inertia during each time slice.
Select this option if a finer resolution of the profile segments is needed to detect significant changes to force or inertia during each
Fine Data time slice.
You can copy spreadsheet data and paste into this grid. Click the Time column, Row zero, and then press Ctrl + v.
Delta T Column Profile segment duration (dT).
Final velocity at the end of the profile segment. Row zero is reserved for the start velocity only, hence the time
Velocity Column
Profile Table and S-curve cells are grayed out.
Acceleration Peak/Average. The following values apply:
Profile Window 1 = Trapezoidal acceleration
(label 3 in Figure 92) Acc. Pk/Ave
2 = S-curve acceleration
>1 or <2 = partial S-curve
Insert Insert a new, blank row at the highlighted position.
Delete Delete the row at the highlighted position.
Clear All Remove all profile data.
Display Click to show the load profile for checking purposes.
Maximum Fine Specify the maximum number of profile segments that you would like the coarse segments divided into.
Segments
Peak Inertia Calculated maximum reflected inertia at the crankshaft.
Peak Ext. + Grav. Peak External Force + Gravity Torque is the calculated peak torque, generated from the external linear force and gravity.
Torque
Results Window Cycle Time Calculated cycle time for the specified load profile.
(label 4 in Figure 92) Minimum Time Minimum time slice required for the simulation.
Slice
Apply Click to apply the load profile and close the window.
Cancel Click to close the window without applying any data.
Chart Display Window Shows the crank velocity, the inertia that is reflected to the crankshaft, and the crank torque due to external influences such as gravity and applied force.
(label 4 in Figure 92) These are the parameters that are applied. By checking Show Resultant Load Torque, the associated value can also be displayed.
(1) The Animated Display at the upper left corner of the template is provided for reference to make sure that entered data is accurate and particularly that the orientation of the crank is correct. The animation
rotates the crank so that the system may be better visualized. In this example, the X/Y plane is horizontal.

Click to use the Quick Profile tool. A trapezoidal load profile is entered into
the data grid after clicking Apply.
Figure 94 - Quick Profile Tool
Table 69 - Quick Profile Tool (refer to Figure 94)

Move Angle Angle through which the load profile takes place.
Move Time Time through which the load profile takes place.
Wait Time Length of time to wait before the specified index move repeats.
Velocity Peak/Average. The following values apply:
2 = triangle; minimum peak torque
1.5 = equal trapezoid; minimum RMS (root mean squared) torque
Velocity Pk/Ave
1 = infinite acceleration; not useable
If the start velocity is non-zero, the peak velocity may be adjusted by the program to avoid
crossing the zero line.
Acceleration Peak/Average. The following values apply:
1 = Trapezoidal acceleration
Accel.Pk/Ave
2 = S-curve acceleration
>1 or <2 = partial S-curve

2.1.4.5. Power/Speed Templates
You can use the Power/Speed templates to enter torque and speed values that are
used to calculate the power requirements for the application.
Figure 95 - Power/Speed Templates
Table 70 - Power/Speed Template Options

Power/Speed Template Use this template when the torque and speed values are known at the load 119
(label 1 in Figure 95) for the application.
Constant Power Range
Use this template when three of the following values are known: maximum
Template 120
torque, minimum torque, maximum speed, or minimum speed.

2.1.4.5.1. Power/Speed Template
Use this template (label 1 in Figure 95) when the torque and speed values are
known for the application.
Click to access the Power Calculator.
Figure 96 - Power Calculator
Table 71 - Input Properties (refer to Figure 96)

Torque Torque value for your application.
Speed Speed for your application.

2.1.4.5.2. Constant Power Range Template
Use this template (label 2 in Figure 95) when three of the following four values
are known for the application.
Click to use the Power Calculator and enter the known torque and speed
values.
Figure 97 - Power Calculator
Table 72 - Input Properties (refer to Figure 97)

Max Torque Maximum torque value for your application.
Min Torque Minimum torque value for your application.
Min Speed Minimum speed for your application.
Max Speed Maximum speed for your application.
Click Apply to display the Power value and other missing value.
2.1.5. From SolidWorks
Integration with SolidWorks software can be used to obtain data to accurately

size motors, drives, and accessories for mechanically complex applications.
SolidWorks Motion has built-in tools that let users obtain accurate inertia and
force/torque data. Rather than manually recalculating or simply estimating these
values for motor sizing, Motion Analyzer software integrates with SolidWorks
software for consistency throughout the design process.
SolidWorks software calculates torque/force information for the following two

load types.
Table 73 - Enter Motion Profile

Workflow Method Description Page
Independent Axis
Select From SolidWorks as the load type. 122
Workflow
Inter-dependent Axes
Launch the SolidWorks Simulation tool from the System View page. 131
Workflow

Each load type requires a slightly different workflow in Motion Analyzer

software to obtain the data from SolidWorks software. Both workflows support
linear and rotational motion.
IMPORTANT A SolidWorks Assembly must be open in SolidWorks software when launching

the SolidWorks Interface Wizard from Motion Analyzer software.
IMPORTANT A SolidWorks Motion Study must be set up before launching the SolidWorks
Interface Wizard. Gravity, SolidWorks motors, material properties, and any
additional external forces must be defined in the SolidWorks Motion Study
before integration. Velocity and force/torque Results Plots must be created in
SolidWorks software for the simulation to return results to Motion Analyzer
software.
IMPORTANT Define reference geometry in SolidWorks software to define the axis of

rotation for the component the SolidWorks motor is attached to. Using
component faces to attach SolidWorks motors will work, but may
inadvertently define motion about an incorrect location for some mechanisms.
TIP If you disable animation before SolidWorks software performs calculations the
solver speed improves. This is because the software is not attempting to show
the motion of the assembly while performing calculations.
Follow these steps to improve SolidWorks software solver speed.
1. From the SolidWorks Motion Study explorer bar, click the Motion Study
Properties icon.
2. Clear the Animate during simulation checkbox.

2.1.5.1. Independent Axis Workflow
With independent motors, each motor works alone to move the load in the
single-axis, independent workflow, so the force/torque output stands isolated. An
example is the single-axis lifter mechanism (Figure 98) where one motor drives
the load.
Figure 98 - Independent Motors
SolidWorks Motion software supports linear and rotary motors. For an

independent motor workflow, there are two options for motion:
Translational (linear motion)
Rotational (rotary motion)

Follow these steps for an independent axis workflow.
1. Click the Load tab.

Select Translational (Linear) if a linear load is defined or Rotational
(Rotary) if a rotary load is defined in the SolidWorks Motion Study.
2. Click Next.

3. Click Edit Profile to specify the motion profile that the mechanism will
move through.
This motion profile is placed at the output of the motor or gearbox shaft, if
a gearbox is included in the motion system. Refer to Define Your Profile on
page 139 for more information.
Once you specify the motion profile for the axis, the SolidWorks
integration begins.
4. Click Launch SolidWorks Simulator to obtain force/torque results from
SolidWorks software.

The Selected SolidWorks Assembly dialog box opens.
5. Verify the following conditions:

The SolidWorks assembly must be open in SolidWorks software
before the SolidWorks integration wizard is launched.
The SolidWorks file must be an assembly and not simply a part.
Only one instance of SolidWorks software can be running in order for
integration to work.
6. Click Refresh when changes are made to the associated SolidWorks model
to make sure Motion Analyzer software is interfacing with the most recent
version of the SolidWorks assembly.
7. Verify this is the correct model and click Next.
If the model is not correct, open the correct assembly in SolidWorks
software and click Refresh.

The Motion Study Setup dialog box opens.
8. From the Motion Study Name pull-down menu, choose a SolidWorks

Motion Study for the data.
9. Click Next.
If you need to create a new motion study, return to SolidWorks software.
a. Return to the opening window and click Refresh to register the
changes.
b. Click Next.

The SolidWorks Motor Setup dialog box opens.

This dialog box lets you verify the SolidWorks Motor Setup. For inter-
dependent motors, you assign Motion Analyzer motion profile data to
each SolidWorks motor during this step. The Motor Setup dialog box is
repeated for each axis of motion.
10. From the Motion Analyzer Axis pull-down menu, choose the Motion
Analyzer axis.
IMPORTANT If all axes have the same name and this causes confusion,
go to Options >Application Info to rename the axes.
11. Check Reverse Direction if you find that the load moves in the wrong
direction.
Play the animation in SolidWorks software after the motion profile has
been sent across in a future step. Return to this step using the Back button
and check this box to reverse the direction of the motion profile. If the
motion is incorrect, select the Reverse Direction checkbox to switch the
direction of motion.
12. From the SolidWorks Motor Name pull-down menu, choose the name of
the SolidWorks motor that runs in the motion profile with the chosen
Motion Analyzer axis.
The SolidWorks Moving Part pull-down menu, is for information only.
This states the component that the SolidWorks motor is attached to and
the motion profile it will be applied to. If the component is not correct,
return to SolidWorks to attach the motor to the correct component.
13. Click Next.

The Summary dialog box opens.
14. Enter a value in the Frames/Second field.

This value indicates the number of frames per second the motion profile is
divided into. A large number yields fine resolution while a small number
yields coarse resolution.
15. Click Modify Selections.
Use this feature to edit a specific Motion Analyzer Axis.
a. Select an axis in the table.
b. Click Modify Selections to jump back to the SolidWorks Motor Setup
window for the selected axis.
16. Click Next.

SolidWorks software calculates the force/torque required to move the load

through the specified motion profile and the Results dialog box opens.
17. From the Results pull-down menu, choose the axis of motion you wish to
display.
18. Click the View Graph tab.
This tab displays the data in graphical format.
19. Click the View Data tab.
This tab displays the data in list format.
20. Click Export Data.
The data exports into a spreadsheet.
21. Click Apply to transfer force/torque data to Motion Analyzer software for
use in sizing a motion system.
22. Go to SolidWorks software and click Play from Start in the SolidWorks
Motion Study explorer.
View the motion profile as applied to your mechanism.

23. Verify that the mechanism is moving in the right direction. If you find that
the load moves in the wrong direction, return to step 11 by clicking Back
and check Reverse Direction.

The SolidWorks Load Data dialog box opens.

This dialog box lets you compare the actual Motion Analyzer velocity
profile to the velocity profile returned from SolidWorks.
24. Check Invert SolidWorks Output Data if the velocity profiles were
reversed to resolve the discrepancy and correct your model. The
discrepancy is due to different coordinate systems, which are arbitrarily
defined.
25. Click Proceed to Transmissions.
This step changes depending upon the application.
IMPORTANT With these versions of SolidWorks and Motion Analyzer, the inertia
data is not brought out automatically. This means that Motion
Analyzer has no knowledge of the inertia ratio, and therefore cannot
do the Motion Analyzer Simulation on the Solution tab.

2.1.5.2. Inter-dependent Axes Workflow
With inter-dependant motors, several motors work to move one load, so

although the motors have separate force/torque outputs, they depend on each
other to collectively move the load. An example is the two-axis linear pick and
place mechanism (Figure 99) where two motors drive the load.
Figure 99 - Inter-dependant Motors
Once the motion profile for each axis has been specified, the SolidWorks
integration begins. Refer to Define Your Profile on page 139 for more
information on defining a motion profile.
Follow these steps for an inter-dependent axis workflow.
1. Click to access the Motion Analyzer/SolidWorks integration tool,
Motion Analyzer software launches a new window and displays the model
that is open in SolidWorks software.
Use the integration tool to send motion profile data to more than one
SolidWorks motor simultaneously, thereby letting SolidWorks software
accurately calculate the effect of multiple motors working together to drive
one load.

The Selected SolidWorks Assembly dialog box opens.
2. Verify the following conditions:

before the SolidWorks integration wizard is launched.
Only one instance of SolidWorks software can be running in order for
4. Verify this is the correct model and click Next.
If the model is not correct, open the correct assembly in SolidWorks
software and click Refresh.

The Motion Study Setup dialog box opens.
5. From the Motion Study Name pull-down menu, choose the SolidWorks
motion study to be used for simulation.
If you need to create a new motion study, return to SolidWorks. Return to
the opening dialog box and click Refresh to register the changes.
6. Click Next.

7. Enter the number of axes you would like to study.

Motion Analyzer detects the number of SolidWorks motors present in the
chosen SolidWorks motion study.
IMPORTANT The number of Motion Analyzer axes to be studied must be less than or
equal to the number of SolidWorks motors. Also, the number of motion
profiles sent to SolidWorks software cannot exceed the number of
SolidWorks motors waiting to consume the motion profile data.
The number of SolidWorks motors defined in the SolidWorks motion

study can be changed by returning to SolidWorks software to add or delete
motors. After adding or deleting SolidWorks motors, return to the
opening window and click Refresh to register the changes.
8. Click Next.


This dialog box lets you verify the SolidWorks Motor Setup. For inter-
dependent motors, you assign Motion Analyzer motion profile data to
each SolidWorks motor during this step. The Motor Setup dialog box is
repeated for each axis of motion.
9. From the Motion Analyzer Axis pull-down menu, choose the Motion
Analyzer axis.
IMPORTANT If all axes have the same name and this causes confusion,
go to Options >Application Info to rename the axes.
10. Check Reverse Direction if you find that the load moves in the wrong
direction.
Play the animation in SolidWorks software after the motion profile has
been sent across in a future step. Return to this step using the Back button
and check this box to reverse the direction of the motion profile. If the
motion is incorrect, select the Reverse Direction checkbox to switch the
direction of motion.
11. From the SolidWorks Motor Name pull-down menu, choose the name of
the SolidWorks motor that runs in the motion profile with the chosen
Motion Analyzer axis.
The SolidWorks Moving Part pull-down menu, information only, this
states the component that the SolidWorks motor is attached to and the
motion profile will be applied to. If the component is not correct, return to
SolidWorks to attach the motor to the correct component.
12. Click Next.

The SolidWorks Summary dialog box opens.
13. Enter a value in the Frames/Second field.

This value indicates the number of frames per second the motion profile is
divided into. A large number yields fine resolution while a small number
yields coarse resolution.
14. Click Modify Selections.
Use this feature to edit a specific Motion Analyzer Axis.
a. Select an axis in the table.
b. Click Modify Selections to jump back to the SolidWorks Motor Setup
window for the selected axis.
15. Click Next.

SolidWorks software calculates the force/torque required to move the load

through the specified motion profile and the Results dialog box opens.
16. From the Results pull-down menu, choose the axis of motion you wish to
display.
17. Click the View Graph tab.
This tab displays the data in graphical format.
18. Click the View Data tab.
This tab displays the data in list format.
19. Click Export Data.
The data exports into a spreadsheet.
20. Click Apply to transfer force/torque data to Motion Analyzer software for
use in sizing a motion system.
21. Go to SolidWorks software and click Play from Start in the SolidWorks
Motion Study explorer.
View the motion profile as applied to your mechanism.

22. Verify that the mechanism is moving in the right direction; if you find that
the load moves in the wrong direction, return to step 10 by clicking Back
and check Reverse Direction.

The System View dialog box in Motion Analyzer software opens.
23. Click the Motor and Drive icons to continue the sizing process.
With these versions of SolidWorks and Motion Analyzer software, the
inertia data is not brought out automatically. This means that Motion
Analyzer has no knowledge of the inertia ratio and therefore cannot do the
Motion Analyzer Simulation on the Solution tab.

2.2. Define Your Profile There are two ways to enter your Motion Profile into Motion Analyzer software.
Begin by clicking Edit Profile in the Cycle Profile Data dialog box.
Table 74 - Motion Profile Options

This is the default mode. This mode is also accessed by clicking Less Options
Less Options Profile Editor in the More Options Profile mode. This mode lets you enter a simple profile 140
Mode which consists of an acceleration, coast/dwell, and deceleration.
This mode is accessed by clicking More Options in the Less Options Profile
More Options Profile Editor mode. This mode lets you enter more complex motion profiles by providing
you with the ability to enter data for individual profile segments, import or 142
Mode export profile data, and apply external loads to the individual profile
segments.

2.2.1. Less Options Profile Editor Mode
The Less Options Profile mode is the default mode. This mode is also accessed by
clicking Less Options when in the More Options Profile mode.
Figure 100 - Simple Index Motion Parameters
When using this mode to enter motion profile data, a trapezoidal velocity index
profile segment (see Automatic Index Type below) is the default motion profile.
This motion profile is optimized for minimal motor heating.
Table 75 - Less Options Profile Editor Properties
Move Distance Total distance for the motion profile.
Move Time Total time for the motion profile.
Dwell Time Total dwell time, if any, for the motion profile before the motion profile repeats.
From the pull-down menu, choose one of three available index types.
This is a 1/3 acceleration, 1/3 coast, 1/3 deceleration trapezoidal motion profile. This is
Automatic the default setting.
Index Type This is a motion profile where the time is spent accelerating and is spent
Triangular decelerating.
Simple Index Motion This index type lets you use sliders to adjust the velocity and time axes of the motion
Parameters Trapezoidal profile. As you mouse over a slider, the axis value is displayed.
This is used to decrease the discontinuity in the transition from a dwell to motion. From the pull-down menu, choose
one of three available smoothness options.
Smoothness Automatic 0% Jerk time (Trapezoidal)

Standard 40% Jerk time (Partial S-curve)
Maximum 100% Jerk time (Full S-curve)
IMPORTANT Smoothness is used to reduce mechanical wear and tear. Due to display limitations, the More
Options Profile Editor Mode does not show infinite jerk at points of velocity discontinuity.
Using 0% jerk time may lead to premature mechanical failure.

Table 75 - Less Options Profile Editor Properties

Reset Zoom (1) Resets the zoom to 1x.
Zoom (1) Magnifies 1x, 2x, 6x, or 8x.
(1)
Grid Select Normal, Fine or Remove Grid to change the display.
(1)
Color Adjust the background, curve and grid colors.
Segment Plot (1)
(refer to label 2 in Figure 100 Show Curve Select which curves you would like to display on the plot.
and the example in
Figure 101) Show Y Axis (1) Toggle the Y-axis labels on and off when more than one curve is shown.
This adjusts the height/velocity component of the motion profile. As you increase the value of this slider, more time is
Vertical Bar spent accelerating and decelerating the load and less time is spent dwelling at a constant velocity.
This adjusts the ratio of the time spent accelerating to the time spent decelerating for the motion profile. A negative
Horizontal Bar value on the slider indicates that more time is spent decelerating the load than accelerating it. A positive value on the
slider indicates that more time is spent accelerating the load than decelerating it.
(1) In addition to the parameters in Figure 100, these options are also available when you right-click the Segment Plot window.
Figure 101 - Segment Plot Example

2.2.2. More Options Profile Editor Mode
The More Options Profile Editor mode helps you create a variety of industry-
standard motion profiles. To access this mode, click More Options when in the
Less Options Profile mode.
Figure 102 - Profile Editor - More Options Mode
These windows are displayed by default when you open the More Options Profile
Editor Mode.
Table 76 - More Options Mode Features

Feature Description Page
Profile Toolbar This toolbar (label 1 in Figure 102) contains buttons and pull-down menus for 145
adding, moving, and removing profile segments or an entire motion profile.
Each profile segment type has an associated Segment Parameters window
(label 2 in Figure 102. As you highlight a particular profile segment in your
Segment Load Window motion profile, that segments parameter window becomes available for 147
entering data. The default profile segment type is an Index profile segment.
This window (label 3 in Figure 102) displays a plot for a single profile segment
Segment Plot Window in the motion profile. The x-axis is time, and the y-axis can be adjusted to 148
display various motion curves (for example, Distance, Velocity, or Acceleration.
This window (label 5 in Figure 102) displays the entire motion Profile Plot that
Profile Plot consists of a series of profile segments. The plot can be adjusted and analyzed 149
with the two sub-windows that accompany the plot.

In addition to the windows that are opened by default, there are several tabs along
the bottom (label 6 in Figure 102) and left side (red arrow in Figure 102) of the
More Options Profile Editor Mode that open other windows.
Table 77 - Additional More Options Mode Features

Feature Description Page
Profile Grid Lets you quickly input parameters into a table for each segment of your motion 152
profile.
Derived Parameters Displays various calculated values related to Time, Position, Speed, 153
Acceleration, and Jerk.
Comments Window Enter comments for the motion profile or for particular profile segments. 154
Error List Window Contains a list of errors as they occur. 155
Segment Parameters Enter load values for individual profile segments or for the entire motion 167
Window profile.
In these windows, you can click the thumb-tack icon to toggle between Fixed
mode and Auto-hide mode. In Fixed mode, the window is held in place and in
Auto-hide mode, the window is displayed when you hover over the window tab.
The window reverts back to a tab when the mouse pointer is moved off of the
window.
When you have completed your motion profile and have entered the relevant
parameters, you can export the data from the More Options Profile Editor Mode
to external programs. Prior to exporting the data, make sure that the master and
slave units are properly designated. From the Settings menu, choose Custom
Units to change these.
Table 78 - Export Options (refer to Figure 102)

Feature Description
With this option you can export the motion profile data to RSLogix 5000 software as a fixed
Logix CAM Profile Editor cam profile. When using this export option, you must choose whether to export the data as
a Motion Axis Time Cam (MATC) or a Motion Axis Position Cam (MAPC) profile.
With this option you can export the motion profile data as a rung of RSLogix 5000 code that
Logix Ladder Add-On dynamically builds the cam at run time. When using this export option, you choose
Instructions whether to export the data as a Motion Axis Time Cam (MATC) or a Motion Axis Position
Cam (MAPC) profile. This type of instruction lets you adjust portions of the motion profile.
SolidWorks Motion With this option you can export the motion profile data that SolidWorks uses for its
Study Move Profile animations.
With this option you can export the motion profile data to the clipboard or to a specified file
User Defined type.

You also have the option to import motion profile data from external programs.
The following import options are available.
Table 79 - Import Options (refer to Figure 102)

Feature Feature Description
This option lets you import motion profiles created in the RSLogix 5000 Cam Editor. A Logix
Elements type profile segment is created and populated. You have four import options
available for this type of import.
The imported motion profile is placed before the profile segment
Before Selected Seg you selected in More Options Profile Editor Mode.
Logix CAM Profile Editor The imported motion profile is placed after the profile segment
After Selected Seg you selected in More Options Profile Editor Mode.
The imported motion profile replaces the profile segment you
Replace Selected Seg selected in More Options Profile Editor Mode.
The imported motion profile replaces the entire profile in More
Replace Profile Options Profile Editor Mode.
Logix Ladder Add-On This option lets you import motion profiles created as RSLogix 5000 Ladder Add-On
Instructions Instructions.
User Defined This option lets you import a motion profile directly from a program of your choice.

2.2.2.1. Profile Toolbar
The Profile toolbar contains buttons and pull-down menus for adding, moving,
and removing profile segments or an entire motion profile.
Figure 103 - Profile Toolbar Features
Table 80 - Profile Toolbar Features (label 1 in Figure 103)

Feature Description
Use the Segment Selector arrows (red box in Figure 103) to navigate through the various
segments in your motion profile. As you navigate to a profile segment, the associated
Segment Selector Segment Parameters Window and Segment Plot Window are displayed. The Zero profile
segment is the start condition.
Lets you copy a motion profile from another axis in your Motion Analyzer project. It also lets
Profile you go to the More Options Profile Editor Mode for another axis in your Motion Analyzer
project.
Opens the Segment Parameters window and the Segment Plot window for the start
Start Condition condition.
Lets you add profile segments to the end of your motion profile. Also, refer to the Segment
Add Parameters section for information about the various profile segments that are available in
the More Options Profile Editor Mode.

Figure 104 - Add Feature Pull-down Menu
Table 81 - Add Feature Properties (refer to Figure 104)

Feature Description
Edit Lets you change the selected profile segment to another segment type.
Deletes the selected profile segment. You can also click the drop-down arrow and select the
Delete Delete All option to delete all of the segments in your motion profile.
Lets you remove the selected profile segment in order to place it in another location in the
Cut motion profile.
Lets you create a copy of the selected profile segment in order to replicate the segment in
Copy another location in the motion profile.
Paste Lets you replace the selected profile segment with a cut or copied profile segment.
Invert Lets you invert an index profile segment about the x-axis.

2.2.2.2. Segment Load Window
Each profile segment type has an associated Segment Parameters window (label 2
in Figure 102. As you highlight a particular profile segment in your motion
profile, that segments parameter window becomes available for entering data.
The default profile segment type is an Index profile segment.
Figure 105 - Segment Load Properties
Table 82 - Segment Load Properties

Lets you apply the current profile segment load parameters to all existing profile segments.
The load values are not applied to any profile segments that are added after you apply this
Apply All Segments feature. However, you can return to this window and click Apply All Segments again to
apply the load values to new profile segments.
External Force This is the external force that exists for the selected profile segment.
Payload Mass This is the payload mass that exists for the selected profile segment.
These Load Mass Offsets generate moments that are used in the calculation of Life for
Bulletin MPAS stages. Moments are generated when the Load Mass is off-line with the
actuator. They arise as a consequence of forces generated by acceleration or deceleration of
the load mass and gravity acting on the load mass being multiplied by the offset distance.
Mass X, Y & Z - Offset The offsets and moments are resolved into the three cartesian coordinates.
The load can be divided into either a fixed load or a load that changes by segment
throughout the profile. Motion Analyzer software analyzes the sum of the fixed loads and
moments (entered in Mechanism Type on page 178) and segment wise loads and moments
generated by these offsets.
Starts a simple animation that demonstrates a pick-and-place machine where a heavy load
Payload Animation
is picked up and moved forward. The return stroke has no load. Refer to Figure 106.
Figure 106 - Payload Animation Example

2.2.2.3. Segment Plot Window
The Segment Plot window displays a plot for a single profile segment in the
motion profile. The x-axis is time, and the y-axis can be adjusted to display
various motion curves (for example, Distance, Velocity, or Acceleration).
Figure 107 - Profile Editor - Segment Plot Window
Right-click the Segment Plot window to display the properties.
Figure 108 - Segment Plot Properties (label 3 in Figure 107)
Table 83 - Segment Plot Properties (refer to Figure 108)

Reset Zoom Resets the zoom to 1x.
Zoom Lets you zoom in 1x, 2x, 6x or 8x.
Grid Select Normal, Fine or Remove grid.
Color Adjust the background, curve, and grid colors.
Show Curve Select which curves you would like to display on the plot.
Show Y Axis Toggle the Y-axis labels on and off when more than one curve is shown.

2.2.2.4. Profile Plot
The Profile Plot window lets you view the entire motion profile and quickly
navigate to specific segments within the profile.
Figure 109 - Profile Editor - Main Profile Plot
Right-click the Main Profile Plot window to display the properties.
Figure 110 - Main Profile Plot Properties (label 4 in Figure 109)

Table 84 - Main Profile Plot Properties (refer to Figure 110)

Create a copy of the selected profile segment to reuse in another location in the motion
Copy profile.
Cut Remove the selected profile segment to use in another location in the motion profile.
Paste Replace the selected profile segment with a cut or copied profile segment.
Deletes the selected profile segment. Also, from the pull-down menu, you can choose the
Delete Delete All option to delete all of the profile segments in the Profile Plot window.
Reset Zoom Resets the zoom to 1x magnification.
Zoom Zoom in 1x, 2x, 6x or 8x magnification.
Show Segment Select whether or not you would like to highlight the selected profile segment within the
Selection Profile Plot window.
Grid Select Normal, Fine, or Remove grid.
Show Curve Select which curves you would like to display on the plot (for example, Distance or Velocity).
Show Y Axis Toggle the Y-axis labels on and off when more than one curve is shown.
The Plot Parameters sub-window appears to the left of the Main Profile Plot
window. Click the arrows, left of the Main Profile Plot window, to open it. Click
the arrows again to close the window.
Clicking the motion curves (for example, Distance or Velocity) toggles them on
and off. From the motion curve pull-down menu, you can change the color for
the curve in both the Main Profile Plot window and the Segment Plot window.
Figure 111 - Plot Parameters
In addition, as you hover over the Main Profile Plot window with the mouse
pointer, the Plot Parameters sub-window provides a display of the numeric values
of the time (x-axis), and active motion curves (y-axis) associated with the mouse
pointer position.

Figure 112 - Main Profile Plot X and Y-axis Values
The Profile Zoom Plot sub-window appears below the Main Profile Plot window.
Click the arrows, below the Main Profile Plot window, to open it. Click the
arrows again to close the window.
The Profile Zoom Plot window contains a slider (refer to the red box in
Figure 113) that you can move along the motion profile by clicking and dragging
it. As the slider moves, the Main Profile Plot window displays a magnified view of
the portion of the plot that is selected by the slider. You can resize the slider by
clicking and dragging from either edge.
Figure 113 - Profile Zoom Plot Window
Right-click the Profile Zoom Plot sub-window to display these options.
Figure 114 - Profile Zoom Plot Options
Table 85 - Profile Zoom Plot Options


2.2.2.5. Profile Grid
Click Profile Grid (label 5 in Figure 115) to use a table to input parameters for
each segment of your motion profile.
Figure 115 - Profile Grid Window
If you click a row in the Profile Grid window, the Segment Parameter window
and the plot for that profile segment are opened at the top of the More Options
Profile Editor Mode dialog box.
You have the option to enter the parameters in the Segment Parameters window
or the Profile Grid. Refer to Segment Parameters on page 167 for detailed
descriptions of the parameters. The parameter values are automatically shared
between the two windows.
As you enter the profile segment parameters,

calculated Peak Acceleration and Peak
Deceleration values are displayed for reference in
the Profile Grid window.
Click Table Setup in the

Profile Grid window to
adjust column width
preferences.

2.2.2.6. Derived Parameters
Click Derived Parameters (label 5 in Figure 116) to display various calculated

values related to Time, Position, Speed, Acceleration, and Jerk for the highlighted
profile segment. Refer to the Segment Parameters windows on page 167 to adjust
these values.
Figure 116 - Derived Parameters

2.2.2.7. Comments Window
Click Comments (label 5 in Figure 117) to enter notes about the overall motion
profile in the Profile Comments window. For specific profile segments in the last
comment of the table labeled Segment Comments. Highlight the row for a
particular profile segment and the segment plot is displayed at the top of the
More Options Profile Editor Mode dialog box.
Figure 117 - Profile Editor - Comments Window

2.2.2.8. Error List Window
Click Error List (label 5 in Figure 118) to display errors in the Error List window.
Errors are listed as they occur.
Figure 118 - Error List Window
An example of a common error is a negative value for time in Absolute mode.
Figure 119 - Error List Example

2.2.2.9. Profile Export
When you have completed your motion profile and have entered the relevant
parameters, you can export the data from the More Options Profile Editor Mode
to external programs. Prior to exporting the data, make sure that the master and
slave units are properly designated. From the menu bar go to Settings>Custom
Units to change these.
The Profile Export wizard is designed to help you successfully export your
profile.
1. From the Profile Editor dialog box, click Export.

The Profile Export Wizard dialog box opens.
2. Click Next.
The Types of Exports dialog box opens.

Table 86 - Type of Export Options

With this option you can export the motion profile data to RSLogix 5000
Logix CAM Profile software as a fixed cam profile. When using this export option, you choose 157
Editor whether to export the data as a Motion Axis Time Cam (MATC) or a Motion Axis
Position Cam (MAPC).
With this option you can export the motion profile data as a rung of RSLogix
5000 code that dynamically builds the cam at run time. When using this export
Logix Ladder Add-On option, you choose whether to export the data as a Motion Axis Time Cam 161
Instructions (MATC) or a Motion Axis Position Cam (MAPC). This type of instruction lets you
adjust portions of the motion profile.
SolidWorks Motion With this option you can export the motion profile data that SolidWorks 165
Study Move Profile software uses for its animations.
With this option you can export the motion profile data to the clipboard or to a
User Defined 166
specified file type.
2.2.2.9.1. Logix CAM Profile Editor
1. On the Types of Exports dialog box, select Logix CAM Profile Editor.
2. Click Next.
The CAM Set-up dialog box opens.
3. Select whether your CAM in RSLogix 5000 software is time or position

based.
In this example, an MATC export was selected.
4. Click Next.

The Export Options - Logix CAM dialog box opens and a preview of the
data for export is displayed.
5. Click Next.
The Target Location for Export dialog box opens.
6. Select how you would like to store the data.
Table 87 - Target Location Options

The clipboard stores the data until you copy something else and it is useful if you are going to
Clipboard paste the data into RSLogix 5000 software immediately.
File Save the data to a file location if you wish to email the file or save it for future use.
7. Click Next.

The Profile Export Successful dialog box opens.
TIP If the Start and End Slope values are non-zero in your application,
enter them into the Cam Editor manually.
8. Click Finish.
9. Open your RSLogix 5000 software application program to your MATC
instruction.
10. Click the Cam Profile ellipse

The Cam Editor dialog box opens.
11. Right-click the first row entry arrow and from the window choose Paste.
Your move data appears in the Cam Editor dialog box.
TIP Click the magnifier icon to adjust the zoom.
12. Click OK.

2.2.2.9.2. Logix Ladder Add-On Instructions
To use this function it is necessary to have the following suite of cam-building

Add-On Instructions installed with your RSLogix 5000 project:
Table 88 - CAM-building Add-On Instructions

File Name Description
AOI_CG_00_Import_then_delete_this.L5X
Add-On Instructions files
AOI_CG_00_Controller_Tags.CSV
AOI_CG_00_Cam Generator Setup.doc Installation instructions
Cam_Generator_V2_1_Example.ACD Generic (blank) project file
1. On the Types of Exports dialog box, select Logix CAM Profile Editor.
2. Click Next.
The CAM Set-up dialog box opens.
3. Select whether your CAM in RSLogix 5000 software is time or position

based.
In this example, an MATC export was selected.
4. Click Next.

The Export Options - Logix Ladder dialog box opens.
5. Click Next.
The Target Location for Export dialog box opens.
6. Select how you would like to store the data.
Table 89 - Target Location Options

The clipboard stores the data until you copy something else and it is useful if you are going to
Clipboard paste the data into RSLogix 5000 software immediately.
File Save the data to a file location if you wish to email the file or save it for future use.
7. Click Next.

The Profile Export Successful dialog box opens.
TIP If the Start and End Slope values are non-zero in your application,
enter them into the Cam Editor manually.
8. Click Finish.
9. Open your RSLogix 5000 software application program and paste the data
into an empty rung.
IMPORTANT Make sure the entry type is In Neutral Text.

The Add-On Instruction appears on the rung. In this example, the

Add-On Instruction is a simple index move.

2.2.2.9.3. SolidWorks Motion Study Move Profile
1. On the Types of Exports dialog box, select SolidWorks Motion Study

Move Profile.
This is not the preferred workflow. A direct link using API calls has been
developed and is described in From SolidWorks on page 120.
2. Click Next.
The Export Options - SolidWorks dialog box opens.
3. Define the number of segments you would like to export the data in.
For example, a 2 second motion profile would be broken into 50 frames/
second if 100 segments are defined.
4. Click Next.
A preview of the data and success dialog box is displayed, similar to the
workflow in Logix CAM Profile Editor beginning on page 157.

2.2.2.9.4. User Defined
1. On the Types of Exports dialog box, select User Defined.

2. Click Next.
The Export Options - User Defined dialog box opens.
3. Select the unit options.

You can export data in your application units or in SI units. In this
example, application units are chosen.
4. From the pull-down menu, choose the delimiter.
In this example, TAB was chosen. TAB delimited is a standard format for
Microsoft Excel software.
5. Click Next.
A preview of the data and success dialog box is displayed, similar to the
workflow in Logix CAM Profile Editor beginning on page 157.

2.2.2.10. Segment Parameters Window
Each profile segment type has a different associated Segment Parameters window.
The default profile segment type is an Index profile segment (label 2 in
Figure 120).
Figure 120 - Segment Parameters
The following basic profile segments are available in the More Options Profile
Editor Mode dialog box.
Table 90 - Basic Profile Segment Options

Start Condition Sets the start conditions for your motion profile. The start condition is the initial time, 168
position, and velocity of the motion profile.
Accel/Decel Where you enter parameters for an Acceleration or Deceleration profile segment. 168
Where you enter parameters for a Cruise or Dwell profile segment. The profile
Cruise/Dwell segment is considered a cruise if the velocity at the end of the previous profile 170
segment is non-zero and is considered a dwell if that velocity is zero.
Index Where you enter parameters for an Index profile segment. An Index profile segment 171
consists of an acceleration, a cruise, and a deceleration.
In addition to the basic profile segments, the following advanced profile segments
are available in the More Options Profile Editor Mode dialog box.
Table 91 - Advanced Profile Segment Options

Index Advance Selects more advanced velocity, acceleration, and jerk profiles for an Index profile 173
segment.
Logix Element Contains parameters that you can easily import or export into RSLogix 5000 software. 174
Motion Axis Where you enter parameters for a Motion Axis Move command. The parameters are 176
Move (MAM) easily exported into a MAM instruction in RSLogix 5000 software.

2.2.2.10.1. Start Condition
Start Condition (refer to Figure 120) sets the start conditions for your motion
profile. The start condition is the initial time, position, and velocity of the
motion profile.
Figure 121 - Start Condition Dialog Box
Enter the following parameters for the Start Condition, if relevant.
Table 92 - Start Condition Properties

Time The initial time that the motion profile begins.
Position The initial position that the motion profile begins.
Velocity The initial velocity that the motion profile begins.
2.2.2.10.2. Accel/Decel
Where you enter parameters for an acceleration or deceleration profile segment

(refer to Figure 120).
Figure 122 - Acceleration/Deceleration Dialog Box

Enter the following parameters for Acceleration/Deceleration, if relevant.
Table 93 - Acceleration/Deceleration Properties

Segment Name Enter a meaningful name for the profile segment.
Select an option for entering the profile segment parameters based on two data types
Data Entry Permutation (for example, Time and Distance or Time and Velocity).
Select whether to input Incremental or Absolute parameter values. Incremental values
represent the change in either the distance or time that occurs during the profile
Increment/Absolute segment. Absolute values represent the total distance or time elapsed throughout the
entire motion profile.
Enter the parameter values for the two data types selected from the Data Entry
Parameter Entry Permutation pull-down menu, located below the Increment and Absolute buttons.
This value sets the amount of S-curve of the Acceleration/Deceleration profile segment.
Increasing the percent jerk increases the amount of S-curve. You can manually enter a
Jerk - Percentage value or adjust the value with the slider in the pull-down menu or the slider along the
right side of the Segment Plot window (refer to Figure 123).
Changing the skew of jerk alters the time in the Acceleration/Deceleration profile
segment at which the S-curve occurs. You can manually enter a value or adjust the value
Jerk - Skew with the slider in the pull-down menu or the slider along the right side of the Segment
Plot window (refer to Figure 123).
IMPORTANT Due to display limitations, the More Options Profile Editor Mode dialog box
does not show infinite jerk at points of velocity discontinuity. Using 0% jerk
may lead to premature mechanical failure.
Figure 123 - Segment Plot Window

2.2.2.10.3. Cruise/Dwell
The profile segment is considered a cruise if the velocity at the end of the
previous profile segment is non-zero and is considered a dwell if that velocity is
zero.
Figure 124 - Cruise/Dwell Dialog Box
Enter the following parameters for a Cruise/Dwell profile segment, if relevant.
Table 94 - Cruise/Dwell Properties

This is the velocity of the profile segment. This value is non-zero for cruise and zero for
Velocity dwell.
represent the change in either the distance or time that occurs during the profile segment.
Increment/Absolute Absolute values represent the total distance or time elapsed throughout the entire motion
profile.
Select and enter either the Distance or Time parameter to define your Cruise/Dwell profile
Distance/Time segment.

2.2.2.10.4. Index
An Index profile segment consists of an acceleration, a cruise, and a deceleration.
Figure 125 - Index Motion Parameters Dialog Box
Enter the following parameters for a Index profile segment, if relevant.
Table 95 - Index Properties

profile.
Distance/Time Enter either the Distance or Time parameter to define your Cruise/Dwell profile segment.
From the pull-down menu, choose one of the three available index types.
1/3 acceleration, 1/3 coast, and 1/3 deceleration trapezoidal motion profile. This
Automatic is the default setting.
Triangular acceleration and deceleration motion profile.
This index type lets you use sliders to adjust the velocity and time axes of the
motion profile.
Index Type
Vertical Bar: Adjusts the height/velocity component of the motion profile. As
you increase the value of this slider, more time is spent accelerating and
Trapezoidal decelerating the load and less time is spent dwelling at a constant velocity.
Horizontal Bar: Adjusts the ratio of the time spent accelerating to the time
spent decelerating for the profile segment. A negative value on the slider
indicates that more time is spent decelerating the load than accelerating it. A
positive value on the slider indicates that more time is spent accelerating the
load than decelerating it.

Figure 126 - Trapezoidal Profile
Used to decrease the discontinuity in the transition from a dwell to motion. Select the
smoothness from the pull-down menu. Three smoothness options are available.
Smoothness Automatic 0% Jerk (Trapezoidal)

Standard 40% Jerk (Partial S-curve)
Maximum 100% Jerk (Full S-curve)
The percent of time for Acceleration/Deceleration Jerk increases the peak acceleration (and
therefore current) above that of a trapezoidal motion profile. The following values illustrate
the effect of Acceleration/Deceleration Jerk on current. The acceleration of a trapezoidal
motion profile is taken to be 100%.
Accel/Decel Jerk
0% Jerk 100% acceleration and current (Linear or Trapezoidal).
18% Jerk 110% acceleration and current.
100% Jerk 200% acceleration and current (S-curve).
Apply +ve/-ve When you enter the Positive or Negative Velocity Limit for the profile, Motion Analyzer adjusts
Velocity Limit the acceleration and deceleration times required to reach the desired velocity limits.
IMPORTANT Smoothness is used to reduce mechanical wear and tear. Due to display
limitations, the More Options Profile Editor Mode dialog box does not show
infinite jerk at points of velocity discontinuity. Using 0% Jerk time may lead to
premature mechanical failure.

2.2.2.10.5. Index Advance
Index Advance selects more advanced velocity, acceleration, and jerk profiles for
an Index profile segment.
Figure 127 - Index Advance Parameters Dialog Box
Enter the following parameters for a Index Advance profile segment, if relevant.
Table 96 - Index Advance Properties

Index SHM Harmonic Motion.
Index 3 4 5 Poly Fifth order polynomial.
Index Mod Sine Modified Sine wave.
Index 2 3 Poly Third order polynomial.
Advance Index Type
Index 4 5 6 7 Poly Seventh order polynomial.
Index Adjusted Sine Industry standard cam profile.
Index Modified Industry standard cam profile.
Trapezoidal
profile.
Distance Distance for the Index profile segment.
Time Time for the Index profile segment.
No. of Elements Number of Elements for the profile segment.

2.2.2.10.6. Logix Element
Use this dialog box to import or export Logix elements into RSLogix 5000
software.
Figure 128 - Logix Element Dialog Box
The Logix Element Motion Parameter table is essentially the same as the
RSLogix 5000 cam editor. These profile segments can be mixed with any other
types available in the More Options Profile Editor Mode dialog box, thus a small
section of non-linear motion profile (for example, a cosine compensation profile
segment) can be created in a spreadsheet and combined with a simple index
profile segment.
It is important to distinguish between the terms segment and element.

Term Definition
Element Term used for each row of the RSLogix 5000 cam editor. These are indivisible or raw elements.
Term used for all the profile pieces available in More Options Profile Editor Mode. Each of these
Segment
typically create one or many elements when exported to RSLogix 5000 software.

Enter the following parameters for a Logix Element profile segment, if relevant.
Table 97 - Logix Element Properties

This is directly equivalent to the Master column in RSLogix 5000 software. These values can be
Master entered only as Master and Slave Custom Units. From the Settings menu, choose Custom Units
to change these.
This is directly equivalent to the Slave column in RSLogix 5000 software. These values can be
Slave entered only as Master and Slave Custom Units. From the Settings menu, choose Custom Units
to change these.
Only the final row allows a value to be entered directly and then only if the corresponding
Slope element is cubic.
This is equivalent to the Type column in RSLogix 5000 software except that the Cubic/Linear
Type format is applied to the element defined by the current line and the previous line. While in
RSLogix 5000 software it is applied to the element defined by the current line and the next line.
The first row (row zero in RSLogix 5000 software) displays the start conditions.
These cannot be entered directly, but are defined either by the end conditions of
the previous profile segment or, if this is the first segment in the motion profile,
by the Start Condition on page 168.
Each subsequent row completely defines the respective element.
Table 98 - Logix Element Properties

This button places the data onto the clipboard in order to be pasted into the
RSLogix 5000 cam editor. In the cam editor, click the * to highlight the first row
Export to Logix Editor then right-click in the box and choose paste to paste the Logix Element. The start
and end slopes must be entered manually in RSLogix 5000 software.
Logix Element The start and end slopes must be entered manually in RSLogix 5000 software.
This button pastes data from the clipboard that was copied from the RSLogix 5000
Import from Logix Editor cam editor. In the cam editor, click the [] column and drag down to highlight all
rows containing data. Then press Ctrl + c to copy the element. The Start and End
Slopes must be entered manually.

2.2.2.10.7. Motion Axis Move (MAM)
This window lets you enter data as if for a Motion Axis Move (MAM)
instruction. For detailed information regarding a MAM, refer to the
RSLogix 5000 software help files.
Figure 129 - MAM Dialog Box
Enter the following parameters for a MAM profile segment, if relevant.
Table 99 - MAM Instruction Properties

Select the required position units in the pull-down menu above the MAM profile segment.
Position Units From the Settings menu, choose Custom Units to change these.
Axis This is the Axis name for the RSLogix 5000 MAM instruction.
Motion Control This is the control tag for the instruction.
Select either 0 or 1 from the pull-down menu. The profile segment is inverted when this option
Move Type is changed.
Position This is the final position after the Motion Axis Move profile segment.
Speed This is the final velocity after the Motion Axis Move profile segment.
These units cannot be adjusted here. To change the units, choose an option from the Position
Speed Units Units pull-down menu at the top of the MAM Segment Parameters window.
This places the information onto the clipboard. Clicking on a rung of an RSLogix 5000 project
Export MAM creates a MAM instruction with this data already filled in; only the Axis and a unique instruction
tag need to be created.

Click More and enter the following parameters for a MAM profile segment, if
relevant.
Table 100 - More MAM Instruction Properties

Accel Rate This is the acceleration rate for the MAM profile segment.
Accel Units Units pull-down menu at the top of the MAM Segment Parameters window.
Decel Rate This is the deceleration rate for the MAM profile segment.
Decel Units Units pull-down menu at the top of the MAM Segment Parameters window.
Profile From the pull-down menu, choose Trapezoidal or S-curve.
Accel Jerk This is the jerk for the acceleration of the MAM profile segment.
Decel Jerk This is the jerk for the deceleration of the MAM profile segment.
Jerk Units Units pull-down menu at the top of the MAM Segment Parameters window.
From the pull-down menu, choose Enabled or Disabled. Refer to the RSLogix 5000 help files for
Merge more information.
From the pull-down menu, choose Current or Programmed. Refer to the RSLogix 5000 help files
Merge Units for more information.

2.3. Specify Your Linear Load A linear load mechanism is used to convert rotary motor torque to linear motion
through a transmission (belt drive, lead screw, chain and sprocket, or rack and
Mechanism pinion), where thrust from a linear motor, electric cylinder, or linear stage
produces linear motion directly.
Figure 130 - Mechanism Type
The following mechanisms are available in Motion Analyzer software.
Table 101 - Mechanism Types

Type Description Page
Belt Drive A rotary motor coupled to a timing pulley that drives a flexible toothed belt, 180
with its coupled load, back and forth between two idler pulley guides.
A lead screw is coupled to a rotary motor and causes relative linear motion
Lead Screw 181
between a rotating screw and its non-rotating nut.
A chain and sprocket is a rotary motor coupled to a sprocket wheel that drives a
Chain and Sprocket linked chain, with its coupled load, back and forth between idler sprocket 182
guides.
Rack and Pinion A rack and pinion is a rotary motor coupled to a toothed pinion wheel that 183
engages a toothed rack to create relative motion between the two elements.
Linear motors are either iron-core and ironless motors that directly create
linear thrust. Their separate sections (coil and magnet channel) produce
Linear Motor 184
relative motion between a carriage and its base along the user-supplied linear
bearing guides.

In addition to the many linear mechanisms in Table 101, a few fully-integrated

linear mechanisms, listed in Table 104, are also included.
Figure 131 - Integrated Linear Mechanisms
Table 102 - Additional Mechanism Types

Linear Options Description Page
These electric cylinders provide flexible, digital servo control of a rod actuator
(linear control of force/clamping or position). They provide an
electromechanical system for applying digital servo control with a familiar
Electric Cylinders fluid power format. The cylinders are integrated into machines with the same 186
fluid power application principals, mounting methods (trunnion mounts, rear
clevis attachment kits, and front flanges, for example.) and rod-end
attachments for connected loads (rod eye and rod clevis, for example).
A linear stage is used to restrict the load to a single axis of motion. It contains
Linear Stages all the elements required to produce linear motion: base and carriage; drive 187
(linear motor or lead screw); linear bearings; and position feedback.
Linear Thrusters A linear thruster is used to provide a completely integrated linear motor-driven 189
system.

2.3.1. Belt Drive
A belt drive is a rotary motor coupled to a timing pulley that drives a flexible
toothed belt, with its coupled load, back and forth between two idler pulley
guides.
Figure 132 - Mechanism Type - Belt Drive
Enter the following parameters for belt drive mechanisms, if relevant.
Table 103 - Belt Drive Properties

Mechanism Type From the pull-down menu, choose the mechanism type.
Mechanism Data The load, stroke, speed, and acceleration values are calculated based on the parameters
(label 1 in Figure 132) entered in the previous Load and Profile tabs and displayed here for reference.
The diameter of the drive shaft and idler shafts that make contact with
Diameter the belt.
Inertia (2) The inertia of the driver and idler groups.
Belt Drive and Application (1)
(label 2 in Figure 132) Friction Torque loss due to friction at the driver or idler shaft. You can obtain this
Torque value from the supplier or Engineering tables.
No. of The number of rollers for each idler group.
Rollers
Table The mass of the linear load table. This mass is affected by gravity if the
Mass inclination in the Load Type Tab on page 82 is non-zero.
Additional Loads
(label 3 in Figure 132) Belt Mass The mass of the belt. This mass is not affected by gravity.
The total torque loss due to friction at the driver and the idler groups is
Losses calculated and displayed here.
(1) The Driver is the shaft that is driven by the motor through optional gearbox and transmission stages. The Idlers are the rotary
elements driven by the belt. You may enter data for up to three Idler Groups. Check the corresponding box to add a second or third
group of idlers. A graphic is displayed to help visualize the orientation of the additional idler groups and rollers.

2.3.2. Lead Screw
A lead screw is coupled to a rotary motor and causes relative linear motion
between a rotating screw and its non-rotating nut.
Figure 133 - Mechanism Type - Lead Screw
Enter the following parameters for lead screw mechanisms, if relevant.
Table 104 - Lead Screw Properties

Mechanism Data The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered
(label 1 in Figure 133) in the previous Load and Profile tabs and displayed here for reference.
The distance that the slide moves per one full rotation of the screw shaft. Pitch is
Lead sometimes used loosely to describe this parameter. Pitch is actually the distance
between adjacent threads and is equal to lead only for single start threads.
The inertia of the lead screw in the event that the lead screw rotates and the nut
Inertia (1) is stationary. Enter the inertia of the nut when the lead screw is stationary and
the nut rotates.
Lead Screw Parameters
(label 2 in Figure 133) The friction torque produced by pre-loading the two nuts of a ball screw against
each other. This is done to reduce backlash and increase stiffness in the system.
Pre Load Seal friction should be included in this value. This value can be obtained from the
manufacturers data and is normally quoted in data sheets.
The efficiency of the lead screw. This value is available from the manufacturer.
Efficiency Plain Acme screw = typically 4060%
Precision screw (with rolling elements) = typically 85 90%
Additional Load The mass of the slide that travels along the lead screw. This mass is affected by
(label 3 in Figure 133) Slide Mass gravity if the inclination in the Load Type Tab on page 82 is non-zero.

2.3.3. Chain and Sprocket
A chain and sprocket is a rotary motor coupled to a sprocket wheel that drives a
linked chain, with its coupled load, back and forth between idler sprocket guides.
Figure 134 - Chain and Sprocket Dialog Box
Enter the following parameters for chain and sprocket mechanisms, if relevant.
Table 105 - Chain and Sprocket Properties

Mechanism Data The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters
Pitch Circle Diameter. This can be calculated by multiplying the link pitch
PCD by the number of teeth on the sprocket and dividing by pi.
Chain and Sprocket Inertia (1) The inertia of the driver and idler groups.
Application Friction The torque loss due to friction at the driver or idler shaft. This value can be
(label 2 in Figure 134) Torque obtained from the supplier or Engineering tables.
No. of The number of sprockets for each idler group.
Sprockets
The mass of the linear load table. This mass is affected by gravity if the
Table Mass inclination in the Load Type Tab on page 82 is non-zero.
Additional Loads
(label 3 in Figure 134) Chain Mass The mass of the chain. This mass is not affected by gravity.
The total torque loss due to friction at the driver and the idler groups is
Losses calculated and displayed here.
available.

2.3.4. Rack and Pinion
A rack and pinion is a rotary motor coupled to a toothed pinion wheel that
engages a toothed rack to create relative motion between the two elements.
Figure 135 - Rack and Pinion Dialog Box
Enter the following parameters for rack and pinion mechanisms, if relevant.
Table 106 - Rack and Pinion Properties

Pinion Pitch Circle Diameter. The pitch circle diameter value can be
obtained from standard catalogue data. The value can also be calculated
Pinion PCD by multiplying the tooth pitch by the number of teeth on the sprocket and
Pinion Application dividing by pi.
Inertia (1) The inertia of the pinion.
Friction The torque loss due to friction at the pinion shaft. This value can be
Torque obtained from the supplier or Engineering tables.
Additional Loads Table Mass The mass of the linear load table. This mass is affected by gravity if the
(label 3 in Figure 135) inclination in the Load Type Tab on page 82 is non-zero.
available.

2.3.5. Linear Motor
Linear motors are either iron-core and ironless motors that directly create linear
thrust. Their separate sections (coil and magnet channel) produce relative
motion between a carriage and its base along the user-supplied linear bearing
guides.
Figure 136 - Linear Motor Dialog Box

Enter the following parameters for linear motor mechanisms, if relevant.
Table 107 - Linear Motor Properties

Mechanism Data The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered in the previous Load and
(label 1 in Figure 136) Profile tabs and displayed here for reference.
Relative motion between the two motor elements is directed horizontally.
Horizontal
Relative motion between the two motor elements is directed vertically.

Orientation Vertical
Relative motion between the two motor elements is directed at this angle relative to
the horizontal plane.
Custom
Due to its non-cogging and low magnetic attraction characteristics, direct-drive ironless linear motors are
Ironless typically used for lighter duty bearings, smooth motion, and/or high precision applications.
At slightly lower cost relative to the Ironless configuration (one row of magnets versus two with ironless),
Iron Core these high magnetic attraction motors are typically used with heavy-duty bearings to produce high
Configuration dynamic thrust performance.
(label 3 in Figure 136) The additional length of travel at each end of the motion profile to allow for user-defined machine
movements outside of the motion profile (for example, setup of a mechanism or tool change spacing). It
Overtravel Length also provides room for the motor to stop if it accidentally exceeds the nominal travel envelope. Switches
(physical or software) detect this and the drive performs a controlled stop. Click the Axis Stop tab to
determine the minimum stopping distance required. The value is added to both ends of the calculated
motion profile travel to make sure the proper length motor is specified and selected for the application.
User input that specifies the mass of the moving carriage, including its support bearing pucks. This mass
Carriage Mass should not include the mass of the moving motor elements.
The constant mass of the moving parts of the load. This value does not include profile loads that are
Payload Mass entered in the Load Type Tab on page 82.
This represents any linear force that the motor must overcome (both during motion and while at rest). It
External Force does not include frictional loads that are calculated elsewhere.
Load and Application From the Heat Sink Type pull-down menu, choose a heat sink type. The heat sink affects the motor
(label 4 in Figure 136) Heat Sink Type thermal continuous operation ratings.
Bearing Friction The friction coefficient between the linear moving parts and the fixed parts of the system. You can edit
Coefficient this value in the Load Type Tab on page 82.
Counter Balance From the Counter Balance Type pull-down menu, choose a Counterbalance Type (refer to page 84).
Type
Counter Balance The mass of the Counterbalance (refer to page 85).

2.3.6. Electric Cylinders
The MP-Series and TL-Series electric cylinders provide flexible, digital, servo
control of a rod actuator (linear control of force/clamping or position). They
provide an electromechanical system for applying digital servo control with a
familiar fluid power format. The cylinders are integrated into machines with the
same fluid power application principals, mounting methods (for example,
trunnion mounts, rear clevis attachment kits, front flanges) and rod end
attachments for connected loads (for example, rod eye and clevis).
Figure 137 - Electric Cylinders Dialog Box
Enter the following parameters for electric cylinder mechanisms, if relevant.
Table 108 - Electric Cylinder Properties

(label 1 in Figure 137) entered previously in the Load Type Tab and Profile Tab, and displayed here for reference.
This accessory is used when the cylinder shaft is exposed to moment (Mx,
Rod Guide My, Mz) and/or lateral side loading (Fy, Fz).
This is the additional length of travel at each end of the motion profile to
allow for user-defined machine movements outside of the motion profile
(for example, setup of a mechanism or tool change spacing). It also
Electric Cylinder allows room for the motor to stop if it accidentally exceeds the nominal
(label 2 in Figure 137) travel. Switches (physical or software) detect this and the drive performs
Overtravel a controlled stop. Once you have entered your motor and drive
Length requirements, and have searched for possible solutions for your system,
click the Axis Stop tab to determine the minimum stopping distance
required. This is added to both ends of the calculated motion profile travel
to make sure the proper length electric cylinder is specified and selected
for the application.

2.3.7. Linear Stages
The MP-Series integrated linear stage actuators are used to restrict the load to a
single axis of motion. They contain all of the elements required to produce linear
motion: base and carriage; drive (linear motor or lead screw); linear bearings; and
position feedback.
Figure 138 - Linear Stage Dialog Box

Enter the following parameters for linear motor mechanisms, if relevant.
Table 109 - Linear Motor Properties

Mechanism Data The Load, Stroke, Speed, and Acceleration values are calculated based on the parameters entered in the previous Load and Profile
(label 1 in Figure 138) tabs and displayed here for reference.
The actuator lies flat on a table.
Horizontal Table
Mount
The actuator moves up and down on a vertical wall.

(1)
Orientation Vertical Wall
(label 2 in Figure 138) Mount
The actuator moves horizontally on a vertical wall.

Horizontal Wall
Mount
Direct Drive Linear brushless motor.

Ball Screw Conventional rotary brushless motor driving a screw.
Cover An actuator cover provides protection from dust and dirt.
The addition length of travel at each end of the motion profile to allow for user-defined machine movements
Configuration outside of the motion profile (for example, setup of a mechanism or tool change spacing). It also allows room
(label 3 in Figure 138) Overtravel Length for the stage to stop if it accidentally exceeds the nominal travel. Switches (physical or software) detect this
and the drive performs a controlled stop. Click the Axis Stop tab to determine the minimum stopping
distance required.
From the Select Actuator Stroke pull-down menu, choose the required stroke length. If the option Automatic
Actuator Stroke is selected, the next largest value above Required Stroke + (2 x Overtravel) is selected. Larger sizes may be
selected at will if additional stroke is required for a function not considered in the motion profile.
Constant Mass Any unchanging mass attached to the actuator. The actuator mass itself is automatically taken into account.
This value is editable in the Load Type Tab on page 82.
Any unchanging force, other than gravity, acting on the load. It is also known as static force. This value is
External Force editable in the Load Type Tab on page 82.
X, Y, and Z - Offset These offsets allow for a load that has a center of gravity that is not close to the mounting plate of the
Constant Load actuator. This value is significant for linear stage life calculations.
Profile Based Any mass or force that changes during the cycle. The values must be entered for each segment of the motion
Loads profile. These are entered in More Options Profile Editor Mode, under the Profile toolbar.
Edit Payload Lets you quickly access More Options Profile Editor Mode.
Payload Displays a simple example of an application with a varying load.
Animation
(1) Only horizontal and vertical mounts are permitted corresponding to 0 and 90 inclination in the Load Type Tab on page 82. Any other inclination in the Load tab is converted to
horizontal mount.

2.3.8. Linear Thrusters
The Bulletin LDAT linear thruster is a new type of Allen-Bradley linear actuator
product being developed by Rockwell Automation. Its purpose is to provide a
completely integrated linear motor driven system. The Bulletin LDAT product is
integrated with linear motor, mechanical bearings, high-resolution linear
encoder, and standard circular DIN connectors for easy integration with Bulletin
2090 extension cables.
Figure 139 - Linear Thrusters Dialog Box

Table 110 - Linear Thruster Properties

The Constant/Peak Load Mass, Constant/Peak Applied Force, and Stroke values are calculated
Mechanism Data based on the parameters entered in the previous Load and Profile tabs and displayed here for
(label 1 in Figure 139) reference.
Only horizontal and vertical mounts are allowed, corresponding to 0 and 90 inclination in the
Load tab. Any other inclination in the Load tab is converted to horizontal mount.
Select the appropriate thruster orientation image for your application:
Orientation Horizontal table base mounting
(label 2 in Figure 139) Horizontal table side mounting
Horizontal wall base mounting
Horizontal wall side mounting
Vertical wall base mounting
Vertical wall side mounting
This is the additional length of travel at each end of the motion profile to allow
for user-defined machine movements outside of the motion profile For
example, setup of a mechanism or tool change spacing. It also allows room for
the motor to stop if it accidentally exceeds the nominal travel envelope.
Overtravel Switches (physical or software) detect this and the drive performs a controlled
Length stop. Click the Axis Stop tab to determine the minimum stopping distance
required. The value is added to both ends of the calculated motion profile travel
Configuration to make sure the proper length motor is specified and selected for the
(label 3 in Figure 139) application.
From the Actuator Stroke pull-down menu, choose the required actuator stroke
Actuator length. If Automatic is chosen, the next largest value above Required Stroke +
Stroke (2 x Overtravel) is selected. Larger sizes may be selected if additional stroke
Length length is required for a function not considered in the motion profile.
Mounting From the Mounting Surface pull-down menu, choose the type of surface the
Surface thruster is mounted to.

2.4. Specify Your A transmission helps to provide a speed-torque conversion, such as a gear
reduction or speed reduction, from a higher speed to a slower, more forceful
Transmission output.
Figure 140 - Transmissions Tab
Enter the following parameters for transmissions, if relevant.
Table 111 - Transmission Properties

Required Components Select the transmission components for your application. You may add up to two
(label 1 in Figure 140) transmission components and one gearbox by checking the boxes above the appropriate
component.
A belt drive consists of a loop of flexible material that is used to
Belt Drive mechanically link two or more rotating shafts with pulleys.
Chain and A sprocket is a profiled wheel with teeth that mesh with a chain.
Sprocket
Type A spur gear consists of a rod or disk with the teeth extruding radially.
(label 2 in Figure 140) Spur Gear These gears can be meshed together correctly only if they are fitted to
parallel shafts.
A coupling is a device used to connect two shafts together at their ends
Coupling for the purpose of transmitting power. The inertia, stiffness, and backlash
of couplings can be found in Manufacturers Data Sheets.
Define Parameters
(label 3 in Figure 140) Click Edit for each transmission selected to enter data.

Figure 141 - Transmission Data Dialog Box
There are three options for entering transmission component parameters to

calculate the transmission component Ratio, Efficiency, Inertia and Friction
Torque values. The applicability of these options change depending upon the
type of transmission component.
Table 112 - Calculate the Transmission Component Ratio

Directly enter the transmission component ratio and effective
Compute Using Inertia and Ratio 193
inertia. This option is available for all transmission components.
Compute the desired data (ratio and inertia values) by using the
Compute Using Pitch Circle Diameter pitch circle diameter. This option is not available for a coupling 194
transmission.
Compute the desired data (ratio and inertia values) by using the
Compute Using Number of Teeth number of teeth. This option is not available for a coupling 195
transmission.

2.4.1. Compute Using Inertia and Ratio
Use this mode to directly enter the transmission component ratio and effective
inertia. This option is available for all transmission components.
Figure 142 - Compute Using Inertia and Ratio Dialog Box
Enter the following parameters for inertia and ratio, if relevant.
Table 113 - Compute Using Inertia and Ratio Properties

Transmission component ratio. If a straight-through coupling is being modeled,
Ratio
Inertia and Ratio set Ratio = 1.
(label 1 in Figure 142) Inertia on the motor side (the rotor inertia and if a gearbox is present, the
Inertia inertia of the pinion attached to the rotor).
Efficiency is widely misused. It refers to the ratio of output power to input
power for a single operating condition, but a servo system typically operates
over a wide range of operating conditions. A gearbox supplier normally
specifies the efficiency at an optimum point such as full load and full speed.
For example, a gearbox that has an output rating of 100 Nm (885 lbin) and an
efficiency of 98%. This means that the losses at full load are 2 Nm (18 lbin).
But because most of the losses in a gearbox are due to shaft seal friction and
churning of the lubricant, this would not reduce significantly at a lower load
torque.
Efficiency
In using this gearbox, a well-matched servo motor only has a continuous rating
Efficiency and Losses around one third of the peak torque, and it is quite likely that the average
(label 2 in Figure 142) torque over the motion cycle would be even lower, for example about 20 Nm
(177 lbin) at the gearbox output. The losses of 2 Nm (18 lbin) amount to 10%
of the load on the motor, which can have a significant effect on the
temperature rise of the motor.
Motion Analyzer software overcomes this problem by dynamically computing
the real losses throughout the motion cycle, and thereby avoids
underestimating the effect of losses on the motor.
This is the torque caused by friction on the motor side between the rotor and
Friction the transmission component. This value can be obtained from the supplier or
Torque Engineering tables.

2.4.2. Compute Using Pitch Circle Diameter
Use this mode to compute the desired data (Ratio and Inertia values) by using the
pitch circle diameter. This option is not available for a coupling transmission.
Figure 143 - Compute Using Pitch Circle Diameter Dialog Box
Enter the following parameters for pitch circle diameter, if relevant.
Table 114 - Compute Using Pitch Circle Diameter Properties

Belt/Chain Transmission component ratio. If a straight-through coupling is being modeled, set Ratio = 1.
Motor Side Pulley/ (1) These values are the Pitch Circle Diameter (PCD) and Inertia for the transmission component on
Inertia and Ratio Sprocket/Gear the motor side.
Load Side Pulley/ (1) These values are the Pitch Circle Diameter (PCD) and Inertia for the transmission component on
Sprocket/Gear the load side.
Efficiency is widely misused. It refers to the ratio of output power to input power for a single
operating condition, but a servo system typically operates over a wide range of operating
conditions. A gearbox supplier normally specifies the efficiency at an optimum point such as
full load and full speed.
For example, a gearbox that has an output rating of 100 Nm (885 lbin)and an efficiency of
98%. This means that the losses at full load are 2 Nm (18 lbin). But because most of the losses
in a gearbox are due to shaft seal friction and churning of the lubricant, this would not reduce
significantly at a lower load torque.
Efficiency
Efficiency and Losses In using this gearbox, a well-matched servo motor only has a continuous rating around one
(label 2 in Figure 143) third of the peak torque, and it is quite likely that the average torque over the motion cycle
would be even lower, for example about 20 Nm (177 lbin) at the gearbox output. The losses of
2 Nm (18 lbin) amount to 10% of the load on the motor, which can have a significant effect
on the temperature rise of the motor.
Motion Analyzer software overcomes this problem by dynamically computing the real losses
throughout the motion cycle, and thereby avoids underestimating the effect of losses on the
motor.
This is the torque caused by friction on the motor side between the rotor and the transmission
Friction Torque component. This value can be obtained from the supplier or Engineering tables.

2.4.3. Compute Using Number of Teeth
Use this mode to compute the desired data (ratio and inertia values) by using the
number of teeth. This option is not available for a coupling transmission.
Figure 144 - Compute Using Number of Teeth Dialog Box
Enter the following parameters for number of teeth, if relevant.
Table 115 - Compute Using Number of Teeth Properties

This is the mass and tooth pitch for the belt/chain. This value is required for belt drive and chain
Belt/Chain and sprocket transmission components only.
Inertia and Ratio Motor Side Pulley/ (1) These values are the Number of Teeth and Inertia for the transmission component on the motor
(label 1 in Figure 144) Sprocket/Gear side.
Load Side Pulley/ (1) These values are the Number of Teeth and Inertia for the transmission component on the load
Sprocket/Gear side.
Efficiency is widely misused. It refers to the ratio of output power to input power for a single
operating condition, but a servo system typically operates over a wide range of operating
conditions. A gearbox supplier normally specifies the efficiency at an optimum point such as
full load and full speed.
For example, a gearbox that has an output rating of 100 Nm (885 lbin)and an efficiency of
98%. This means that the losses at full load are 2 Nm (18 lbin). But because most of the losses
in a gearbox are due to shaft seal friction and churning of the lubricant, this would not reduce
significantly at a lower load torque.
Efficiency
Efficiency and Losses In using this gearbox, a well-matched servo motor only has a continuous rating around one
(label 2 in Figure 144) third of the peak torque, and it is quite likely that the average torque over the motion cycle
would be even lower, for example about 20 Nm (177 lbin) at the gearbox output. The losses of
2 Nm (18 lbin) amount to 10% of the load on the motor, which can have a significant effect
on the temperature rise of the motor.
Motion Analyzer software overcomes this problem by dynamically computing the real losses
throughout the motion cycle, and thereby avoids underestimating the effect of losses on the
motor.
This is the torque caused by friction on the motor side between the rotor and the transmission
Friction Torque component. This value can be obtained from the supplier or Engineering tables.

Figure 145 - Gearbox Data Dialog Box
Enter the Manufacturer, Configuration, Series, and Frames gearbox data.
2.5. Choose Your Motor Use the Motor Series Selection tab to enter application requirements and then
select a compatible motor series.
Series
Figure 146 - Motor Series Selection Dialog Box

Enter the following parameters to further narrow the motor options and help you
decide which motor is best for your application.
Table 116 - Motor Series Selection Properties

Maximum Speed
Values are based on the information you entered in the previous tabs. These values cannot be
Continuous Torque changed in this tab.
Applications Peak Torque
Requirements Ambient
(label 1 in Figure 146) Ambient temperature for the application environment.
Temperature
Altitude Altitude for the application environment.
Brake From the Brake pull-down menu, choose YES or NO depending on your application.
Display Window Displays the available motor series. As application requirements are entered or motor series are selected, incompatible
(label 2 in Figure 146) motors are dimmed and crossed-out (boxed in red in Figure 147).
Figure 147 - Compatible Motor Series
Table 117 - Motor Series Legend (refer to Figure 147)

Symbol Description
By hovering over this symbol, the particular motor series voltage ratings are displayed.
Indicates that the motor series supports the application.
Indicates that the motor series support for the application is marginal.
Indicates that the motor series is not recommended for the application.
Indicates that the motor series is incompatible with the application.

Select the List View option to view details regarding Key Features and
Applications, Voltage/Travel & Speed, Feedback Options, and Continuous Stall
Torque/Force.
Click Compatibility List to view a comprehensive table containing Motor Series

Voltage Compatibility and Motor Series-Drive Family Compatibility.

2.6. Choose Your Electric Use the Electric Cylinder Selection tab to enter application requirements and
select a viable electric cylinder series.
Cylinder Series
Figure 148 - Electric Cylinder Selection Dialog Box
Enter the following parameters to further narrow the electric cylinder options
and help you decide which actuator is best for your application.
Table 118 - Electric Cylinder Selection Properties

Maximum Speed
Values are based on the information you entered in the previous tabs. These values cannot be
Continuous Force changed in this tab.
Applications Peak Force
Requirements Ambient
(label 1 in Figure 148) Ambient temperature for the application environment.
Temperature
Altitude Altitude for the application environment.
Brake From the Brake pull-down menu, choose YES or NO depending on your application.
Display Window
(label 2 in Figure 148) Displays the available electric cylinder options.

Table 119 - Electric Cylinders Legend (refer to Figure 148)

Symbol Description
By hovering over this symbol, the particular electric cylinder voltage ratings are displayed.
Indicates that the electric cylinder supports the application.
Indicates that electric cylinder support for the application is marginal.
Indicates that the electric cylinder is not recommended for the application.
Indicates that the electric cylinder is incompatible with the application.
Torque/Force.
Click Compatibility List to view a comprehensive table containing Actuator

Series Voltage Compatibility and Actuator Series-Drive Family Compatibility.

2.7. Choose Your Drive Use the Drive Family Selection tab to enter application requirements and select a
viable drive family.
Family
Figure 149 - Drive Family Selection Assistant Dialog Box
Enter the following parameters to further narrow the drive family options and
help you decide which drive is best for your application.
Table 120 - Servo Drive Family Selection Properties

Supply Type Select Single phase AC (AC1ph), 3-phase AC (AC3ph), or DC supply type.
Applications
Requirements Nominal Voltage From the Nominal Voltage pull-down menu, choose the nominal voltage value.
(label 1 in Figure 149) Average Motoring This value is displayed for reference. Click Details to view more information.
Power
Voltage Type Select an option to enter a single value for voltage or a range of voltages.
This parameter is required when you select the option to enter a range for the voltage type.
Lower Nominal
More Options (1) Enter the lower value for the voltage range.
(Figure 150) This parameter is required when you select the option to enter a range for the voltage type.
Upper Nominal Enter the upper value for the voltage range.
Tolerance This is the high and low tolerance for the voltage range.
Display Window
(label 2 in Figure 149) Displays the available electric cylinder options.
(1) Click More Options to further narrow the drive parameters and help you decide which motor is best for your application.

Figure 150 - Additional Servo Drive Selection Properties
Figure 151 - Compatible Drive Families
Table 121 - Drive Family Legend (refer to Figure 149)

Symbol Description
By hovering over this symbol, the particular drive familys voltage ratings are displayed.
Indicates that the motor series supports the application.
Indicates that the motor series support for the application is marginal.
Indicates that the motor series is not recommended for the application.
Indicates that the motor series is incompatible with the application.

Torque/Force.
Click Details to view a comprehensive table containing Motor Series and Drive
Family Compatibility.

Notes:

Chapter 3
Understanding Your System Solution
Topic Page
Selection 206
Automatic 207
Manual 208
Solution 208
Solution List 209
View Solution 211
Axis Stop 250
Controlled Stop 250
Resistive Brake Module 252
Load Data 252
RBM Selection 253
Apply RBM Selection 255
Life Estimate 256
Configure Axis BOM 258
Super Review 260
Summary View 260
Details View 265

Chapter 3 Understanding Your System Solution
In the Selection tab, you perform a search for the drive/motor solution for your
3.1. Selection application, based on the drive and motor families you selected previously. The
search also includes a gearbox, if gearbox was selected in the Transmission tab.
Figure 152 - Sizing and Selection Dialog Box
The search for possible drives and motors is performed based on these two
options:
Select Full if you want the search performed on the entire database of
motors, drives, and gearboxes.
Select My Preferred if you want the search performed on motors, drives,
and gearboxes that you have selected within My Preferred Database on
page 62.
Searching methods include these two options:

Select Automatic if you want Motion Analyzer software to perform the
search based on the selected database option (refer to page 207).
Select Manual if you want to select the components (motor, drive, and/or
gearbox) from a list (refer to page 208).

Understanding Your System Solution Chapter 3
3.1.1. Automatic
Follow these steps to have Motion Analyzer software to make the motor, drive,
and/or gearbox selections for you.
1. In the Automatic field, select Motor, Drive, and Gearbox (if present).
2. Click Search.
The Search in Progress dialog box opens.
When the search is complete, the Solution List opens with a list of motor/
drive combinations and a selection based on the application requirements
that you entered previously.
3. Click View Solution.

The Component Details and Axis System Performance windows open.
If the automatic selection process does not find a solution, it means that no motor
or drive in the specified family is capable of performing the task. When this
happens, the result is No Solution Found, which means you should try one or
more of the following:
Select a Motor Mounted Gearbox in the Transmissions Tab on page 191.
Try a bigger family of motors and drives.
Reduce application requirements until a solution is found.
Use Torque Analysis, within the Efficiency Analysis tool on page 227, to
determine which parameters are dominant. This may indicate which factor
to investigate.
Use Tolerance/Design Analysis on page 222 to explore how much a
parameter should change to obtain a passing solution.

3.1.2. Manual
Follow these steps to select the components yourself (motor, drive, and/or
gearbox) from a list.
1. In the Manual field, select Motor, Drive, and Gearbox (if present).
2. Click Select.
The Manual Selection dialog box opens.
3. Select the motor/actuator required for your application from the

MotorID column.
For each motor/actuator selected, the compatible drives appear below in
the Drive column.
4. Select a drive.
5. Click View Solution.
The Component Details and Axis System Performance windows open.
3.2. Solution When using the automatic method of selecting components, the Solution tab
opens providing a solution list of motor/drive combinations and a selection,
based on the application requirements that you entered previously.
If you are using the manual method of selecting components go directly to View
Solution on page 211.

3.2.1. Solution List
You can organize the solutions by using the List Categories pull-down menu, or
by clicking one of the headings in the table. The column data is sorted in
descending order the first time the heading is clicked and ascending order when
you click the heading a second time. You can also rearrange the columns by
clicking and dragging them.
Figure 153 - Solution List Dialog Box
Table 122 - Solution Tab Properties

Text Data in columns appear only as text (for example, 17%).
View Utilizations as
Graphically Data in columns appears as text and graphic ally to enhance the view (this is the default setting).
Solution View Setup Click to adjust display options for the solution list.
View Solution Click to open the View Solution dialog box.
System Notes Enter system notes for the application (optional).
Table 123 - Solution List Legend

Symbol Status Definition
Supports All parameters passed.
One or more parameters exceeded the recommended limit, but the solution is viable
Marginal provided all customer data is accurate.
Not One or more parameters exceeds 100%. The solution is not viable as entered, but may
Recommended respond to optimization. For more information, refer to Automatic on page 207.

3.2.1.1. Preferred Product
A preferred product is a top selling product of Rockwell Automation that is

guaranteed to ship from the factory within five days. The preferred status is
displayed in the Preferred Product column in the solution list.
Figure 154 - Preferred Product Solution List Dialog Box
Table 124 - Preferred Product Status (refer to Figure 154)

Preferred Product Status Definition
The drive is a preferred product and has a shorter lead time/quicker delivery. The motor
may be a preferred product depending on options (for example, encoder option, brake,
Motor & Drive key, and others). Please view the complete catalogue number in the ProposalWorks
application for preferred product status.
Drive The drive is a preferred product and has a shorter lead time/quicker delivery.
The motor may be a preferred product depending on options (for example, encoder
Motor option, brake, key, and others). View the complete catalogue number in the
ProposalWorks application for preferred product status.
Neither the motor nor the drive is a preferred product. Contact your local Rockwell
- Automation distributor for the lead time/delivery schedule of these products.

3.2.2. View Solution
The View Solution dialog box contains information and tools that you can use to
to evaluate system performance and efficiency.
Figure 155 - View Solution Dialog Box
View the following parameters for your solution. The Component Details
portion of the detailed solution view provides an overall summary of the
performance characteristics for the various components of the system.
Table 125 - Component Details (label 1 in Figure 155)

Motor Cat. No. Click to access the product specifications for that catalog number.
Forward/Backward Navigate to the View Solution information for the next component in the solution list.
Arrows
When a solution includes a gearbox, the inertia ratio is not simply the Reported
Application Inertia divided by the Reported Motor Inertia (rotor inertia), as with
systems that do not include a gearbox.
When a system includes a gearbox, the Input Pinion of the gearbox is rigidly
attached to the rotor, while the rest of the gears in the gearbox remain connected
to the application. Most of the backlash in the system occurs between the input
pinion and the rest of the system.

To correctly calculate the inertia ratio, the Input Pinion Inertia must be removed
from the Reported Application Inertia and added to the Reported Motor Inertia.
Reported Application Inertia - Input Pinion Inertia
= Inertia Ratio
Reported Motor Inertia + Input Pinion Inertia
For example, the system in Figure 156 with an MPL-B680F motor and a
VDT100-MF1 gearbox has a 6.50:1 inertia ratio.
Figure 156 - Inertia Ratio Calculation
Click the Motor tab to view the Reported Application Inertia and the Reported
Motor Inertia.
Figure 157 - Motor Tab

The Motion Analyzer database contains the Input Pinion Inertia for every
available gearbox. In this example, the Input Pinion Inertia is 0.00298 kg-m2. To
obtain a correct inertia ratio, Motion Analyzer software adds the Input Pinion
Inertia to the Reported Motor Inertia, which decreases the application inertia
and increases the motor inertia. Division produces the correct inertia ratio of
6.50:1.
0.07274 - 0.00298 = 6.50
0.00775 + 0.00298 1.0
The individual component tabs (for example, Motor, Drive, Gearbox and
Transmission) provide detailed performance information.
Figure 158 - Motor Tab
In the Motor tab, the brake rating compares the maximum static torque that can
be applied to the brake with the quoted holding torque of the brake. This
normally occurs when the drive is disabled with the motor/load stationary. This
static torque arises from any applied load torques or forces, including
gravitational effects. It does not take into account friction. If a high proportion of
the brake torque (or force) is used for static loads, then little may be left in case
the brake is required to stop motion suddenly. Brakes reduce performance if
operated during motion. The motor brake is intended as a holding brake applied
when motion is stopped and cannot be relied upon to stop a moving load when
the drive fails or loses power. An independent method of stopping is
recommended for all emergency situations where there is a gravitational load or
applied force/torque. A resistive brake module provides some braking but will
never stop a mechanism with a gravitational load or applied force/torque.
If available, Get Engineering Data opens a webpage with the Product Description
and Supplementary Documents for the selected product.

The Axis System Performance portion of the detailed Solution view provides
graphical representations of the performance characteristics for the system. If you
click the graph, the graph expands to fill your screen. In addition, as you mouse
over the graph, the X- and Y-values are displayed below the graph.
The Torque-Speed tab contains the torque/speed graph for the selected motor/
drive combination. This graph is created dynamically, which means that if the
supply voltage changes in the Motor or Drive tab, the graph will change
accordingly.
Figure 159 - Torque-Speed Graph
Table 126 - Axis System Performance (label 2 in Figure 155)

Single Displays single quadrant graph.
Quadrant
Four Displays four quadrant graph.
Opens the Torque Speed Details dialog box.
Summary Displays only the critical profile segment data on the graph.
All Segments Displays the data for all profile segments on the graph.
Graph Detail Displays the data for one profile segment at a time. Use the Forward and Backward arrows to
Segmentwise navigate between profile segments.
Show RMS Torque Check to display the RMS (root mean squared) torque value on the graph.
Auto Cycle Check to highlight each data point, in order, at the specified update rate.
X-/Y- Axis Button Flips the X- and Y-axes on the graph.

The Power-Speed tab (label 2 in Figure 155) contains the power/speed graph for
the selected motor and drive combination. This graph is typically used for
Variable Frequency Drive (VFD) applications where power is more appropriate
than torque as a measure of performance.
Figure 160 - Power-Speed Graph

The Load tab displays the characteristics of the load alone without the influence
of the motor or drive. It may be viewed before selecting motor or drive. For rotary
loads, the influence of transmission/gear component ratio may be investigated by
moving the ratio slider. This is a preliminary testno transmission losses are
included at this stage. For example, efficiency as defined on the Transmission tab
is not factored into transmissions.
Figure 161 - Load Graph

Summary Displays the data only for the critical profile segment.
All Segments Displays the data for all profile segments on the graph.
Displays the data for one profile segment at a time. Use the Forward and Backward arrows to
Segmentwise navigate between profile segments.
Show RMS Torque Select to display the RMS (root mean squared) torque value on the graph.
Gearbox Ratio Use the slider to adjust the Gearbox Ratio and observe the effect on the Torque-Speed graph.
Quadrant Select the option to view either the Single or Four quadrant graph.

The Thermal tab displays the output of drive and motor thermal models that
reside in the drive firmware.
Figure 162 - Thermal Graph

Motor/Drive Capacity Select the thermal curves you would like displayed on the graph.
Steady State/Single Cycle Select whether to view thermal data for Steady State or for a Single Cycle.
Select whether to view the data on the Full Scale graph (y-axis values from zero to the
Full/Auto Scale maximum value) or Auto Scale graph (y-axis values from the minimum value to the
maximum value).
This graph is available after a Resistive Brake Module (RBM) has been added to the System
RBM tab BOM (bill of materials) in the Axis Stop tab. The graph displays the Velocity versus Time
data for the RBM module.
This graph is available after a Power Supply Analysis has been performed on the system in
Power-Supply the Power Supply/Accessories View. This graph displays the Voltage and Current
Simulation data.

The Data Analysis Toolbar provides tools that can be used to analyze and
optimize the system. Use these tools to quickly evaluate the effect of changing the
application parameters, without having to build physical prototypes. When an
optimized system is realized, return to the appropriate parameter to manually
update it.
Figure 163 - Data Analysis Toolbar
Table 129 - Data Analysis Toolbar (label 3 in Figure 155)

Provides information that you can use to optimize the mechanical advantage
Ratio/Design Analysis 219
and/or transmission stages for the system.
Tolerance/Design Provides information that you can use to determine the sensitivity of the 222
Analysis design to changes.
Efficiency Analysis Provides information that you can use to determine the efficiency of the
system. 227
Provides information that you can use to determine the dynamic

Dynamic Simulation 230
performance of the system.
Segment Data Provides detailed performance data for each profile segment. 249
These parameters can be used to view data for other solutions.
Table 130 - Additional Tools (label 3 in Figure 155)

Solution List Click to return to the Solution List. This feature is dimmed if there is only one 209
solution for the system configuration.

3.2.2.1. Ratio/Design Analysis
You can use the Ratio/Design Analysis tool to analyze the effect of the
transmission or gear component ratios on the system performance and quickly
optimize the ratio values. This tool is not applicable for linear actuators.
When you click Ratio/Design Analysis, the following dialog box opens.
Depending on your system configuration, the following Ratio Analysis options

may be available to you:
Gearbox
Transmission 1
Transmission 2
Lead
Sprocket PCD (sprocket pitch circle diameter)
Pinion PCD (pinion pitch circle diameter)
Drive Diameter
For more information, refer to Ratio Analysis on page 220.
The Cut Length Analysis option is available when you use the Press Roll Feed
(constant time/constant angle), Carriage Cut Off, or Cutter Knife Drive
application templates.
For more information, refer to Cut Length Analysis on page 221.

3.2.2.1.1. Ratio Analysis
When you select a Ratio Analysis option, the following dialog box opens.
Motor Speed an
Ratio Value
Motor Speed and ratio values are displayed above the graph for reference. The
slider below the chart is available to adjust the ratio you are optimizing. As you
mouse over the slider, the ratio value is displayed.
The buttons below the Ratio Analysis chart select which curves are displayed.
When you click Selected Curves, the motor and drive parameters to the right of
the chart are displayed. If you select another button below the chart, only that
parameter is shown.
Table 131 - Ratio Analysis Options

Check which motor and drive parameters are displayed when you click Selected Curves. The value
Motor/Drive for each parameter is listed for the particular gearbox or transmission component ratio indicated
Parameters by the slider.
From the Graph Scale pull-down menu, choose the X-axis scale for the chart. You can set the
Graph Scale to 1, 2 or 3 decades or the scale can be defined. When the User Defined option is
Graph Scale selected, the lower and upper limits for the X-axis of the graph must be entered. Once the axis
limit values are entered, click Recompute to refresh the chart.
Available
Solutions Click the forward or backward arrow to scroll through the various available solutions.
Return Click Return to exit.

3.2.2.1.2. Cut Length Analysis
When you select a Cut Length Analysis option, the following dialog box opens.
Table 132 - Cut Length Analysis Options

Range Parameters Enter the Minimum Cut Length, Maximum Cut Length, and Increment values and click Compute.
The calculated parameters are displayed in the table and Line Speed versus Cut Length chart.
Critical The Minimum Cut Length at Max. Line Speed and Max Line Speed values are displayed here for
Parameters reference. To adjust these values, return to the Application Template Loads tab on page 96.
Print Print the Cut Length Analysis in a project report.

3.2.2.2. Tolerance/Design Analysis
When you click Tolerance/Design Analysis, the following dialog box opens.
The buttons below the Tolerance Analysis chart are available to select which
curves are displayed. When you click Selected Curves, the parameters selected on
the Graph tab (right of the chart) are displayed. If you select another button
below the chart, only that parameter appears.
The slider below the chart is available to adjust the selected Profile, Load, or
Actuator parameter. As you mouse over the slider, the parameter value is
displayed.

3.2.2.2.1. Profile Tab
Follow these steps to adjust the profile parameters.
1. From the Segment No. pull-down menu,

choose the profile segment number you
would like to analyze.
2. Select the motion profile parameter.
This becomes the parameter corresponding
to the X-axis on the graph. The value next to
each parameter indicates the parameter value
based on the current system configuration.
3. Adjust the selected profile parameter range
and number of steps in the Low, High, and
Steps text boxes, as needed.
4. Click Plot Graph to refresh the chart when
you have finished entering the values.
5. Click Setup to designate a parameter to vary by checking the adjacent box

and/or clicking the radio button.
Designate an upper and lower limit for the parameter and the number of
steps to observe on the graph within the specified range.
6. Click Plot to see the graph of the selected parameter versus time.
7. Click OK.

3.2.2.2.2. Load Tab
Follow these steps to adjust the load parameters.
1. Select the Load parameter you would like to

analyze.
to the X-axis on the graph. The number
next to each parameter indicates the
parameter value based on the current system
configuration.
2. Adjust the selected load parameter range
4. Click Setup to enter all of the ranges and numbers of steps for the Load
parameters in the Tolerance Analysis - Setup dialog box.
5. Select whether to enter data ranges as Percentages of nominal values or as

actual Values.
6. Enter the Low, High, and Steps values in the text boxes.
7. Click OK.

3.2.2.2.3. Actuator Tab
Follow these steps to adjust the actuator parameters.
1. Select the Actuator parameter you would

like to analyze.
to the X-axis on the graph. The number
next to each parameter indicates the
parameter value based on the current system
configuration.
2. Adjust the selected actuator parameter range
This tab is not available for the Rack and
Pinion and Sprocket loads.
4. Click Setup to enter all of the ranges and numbers of steps for the Actuator
Tolerance Parameters in the Tolerance Analysis - Setup dialog box.
5. Select whether to enter data ranges as Percentages of nominal values or as

actual Values.
6. Enter the Low, High, and Steps values in the text boxes.
7. Click OK.

3.2.2.2.4. Graph Tab
This tab is not available for the Rack and Pinion and Sprocket loads.
Follow these steps to decide which parameters are displayed.
1. Check the Motor Parameter curves to

display.
2. Check the Drive Parameter curves to display.
3. Click Setup to enter all the ranges and
numbers of steps for the Profile, Load, and
Actuator tolerance parameters.
4. Click Return to exit.

3.2.2.3. Efficiency Analysis
Click Efficiency Analysis to analyze the contribution of various system

parameters to the overall efficiency of the system.
You can use this information to optimize the system configuration and reduce the
torque, power consumption, or energy loss in the system. For example, if more
torque is applied toward overcoming the preload on a ball screw than towards
moving the load, this may indicate a good place for further analysis.
3.2.2.3.1. Torque Tab
Click the Torque tab to identify the torque contributions of the various system
components.
Figure 164 - Torque Tab
Click either the Peak Torque Analysis or RMS Torque Analysis option to display
the data. The torque analysis for the critical profile segment is displayed by
default when you open the Efficiency Analysis dialog box. To change the
Segment Number, click the Forward or Backward arrows.
The torque contributions of each system parameter are listed in descending order.
To view the torque contribution of a particular system parameter for all profile
segments, click the arrow next to the system parameter.

3.2.2.3.2. Power Tab
Click the Power tab to display aids in identifying how the systems power is
distributed.
Figure 165 - Efficiency Analysis Dialog Box
Click Segment Average to display the various power contributions for each
profile segment or Cycle Average to display the power contributions for the entire
motion profile.
The Power Consumption analysis for the critical profile segment is displayed by
default when you open the Efficiency Analysis dialog box. To change the
Segment Number, click the Forward or Backward arrow.
The power consumption contributions of each system parameter are listed in

descending order. To view the power consumption contribution of a particular
system parameter for all profile segments, click the arrow next to the system
parameter.

3.2.2.3.3. Energy Tab
Click the Energy tab to identify how the systems energy consumption is
distributed.
Figure 166 - Efficiency Analysis Dialog Box
Click Return to exit.

3.2.2.4. Dynamic Simulation
Motion Analyzer dynamic simulation lets you predict the dynamic performance
of an axis at the sizing stage. The Dynamic Simulator contains similar
functionality in gains and behavior as RSLogix 5000 software.
Figure 167 - Dynamic Simulation Dialog Box
Table 133 - Dynamic Simulation Options

Simulation Inputs Consists of Controller, Drive, Motor, Load, and Test Disturbances specifications 231
(label 1 in Figure 167) and lets you define the parameters for each.
Simulation Analysis Consists of Simulation Plots, Simulation Data, and Control Loop Diagram tabs 239
(label 2 in Figure 167) and lets you run simulation and analyze output simulation plots and data.
Control Loop Gains and
other Parameters Lets you manually enter control loop gains or perform auto-tuning. 246

3.2.2.4.1. Simulation Inputs
Click to toggle between the expanded and collapsed view of the simulation
inputs.
Figure 168 - Simulation Inputs
Collapsed View Expanded View

Table 134 - Simulation Input Parameters

Coarse Update Rate Coarse update rate of the Logix controller.
Sercos Update Rate Sercos update rate of the Logix controller.
Controller Counts Per Motor Drive feedback counts per motor revolution.
(label 1 in Figure 168) Revolution
Drive feedback counts per user unit. The combination may be chosen arbitrarily to
Counts Per User Unit make sure that the user units are exact. The user unit is the unit selected for Angular
Distance from Preferences->Units of Measure in the main Motion Analyzer window.
Displays drive catalog number as selected in sizing. Parameters cannot be edited.
Drive
(label 2 in Figure 168) Continuous Current Current that may be drawn indefinitely.
Peak Current Maximum current that may be drawn briefly.
Displays motor catalog number as selected in sizing. Parameters cannot be edited.
Motor Inertia Motor rotor inertia.
Continuous Torque Nominal or continuous torque (100%).
Peak available torque from the motor in %. Dynamic simulation assumes that this
Motor Peak Torque Limit peak torque is available at all speeds required by the specified profile. It does not
(label 3 in Figure 168) model bus voltage limit behavior.
You can select the feedback device available to the base motor (for example, selected
Feedback in sizing). Selecting the feedback device changes the motor catalog number to reflect
the feedback device. This motor catalog number also reflects in the BOM area.
Feedback Counts/ Feedback resolution in counts per motor revolution. This field is updated by selecting a
Revolution feedback device.
Select to use the load defined in the Motion Analyzer software. This is the default
Motion Analyzer Load selection when you open Dynamic Simulation.
Load Select SolidWorks software to model a more complex load and use SolidWorks
(label 4 in Figure 168) integration to perform simulation. Dynamic Simulation uses SolidWorks results to
SolidWorks Load predict the dynamic behavior of the load.
If SolidWorks is not installed on your personal computer, the SolidWorks Load option is
dimmed.
Test disturbances test the stability of the system. The defined step torque value is added to the system for the
specified duration.
Test Disturbances Step Torque Simulates a step torque occurring part way through the cycle.
Step Start Time Defines the point in the cycle that the step occurs.
Step Duration Defines the length of time that the torque is applied.

3.2.2.4.1.1. Motion Analyzer Load
Selecting the Motion Analyzer load provides simulation using the Motion
Analyzer software load sizing definitions.
Figure 169 - Motion Analyzer Software Load
Inertia B
Inertia A
The load is modelled as two inertias coupled by compliance (the spring in this
example diagram). Inertia A is rigidly coupled to the motor and so effectively
becomes part of the motor. If backlash is selected, it replaces the spring in this
diagram. The two friction components are not yet supported.
From the Coupling pull-down menu, choose the Coupling type.
Figure 170 - Coupling Type
Table 135 - Coupling Type Options

Rigid Coupling The load is rigidly coupled to the motor. 234
Backlash Simulates backlash such as gearbox. 234
Compliance A spring is connected between motor and load. 235

3.2.2.4.1.1.1. Rigid Coupling
Rigid coupling occurs when the load is rigidly coupled to the motor.
Figure 171 - Rigid Coupling
Table 136 - Rigid Coupling Options

Options Description
Total Inertia Maximum load inertia reflected to the motor shaft.
Any part of the load inertia that is rigidly attached to the motor shaft. This becomes
significant only when resonance or backlash is present because it becomes effectively part
of the motor. Any inertia entered here is subtracted from the Load inertia leaving the total
Rigid Inertia (system) inertia unchanged.
(Inertia A in Figure 169)
For example, a gearbox always has backlash, but its input shaft/pinion is normally coupled
rigidly to the motor shaft. This effectively becomes part of the motor, creating a higher
inertia motor. This can significantly alter the performance of an axis.
This factor is much more indicative of potential dynamic performance than the
conventional Inertia Ratio. Velocity Bandwidth is increased by this factor when the load is
decoupled. Instability typically results beyond 2 unless gains are reduced. Anything greater
Decoupling Factor than 1 starts to impact performance.
DF = Jdc / (Jm + Jrc) + 1
Where, DF = Decoupling Factor, Jdc = decoupled load inertia,
Jm = motor inertia, Jrc = rigidly coupled load inertia
3.2.2.4.1.1.2. Backlash
Backlash occurs (for example) when a gearbox is added to the motor. Choosing
Backlash enables an additional field, in addition to the Rigid coupling fields,
where you can enter a backlash value.
Figure 172 - Backlash Coupling

3.2.2.4.1.1.3. Compliance
Choosing Compliance enables the following additional fields, in addition to the

Rigid coupling fields.
Figure 173 - Compliance Coupling
Table 137 - Compliance Coupling Options (refer to Figure 173)

Options Description
Enter a system damping ratio. The damping ratio provides a means of expressing the level
Damping Ratio of damping in a system relative to critical damping.
Stiffness The Stiffness entry is useful when Natural Frequency is not known, but stiffness is.
Click Stiffness to launch the stiffness calculator and calculate stiffness from Shear Modulus,
Stiffness Calculator diameter and length.
Natural Frequency Simulates a resonance between load and motor (0 = infinitely stiff).
Figure 174 - Stiffness Calculator

3.2.2.4.1.2. SolidWorks Load
Selecting SolidWorks Load provides simulation of complex loads modeled in

SolidWorks software. Using the SolidWorks interface, the Dynamic Simulator
sends the torque value to the load in SolidWorks software and brings back the
position of the load for each time slice. The time slice is the smallest update rate.
For example, Kinetix 6000 drives have the smallest update rate of 0.125 ms. This
position feedback is used to compute the position error and to plot the various
feedbacks such as load position, load velocity, position errors, for example.
Figure 175 - SolidWorks Integration
Use these tips before clicking SolidWorks Integration:

A SolidWorks Assembly must be open in SolidWorks software before the
SolidWorks Load Definition dialog box opens.
A SolidWorks Motion Study must be set up before opening SolidWorks
Load Definition dialog box. SolidWorks Force element must be defined in
the SolidWorks Motion Study before integration.
Define reference geometry in SolidWorks software to define the axis of
rotation for the component the SolidWorks force is attached to. Using
component faces to attach SolidWorks force will work, but may
inadvertently define motion about an incorrect location for some
mechanisms.
Follow these steps to improve solver speed.
1. Click Motion Study Properties on the SolidWorks Motion Study explorer

bar.

2. Clear the Animate during simulation check box.
This increases the speed of the solver (and in turn the speed of Dynamic
Simulation) since SolidWorks software is not attempting to show the
motion of the assembly while performing calculations. Animation is not
necessary because it can be played after the study has been calculated.
3. Set Frames per second to 8000.
This should match the smallest update rate of the Kinetix 6000 drive
(0.125 ms).
4. Click SolidWorks Integration (Figure 175) to open the SolidWorks Load
Definition dialog box.
The Dynamic Simulation launches the SolidWorks Load Definition

dialog box and displays the model that is open in SolidWorks software:
before the SolidWorks Load Definition dialog box will open.
Only one instance of SolidWorks software may be running in order for

6. After verifying that this is the correct model, select the desired motion
study and force element.
Table 138 - SolidWorks Load Definitions

Options Description
Selected SolidWorks Displays the location of the selected SolidWorks model.
Assembly
Selected SolidWorks From the pull-down menu, select the desired SolidWorks motion study from the
Study existing motion studies in the currently selected assembly.
SolidWorks Force From the pull-down menu, select the SolidWorks force element.
Element
7. Click OK to confirm the desired selections and go back to Dynamic

Simulation.
8. Click Run Simulation to invoke SolidWorks based simulation.
9. Click Stop Simulation to stop the analysis.

3.2.2.4.2. Simulation Analysis
Simulation Analysis lets you invoke simulation and analyze various reports
displayed as plots and data. It also lets you enter control loop gains in the Control
Loop Diagram tab.
Figure 176 - Simulation Analysis Dialog Box
Table 139 - Simulation Analysis Tab Definitions (refer to Figure 176)

Simulation Plots Graphical representation of the simulation output data. 240
Simulation Data Displays the simulation output data in a tabular format and provides data 243
export.
Displays control loop diagram of motion control system. You can enter loop
Control Loop Diagram gain and other parameters here. 245

3.2.2.4.2.1. Simulation Plots
Simulation plots can be drawn and displayed for position, velocity, and torque.
Figure 177 - Simulation Plots Tab

Table 140 - Simulation Plots Tab Definitions

Options Description
Motor Position (Default ON) Position of the motor, measured by the feedback device.
(Default ON) Position target from motion planner in the controller to the
Target Position drive.
Load Position Simulated position of the load.
Position Position (): (Default ON) Difference between Command Position and Actual Position
(label 1 in Figure 177) Target-Motor (when simulation Position Feedback is the same as Actual Position).
Position (): Difference between Command Position and Load Position.
Target-Load
Position (): Difference between Actual Position and Load Position.
Motor-Load
Motor Velocity (Default ON) Velocity of the motor.
Velocity command in the drive (output of position loop plus velocity feed
Target Velocity forward).
Load Velocity Simulated velocity of the load.
Velocity
Velocity Velocity command in the drive (magnitude & rate limited)
Reference
Velocity (): Difference between Command Velocity and Velocity Feedback (velocity
Target-Motor feedback is a filtered derivative approximate of position feedback).
Velocity (): (Default ON) Difference between Command Velocity and Load Velocity.
Target-Load
Velocity (): Difference between Actual Velocity and Load Velocity.
Motor-Load
Torque Target Torque (Default ON) Torque target in the drive.

(label 3 in Figure 177) Motor Torque (Default ON) Actual Motor Torque.
Figure 178 - Position Plots
Figure 179 - Velocity Plots

Figure 180 - Torque Plots
Use check boxes to show or hide the simulation curves. From the color pull-down
menu, choose a color for each plot.
Figure 181 - Simulation Plot Pens
The software displays up to four plots at a time. If there are more than four
curves, then use pull-down menus to select desired plot. The selected plots are
dimmed in the pull-down menus.
Figure 182 - Choose Curves to Plot

3.2.2.4.2.2. Simulation Data
The Simulation Data tab displays the simulation output data in a tabular format
and provides data export.
Figure 183 - Simulation Data Tab
Table 141 - Simulation Data Options

Options Description
As there are numerous records of simulation output data, the following data filters can be
used to view more records.
Simulation Data Filters Use to increase or decrease the time step to view records in larger or small
Time Step
(label 1 in Figure 183) time spans.
Time Span Define start and end time of the records being displayed in the grid.
Apply Click to see your changes in the data grid.
Data Grid
(label 2 in Figure 183) Displays the simulation data records. Up to 10,000 records are shown.
Export Data Click to launch the Export Data dialog box (refer to Figure 184).

You can select the export settings (such as data elements, time step, time span,
units, delimiter, and target location for the file export) before exporting the
simulation data.
Figure 184 - Simulation Data - Export Data

3.2.2.4.2.3. Control Loop Diagram
The Control Loop Diagram tab is a graphical representation of the control loops.
You can enter loop gains and other parameters, just as in the Control Loop Gains
and other Parameters window (refer to page 246).
Figure 185 - Control Loop Diagram Tab
If you enter any gains parameters here, it also updates in the Control Loop Gains
and other Parameters window.
Figure 186 - Updating Loop Gains

3.2.2.4.3. Control Loop Gains and other Parameters
Control loop gains and other parameter windows let you manually enter control
loop gains or perform auto-tuning.
Figure 187 - AutoTune Options (expanded)
AutoTune Options simulate the Logix function by setting the Load Inertia Ratio
and the appropriate gains based on measured system inertia. As per the Logix
convention, there are five different application types for AutoTune. Selecting an
application type selects the gain parameters.
Table 142 - AutoTune Options (refer to Figure 187)

Options Description
When selected, position proportional and velocity proportional gains and load inertia ratio are
Basic calculated.
When selected, velocity integral and velocity feedforward are calculated apart from the position
Constant Speed proportional, velocity proportional, and load inertia ratio.
When selected, position integral is calculated apart from the position proportional, velocity
Point to Point proportional, and load inertia ratio.
When selected, velocity integral, velocity feedforward, and acceleration feedforward are
Tracking calculated apart from the position proportional, velocity proportional, and load inertia ratio.
Custom Use for custom/manual selection of the gain parameters to be calculated.
The default damping ratio value is 0.8. This is the classic single-overshoot setting. Higher values
Damping Ratio cause the system to be softer. This may help if the standard value results in an axis that is too hot
or even unstable.
Position Bandwidth This sets to the default for the drive/motor combination selected. It may be overridden
downwards to soften the response or get to a stable condition.

You can perform AutoTune in the collapsed state also. This state shows the
selected application types and parameters to be autotuned.
Figure 188 - AutoTune Options (collapsed)
Figure 189 - Output Parameters
Table 143 - Output Parameter Options (refer to Figure 189)

Options Description
Load Inertia Ratio Ratio of load inertia over motor inertia.
Torque Offset Used to inject a constant torque command into the torque loop, typically used to offset gravity.
Low Pass Filter Used to limit the torque command frequency response.
Notch Filter Used for eliminating a spot frequency.
When you change parameters in any section, Reset appears in the title bar of that
section. For example, the Test Disturbances section is shown in Figure 190. Click
Reset to reset all parameters to default values.
Figure 190 - Reset Feature

Figure 191 - Position and Velocity Gains
Table 144 - Position and Velocity Parameter Options (refer to Figure 191)
Options Description
Position proportional gain creates a velocity reference proportional to position
Proportional Gain error. In Logix this is actually Position Loop Bandwidth (regardless of system
Position Gain inertia). The unit of proportional gain is radians/s.
Position integral gain creates an increasing velocity reference when any position
Integral Gain error exists.
Proportional Gain Velocity proportional gain creates a torque reference proportional to velocity
error. In Logix this is actually Position Loop Bandwidth.
Velocity Gain
Velocity integral gain creates an increasing torque reference when any velocity
Integral Gain error exists.
Integral Hold Integral Hold When checked, the integral terms are ignored if command velocity is zero.
Figure 192 - FeedForward Options
Table 145 - FeedForward Parameter Options (refer to Figure 192)

Options Description
Velocity feedforward creates a velocity reference equal to the theoretical value required.
Velocity Feedforward It reduces position error to zero at constant velocity.
Acceleration feedforward creates a torque reference equal to the theoretical value
Acceleration Feedforward required. It reduces position error to zero at constant acceleration.
Figure 193 - Limits
Table 146 - Limits Parameter Options (refer to Figure 193)

Options Description
Position Error Tolerance Two red lines are displayed if the magnification is appropriate.
Two green lines are displayed if the magnification is appropriate. If this value is exceeded,
the axis decelerates to zero speed at peak torque. When Position Lock Tolerance is
Position Lock Tolerance exceeded, a warning icon appears next to it. When you mouse over the icon, a message
also appears (Limit for Lock tolerance).

3.2.2.5. Segment Data
Click Segment Data to view various system parameters for each individual profile
segment.
Figure 194 - Segment Data Dialog Box
The Initial and Final Velocity, Acceleration, Position, Time, Thrust, and Load
values are listed by profile segment in the Segment Data table. Various system
parameters are listed for the selected profile segment in the Segment Analysis
window. The overall motion profile is displayed in the Segment Profile window.
Click Return to exit.

3.3. Axis Stop The Axis Stop tab is used to determine the time and distance that the system
takes to come to a stop.
Figure 195 - Axis Stop Dialog Box
For each profile segment, Motion Analyzer software finds the highest velocity
and evaluates the time and distance the axis takes to stop from that speed using
the maximum available axis current (for example, at maximum permissible
current limit for the axis). Motion Analyzer software displays the worst possible
scenario.
3.3.1. Controlled Stop
The critical time and distance for the motion profile for each axis are captured
and displayed in the Controlled Stop section of the tab. This gives the machine
designer a guide when determining over-travel limits. These figures are a guide
and do not necessarily show the worst possible case. In a runaway situation or if
the motion programming is faulty, the axis may hit an over travel limit at a higher
speed than those used in this calculation. Similarly, if the real load is greater than
that used in this calculation, the stopping time and distance will be greater. The
machine designer must perform a risk analysis of such situations. The Drive
Capacity (Temp) bar changes color depending on the capacity percentage; for
80%, the bar is yellow, and for 100% the bar is red.
Click Details to view the Controlled Stop Details dialog box. The Deceleration
Distance on both the motor and load sides, Deceleration Time, Amplifier
Utilization, and Energy Absorbed starting and ending values are displayed for
each profile segment.

Figure 196 - Controlled Stop Details Dialog Box
Table 147 - Controlled Stop Details Properties (refer to Figure 196)

This is the critical deceleration distance. It is common to find that the mechanical design does
Decel Distance not allow enough distance to stop, if a fault occurs at the end of normal travel. This display
helps to predict the required distances on both the motor side and the load side.
Decel Time The time required to come to a complete stop.
This mimics the internal drive protection algorithm. In the event that 100% is exceeded, the
Amplifier Utilization drive faults and the motor coasts to a stop.
This is an indication of the energy that must be handled during a controlled stop and may help
Energy Absorbed to size dump resistors.
IMPORTANT Amplifier utilization is critical because it may indicate that a bigger drive is
necessary to achieve the required stopping time and/or distance.

3.3.2. Resistive Brake Module
Check Resistive Brake Module to enable selection and analysis of resistive brake
modules (RBM).
RBM modules provide controlled motor braking by connecting resistors across

the windings. An RBM module does not stop the motor if the axis has a thrust,
an external force, or a gravity force as a result of being inclined. The RBM
module only produces motor torque if the motor is moving and may act as a
speed limiter. When this happens, it is essential to use a fail-safe brake. The motor
brake may not be sufficient to stop the system and should not be applied when it
is in motion.
The stopping behavior depends on the initial velocity, inertia, contactor delay,
and the value of resistance in the RBM module. This tab enables you to select the
optimum resistive brake module.
Table 148 - Resistive Brake Module Properties (refer to Figure 195)

Select the Max. Appl. Speed option if you are sure this value cannot be
exceeded.
Start Speed
Select the Max. Motor Speed option for a high level of security. This is generally
Resistive Brake the worst case scenario.
Modules
This sets the time scale for the distance calculation and graphical display. To
zoom in on the left-hand end of the graph, decrease the Plot Time. Increase the
Plot Time Plot Time if the system has not stopped, to evaluate longer stopping times, and
to view the ultimate speed when not stopping.
3.3.3. Load Data

Table 149 - Load Data Properties (refer to Figure 195)
Select this option to use the External Torque and Load Inertia values from the
Mechanism Data system data that has been entered in previous tabs. This is the torque on the
motor produced by any external torque or force.
Select this option to manually enter External Torque and Load Inertia values. In
Load Data some cases, the maximum inertia/thrust may not coincide with the maximum
speed. When this happens, the default (maximum speed and inertia/thrust)
User Defined may produce an over-cautious solution. Advanced users may want to enter
their own value for the inertia and thrust torque (with reference to the motor)
for the maximum speed condition.

3.3.4. RBM Selection

Figure 197 - Available Resistive Brake Module Dialog Box
Table 150 - RBM Selection Properties (refer to Figure 195)

Click to produce a list of compatible resistive brake modules, with their
associated distances travelled in the Plot Time. You may adjust the Plot Time by
Select RBM entering a new value and clicking Re-Plot. Click each resistive brake module to
RBM Selection view the associated Speed versus Time graph. Click Apply when you determine
the optimum unit (refer to Figure 197).
Details Click to open the Resistive Brake Module Data dialog box (refer to Figure 198).

Click the Speed-Time, Torque-Time, and Distance-Time tabs to view graphs for
the selected resistive brake module. You may also view parameters for a custom
resistive brake module.
Figure 198 - Resistive Brake Module Data
Click Product Catalog to view product specifications.
Figure 199 - RBM Module Product Specifications

3.3.5. Apply RBM Selection
The initial period (70 ms) allows for the contactor change-over. The speed may
stay the same or increase if there an external load during this time and torque will
be zero. The peak torque depends upon the speed and may peak at a medium
speed, being less at higher and lower speeds. Check for distance continuing to
increase over a long period of time, which indicates a non-stopping condition.
Figure 200 - Axis May Not Stop Message
This error message indicates that the axis speed has not fallen close to zero in the
allotted time. This may apply to all resistive brake modules or only some of them.
Increase the allotted time to analyze further. There are several possible outcomes:
Axis may stop with a longer time.
Axis speed may reduce but not stop. Be careful to note if the axis speed has
really become zero and not a low speedmake sure that the position graph
is not increasing.
Axis speed may increase to a sustained higher level.
Axis may run-away; the speed may continue to increase.

3.4. Life Estimate The Life Estimate tab provides information on the life and bearing load
utilizations for electric cylinders.
Figure 201 - Life Estimate Dialog Box
Table 151 - Life Estimate Properties

Operating Conditions The Hours per Day, Days per Week, and Weeks per Year assumptions are listed here. You can adjust these
(label 1 in Figure 201) values by clicking Change Operating Conditions.
To calculate the cylinder bearing load utilization, it is necessary to specify the mechanical forces and
moments applied to the moving part of the cylinder. All loads must be separately guided and supported.
Loads should align along the line of thrust throughout the complete stroke of the cylinders. If residual
radial or torsional loading cannot always be eliminated, enter these expected values here to help
determine if the loading exceeds the recommended limits of the cylinder. If so, counter measures such as
a rod-guide accessory and/or an adjustment to loading and mechanical connections may be necessary.
Normal Forces and Moments These values are not entered if a rod guide is used.
These forces are applied at right angles both horizontally and vertically to the end of
Normal Forces the cylinder as shown in the diagram.
Normal Distances These distances are from the end of the cylinder where each normal force is applied.
These moments are applied to the cylinder in the three planes. They are in addition
Moments to any normal forces.
Life Estimate
(label 3 in Figure 201) The roller screw or ball screw life estimate (depending on the linear actuator type) is listed here.
Bearing Load Utilization This information is available for Bulletin MPAI and MPAR linear actuators. The normal force and moment
(label 4 in Figure 201) utilization (Fz, Fy, Mz, My) and moment utilization (Mx) are displayed here as percentages.
Lubrication Schedule
(refer to Figure 202) Applies to Bulletin MPAI electric cylinders.
Strip Seal Life Estimate Applies to Bulletin MPAS linear stages. The Slide Bearing Life Estimate and Strip Seal and Cable Track life
(refer to Figure 203) estimate is also listed.

Figure 202 - Lubrication Schedule (Bulletin MPAI actuators only)
Figure 203 - Strip Seal Life Estimate (Bulletin MPAS linear actuators only)

3.5. Configure Axis BOM You can complete the Bill of Materials (BOM) for each axis after fully sizing the
application by clicking on the Configure Axis BOM tab. You can configure the
motor encoder, and choose connectors, cables, and drive accessories here.
Many options are already configured in Motion Analyzer software, as these are
required for sizing and cannot be changed in the BOM. These options include,
for example, brake, cover, rod guide, or blower.
Throughout the steps, use More Info or the Product Details links for more
information or refer to the Kinetix Motion Control Selection Guide, publication
GMC-SG001, to access the relevant product specifications.
Figure 204 - Configure Axis BOM Dialog Box

Table 152 - Configure Axis BOM

Select the options required. Options that are not available are dimmed. Standard
options are shown by default.
From the Encoder Options pull-down menu, choose the encoder
Encoder Options type for your motor.
Step 1 Motor/Actuator The brake is chosen during sizing on the Motor tab. The shaft key
Brake and Key
(refer to Figure 204) will be selected if it is available.
Mounting Some motors have different mounting options.
Flange
Different motors and actuators have various options that can be
Miscellaneous selected. Some options such as blowers and covers, for example,
Options affect sizing and have been selected in the sizing process.
Step 2 Select motor and actuator accessories. The rod guide for electric cylinders was
Accessories selected during sizing.
Step 3 Check for connector kit.
Axis Module/Drive/IAM
Check non-flex or continuous-flex cable and cable length options. The length
Step 4 selected for the power cable is used for the other cables, unless the lengths are
Motor/actuator power cable individually changed.
Step 5 Check non-flex or continuous-flex cable, cable length, and flying-lead or connector
Motor/actuator feedback cable at drive-end options.
Check non-flex or continuous-flex cable and cable length options. For most motors,
Step 6 separate brake cable is not required because brake wires are included in the power
Motor/actuator brake cable cable.
Step 7 Resistive Brake Module for the application is selected in the Axis Stop tab on page
Resistive brake module 250 and cannot be changed here.
Step 8 Specify cable AWG size and cable length options.
Resistive brake module cables

3.6. Super Review Click the Super Review tab to review the overall application parameters that were
entered or calculated in the previous tabs.
There are two options for viewing the Super Review dialog box.
Table 153 - Super Review Tab Options

Summary View Provides summary data and plot profile for the application. 260
Details View Provides segment data in table form from all review locations. 265
3.6.1. Summary View
The summary view displays data and the plot profile of your choice.
Figure 205 - Summary View Dialog Box
Table 154 - Summary View Properties

From the Review Location pull-down menu, choose the point in the system where
Review Location you would like to review the data.
These parameters are listed for the chosen Review Location:
Maximum Velocity
Total Time
Summary Data Maximum Inertia
Maximum Acceleration
Total Distance
RMS (root mean squared) Torque
Select the graph type to display:
Profile/Load-Time Graph on page 261.
Plot
Show Force-Speed Graph on page 263.
Show Power-Speed Graph on page 263.

3.6.1.1. Profile/Load-Time Graph
The Profile/Load-Time graph is divided into two sub-windows. In the

explanation that follows, the Show Profile/Load-Time graph is used in the
example.
The Plot Parameters sub-window appears to the left of the Main Profile Plot
window. Click the arrows, left of the Main Profile Plot window, to open it. Click
the arrows again to close the window.
Clicking the motion curves (for example, Distance or Velocity) toggles them on
and off. From the motion curve pull-down menu, you can change the color for
the curve in both the Main Profile Plot window and the Segment Plot window.
Figure 206 - Plot Parameters
In addition, as you hover over the Main Profile Plot window with the mouse
pointer, the Plot Parameters sub-window provides a display of the numeric values
of the time (x-axis), and active motion curves (y-axis) associated with the mouse
pointer position.
Figure 207 - Main Profile Plot X and Y-axis Values

The Profile Zoom Plot sub-window appears below the Main Profile Plot window.
Click the arrows, below the Main Profile Plot window, to open it. Click the
arrows again to close the window.
The Profile Zoom Plot window contains a slider that you can move along the
motion profile by clicking and dragging it. As the slider moves, the Main Profile
Plot window displays a magnified view of the portion of the plot that is selected
by the slider. You can resize the slider by clicking and dragging from either edge.
Figure 208 - Profile Zoom Plot Window
Right-click the Profile Zoom Plot sub-window to display these options.
Figure 209 - Profile Zoom Plot Options
Table 155 - Profile Zoom Plot Options


3.6.1.2. Show Force-Speed Graph
The force versus speed curve is displayed below.
Table 156 - Show Force-Speed Graph Options

Force-Speed Options Select how to view the data: Summary, All Segments, or Elementwise.
RMS Force Check to include the RMS (root mean squared) force on the plot.
Plot Force Curve Check to display the Force Curve.
3.6.1.3. Show Power-Speed Graph
The power versus speed curve is displayed below.
Table 157 - Show Power-Speed Graph Options

Power-Speed Options Select how to view the data: Summary, All Segments, or Elementwise.
Plot Power Speed Curve Check to display the Power Speed Curve.
Right-click one of the plots to choose any of the following options.

Figure 210 - Segment Plot Dialog Box
Table 158 - Graph Options

Reset Zoom Resets the zoom to 1x.
Zoom Lets you zoom in 1x, 2x, 6x or 8x.
Color Adjust the background, curve and grid colors.
Show Curve Select which curves you would like to display on the plot (for example, Distance or Velocity).
Toggle the Y-axis labels on and off when more than one curve is shown. This option is only
Show Y Axis available on the Profile Plot.

3.6.2. Details View
The Details view of the Super Review tab provides a table that contains position,
time, velocity, acceleration, inertia, and various torque values for each Review
Location (Load, Motor, and Drive, for example) and for individual profile
segments.
Figure 211 - Details View Dialog Box
Table 159 - Details View Options

From the pull-down menu, choose All Segments or a specific profile segment to view in the
Select Segment table. You can view the segment data for each Review Location by clicking + to expand the
Review Location.
Click the Export Data link to save the Super Review data as a CSV (Comma Separated
Export Data Variable) file.

Notes:

Chapter 4
Just Quote
Topic Page
Axis View 268
IPIM Power Supply/ Accessories View 272
Power Supply and Accessories 273

Chapter 4 Just Quote
For each axis, enter the required drive family, motion type, and motor/actuator
4.1. Axis View series and associated optional components by clicking BOM Configuration.
Figure 212 - Axis View Dialog Box
Table 160 - Drive and Motor/Actuator a Families

Product Family
(step 1 in From the pull-down menu, choose the drive family for your motion application.
Figure 212)
Motion Type Rotary Motion includes, for example, low-inertia servo motors and direct-drive motors
(step 2 in Linear Motion includes, for example, linear motors, linear stages, and electric cylinders
Figure 212)
MP-Series includes:
Bulletin MPL, MPM, MPF, MPS rotary motors
Bulletin MPAS and MPMA linear stages
Motor/Actuator Bulletin MPAR and MPAI electric cylinders
Series
(step 3 in TL-Series includes:
Figure 212) Bulletin TL and TLY rotary motors
Bulletin TLAR electric cylinders
Integrated Drive-Motor include Bulletin MDF rotary drive-motor units

Just Quote Chapter 4
Figure 213 - Axis View (continued)
Table 161 - Motor/Actuator Options

From the pull-down menus choose the options available for your rotary or linear motion
Options product.
Cat. No. Scroll to select from the valid catalog numbers for your rotary or linear motion product.
Table 162 - Axis Module Options

Cat. No. Scroll to select from the valid servo drive catalog numbers.
Check to indicate the connector kit for your IAM (converter and inverter) or AM (inverter only)
Connector Kits modules.

Table 163 - Motor Power Cable Options

Motor Power Cable Check and from the pull-down menu, choose the length for your drive and motor/actuator
(standard) (standard) power cable.
Motor Power Cable Check and from the pull-down menu, choose the length for your drive and motor/actuator
(continuous-flex) (continuous-flex) power cable.
Table 164 - Motor Feedback Cable Options

Motor Feedback Cable Check and from the pull-down menu, choose the length for your drive and motor/actuator
(standard) (standard) feedback cable with premolded connector on the drive end.
(standard) (standard) feedback cable with flying-leads on the drive end.
(continuous-flex) (continuous-flex) feedback cable.

Table 165 - Motor Brake Cable Options

(standard) (standard) brake cable.
(continuous-flex) (continuous-flex) brake cable.
Table 166 - Resistive Brake Module (RBM) Cable Options

Resistive Brake Select none, or the catalog number for your motion application.
Module
Resistive Brake Check and from the pull-down menu, choose the length for your drive and motor/actuator
Module Cable (standard) RBM cable.
When finished click System View, or use the Axis View pull-down menu to
configure the next axis.

4.2. IPIM Power Supply/ Power Supply Accessories view of an IPIM module helps you select options for
hybrid and network lengths, hybrid coupler cables, and bulkhead adapters.
Accessories View
Figure 219 - IPIM Module Selection
Table 167 - Configure IPIM Module BOM Tab Descriptions

Options Description
Step 1 (Figure 219) IPIM module IPIM module selected on the IPIM Module tab is displayed here.
Step 2 (Figure 219) Hybrid cables Hybrid cable lengths selected on the Cable Lengths tab are displayed here.
Network cables can be routed with the hybrid cables, so network cable lengths
Step 3 (Figure 219) Network cables should be the same as the hybrid cable. The IPIM-to-IDM1 cable must have a
straight connector to the IPIM module.
Step 4 (Figure 219) Hybrid coupler The hybrid coupler connects between two hybrid cables, to bypass an IDM unit.
Step 5 (Figure 220) Network Use the network bulkhead adapter for securing network cables as they pass
bulkhead adapter through the cabinet.

4.3. Power Supply and Click Power Supply/Accessories to select all the power supply components. This
includes any back plane, fuse, contactor, LIM module, or Shunt module. Some
Accessories filtering of suitable units is arranged according to the other components selected.
The power rail field populates based on the number of slots required.

Notes:

Index
A configure
axis BOM 258
AC sharing configuration 56
IPIM BOM tab 45
acceleration 168 power supply BOM tab 35
actuator tab 225 control loop
additional parts tab 39 diagram 245
additional resources 5 gains 246
advanced templates 104 controlled stop 250
allocate 16 conventions 5
analysis tab 33 counterbalance 84
application template 96 force 85
mass 85
advanced
coupling type
four bar linkage 114
inertia calculator 105 backlash 234
winder/unwinder 112 compliance 235
applied force 83 rigid coupling 234
crank 93
automatic
cruise/dwell 170
profile 171
selection 207 cut length analysis 221
autotune 246 cutter knife drive 102
axis
histograms 30, 47
of rotation 91 D
options 269 damping ratio 235
stop 250 data analysis toolbar 218
controlled stop 250
cut length analysis 221
load data 252
dynamic simulation 230
resistive brake module 252, 253
efficiency analysis 227
summary image 25
energy tab 229
power tab 228
B ratio analysis 220
ratio/design analysis 219
backlash 234 segment data 249
ball screw life 62 tolerance/design analysis 222
bearing life 62 torque tab 227
DC sharing configuration 52
belt drive 180
deceleration 168
BOM tab 40, 76
define your profile 139
less options profile editor 140
C more options profile editor mode 142
derived parameters 153
carriage cut off 100
details view 265
center driven 113
download Motion Analyzer 5
chain and sprocket 182
dwell time 140
coefficient of friction 83
dynamic simulation 230
comments window 154
control loop gains 246
complex rotary load simulation analysis 239
template 90 simulation inputs 231
crank 93
unbalanced load 91
user defined 90 E
compliance 235
efficiency analysis 227
compute transmission data using electric cylinders 186
inertia and ratio 193 selection 199
number of teeth 195 empty
pitch circle diameter 194
configuration summary tab 37 diameter 113
inertia 113
end effector 82
energy tab 34, 229

Index
error list window 155 configuration summary tab 37

explorer view 78 software and accessories tab 38
export/import tab 65
axis mapping 67 I
export mapping 67
export options 66 IAM control power tab 32
RSLogix 5000 65 IAM/shunt tab 31
external force 147 IDM
cable length tab 43
control power tab 44
F power data tab 41
feedforward 248 inclination 83
file tab 15 independent axis workflow 122
force counterbalance 85 index
four bar linkage 114 advance 173
from SolidWorks 120 profile 171
type 140
inertia calculator 105
G less options inertia mode 106
more options inertia mode 107
gearbox data 196 SolidWorks import 109
graph inter-dependent axis workflow 131
tab 226 IPIM
view 28 selection 272
graphical view 17 selection tab 42
group view 22
J
H jerk 169, 177
help tab 76 just quote 13
home tab 16 accessories view
axis summary image 25 IPIM selection 272
graph view 28 axis view
graphical view 17 axis options 269
power interface module (IPIM) view 20 motor brake cable options 271
power rail view 18 motor feedback cable options 270
group view 22 motor power cable options 270
multiple profile view 26 motor/actuator options 269
top band fields 27 product family 268
power rail image 24 RBM cable options 271
power supply/accessories view power supply accessories view 273
analysis tab 33 just quote mode 22
configure IPIM BOM tab 45
configure power supply BOM tab 35
energy tab 34 L
IAM control power tab 32 lead screw 181
IAM/shunt tab 31
IDM cable length tab 43 less options inertia mode 106
IDM control power tab 44 less options profile editor 140
IDM power data tab 41 life
IPIM selection tab 42 estimate 256
multi-axis drives 29 operating conditions 62
power data tab 30 limits 248
single-axis analysis tab 48 linear
single-axis config PS BOM tab 50
single-axis drive systems 46 load 83
single-axis energy tab 49 counterbalance 84
single-axis power tab 47 motors 184
single-axis shunt tab 47 stages 187
system BOM view 36 thrusters 189
system bill of materials view load
additional parts tab 39 data 252
BOM tab 40 Motion Analyzer 233

Index
load type tab 82, 224 motor

application template 96 brake cable options 271
advanced 104 feedback cable options 270
carriage cut off 100 power cable options 270
cutter knife drive 102 selection 196
power/speed 118 motor/actuator options 269
press roll feed 97 motoring 30, 47
from SolidWorks 120 move distance 140
linear load 83
rotary complex load 87 move time 140
rotary load 86 multiple profile view 26
Logix elements 174
N
M natural frequency 235
MAM profile 176
manual selection 208
mass counterbalance 85 P
mechanism type 178 payload
belt drive 180 animation 147
chain and sprocket 182 mass 147
electric cylinders 186 power
lead screw 181 data tab 30
linear tab 228
motors 184 power interface module (IPIM) view
stages 187 view 20
thrusters 189 power rail
rack and pinion 183 image 24
menu bar 14 view 18
BOM tab 76 power sharing configuration 51
explorer view 78 power supply accessories view 273
export/import tab 65
file tab 15 power/speed template 118
help tab 76 preface
home tab 16 additional resources 5
preferences tab 62 conventions 5
mode preferences tab 62
just quote 22 preferred product 210
less options inertia 106 preferred product status 210
less options profile editor 140 press roll feed 97
more options inertia 107
more options profile editor 142 profile
select and size 22 automatic 171
more options profile editor 142 grid 152
comments window 154 MAM 176
derived parameters 153 mirror 113
error list window 155 plot 149
profile grid 152 tab 223
profile plot 149 toolbar 145
profile toolbar 145 trapezoidal 171
segment load window 147 triangular 171
segment parameters window 167 ProposalWorks application 210
segment plot window 148
Motion Analyzer
download 5 Q
existing 13 quick access toolbar 14
just quote 13
new 13
motion axis move (MAM) 176 R
rack and pinion 183
ratio analysis 220
ratio/design analysis 219
RBM cable options 271

Index
regenerating 30, 47 torque/speed curve 211

reported application inertia 212 super review 260
reported motor inertia 212 transmission 191
smoothness 140
resistive brake module 252
software and accessories tab 38
selection 253
rigid coupling 234 software requirements 5
roller screw life 62 SolidWorks software
rotary complex load 87 import 109
independent axis workflow 122
rotary load 86 inter-dependent axis workflow 131
load 236
solution 208
S data analysis toolbar 218
S-curve 113 start condition 168
segment stiffness 235
data 249 strip seal life 62
load window 147 summary view 260
parameters window super review 260
acceleration/deceleration 168
cruise/dwell 170 details view 265
index advance 173 summary view 260
index profile 171 surface driven 113
Logix elements 174 system BOM view 36
motion axis move (MAM) 176
start condition 168
plot window 148 T
select and size mode 22 templates 90
selection 206 tolerance/design analysis 222
automatic 207 actuator tab 225
manual 208 graph tab 226
servo drive selection 201 load type tab 224
simulation profile tab 223
analysis 239 torque tab 227
control loop diagram 245 torque/speed curve 211
simulation data 243 transmission 191
simulation plots 240
data 243 compute using
inputs 231 inertia and ratio 193
Motion Analyzer load 233 number of teeth 195
SolidWorks load 236 pitch circle diameter 194
plots 240 trapezoidal profile 171
single-axis triangular profile 171
analysis tab 48
config PS BOM tab 50
drive systems 46 U
energy tab 49 unallocate 16
power tab 47 unbalanced load 91
shunt tab 47
sizing and selection 206 unwind 113
sizing your system user defined 90
axis stop 250
configure axis BOM 258
define your profile 139 W
electric cylinders web
selection 199 speed 113
life estimate 256 tension 113
load type tab 82 wind 113
mechanism type 178 winder/unwinder 112
motor selection 196
selection 206
servo drive selection 201
solution 208 Z
zoom 140

Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support, you can find technical manuals, technical and application notes, sample
code and links to software service packs, and a MySupport feature that you can customize to make the best use of these
tools. You can also visit our Knowledgebase at http://www.rockwellautomation.com/knowledgebase for FAQs, technical
information, support chat and forums, software updates, and to sign up for product notification updates.
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
TechConnectSM support programs. For more information, contact your local distributor or Rockwell Automation
representative, or visit http://www.rockwellautomation.com/support/.
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this
manual. You can contact Customer Support for initial help in getting your product up and running.
United States or Canada 1.440.646.3434
Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html, or contact your local Rockwell
Automation representative.
New Product Satisfaction Return
Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the
manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.
United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your
distributor to complete the return process.
Outside United States Please contact your local Rockwell Automation representative for the return procedure.
Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this
document, complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.
Publication MOTION-UM004B-EN-P - October 2012

Supersedes MOTION-UM004A-EN-P - May 2012 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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User Manual

Motion Analyzer Software

This manual contains new and updated information.

Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012 3

4 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

You can view or download publications at

Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012 5

6 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Welcome to Motion Analyzer Software

Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012 7

TIP Download Motion Analyzer software from

1.1.1. Database Updater Program

1. To start the Motion Analyzer database updater program, go to

The Motion Analyzer Database Updater wizard opens.

Table 1 - Database Updater Analysis

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The program checks for database updates.

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6. If the database updater program detects that your current version of

Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012 11

10. Click Finish.

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1.1.2. Welcome to Motion Analyzer

Figure 1 - Welcome to Motion Analyzer Dialog Box

Table 2 - Motion Analyzer Modes of Operation

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Quick Access Toolbar

The Quick Access toolbar provides shortcuts to commonly used functions.

Table 3 - Menu Bar Tab Descriptions

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1.2.1. File Tab

Figure 3 - File Tab Options

Table 4 - File Tab Descriptions (refer to Figure 3)

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1.2.2. Home Tab

The Home tab contains five sections.

Figure 4 - Home Tab Options

Table 5 - Home Tab Descriptions

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1.2.2.1. Graphical View

Figure 5 - Graphical View Example

Table 6 - Graphical View Options (refer to Figure 5)

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1.2.2.1.1. Power Rail View

Figure 6 - Power Rail View Example

Table 7 - Power Rail View Options

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Figure 7 - Operations to Perform Example

Figure 8 - Drag and Drop Modules to Reposition on Power Rail

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1.2.2.1.2. Power Interface Module View

The integrated drive-motor power interface module (IPIM) mounts to the

20 Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012

Figure 10 - Operations to Perform Example

Figure 11 - Drag and Drop to Reposition IDM Units

Rockwell Automation Publication MOTION-UM004B-EN-P - October 2012 21

1.2.2.2. Group View

Figure 12 - Group View Example (Select and Size mode)

Figure 13 - Group View Example (Just Quote mode)

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Figure 14 - Group View Example

Table 9 - Power Rail View Options