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Motion Control Video Rundown and ReferencesThis LEARN video covers the Part Feeder Station thatuses the DirectLOGIC DL05 PLC’s built-in High-SpeedPulse Output, referred to as Mode 30, to control aSureStep Stepper System. A C-more Micro-Graphic panelis used as the operator interface. Various sensors are alsoused with the Part Feeder to control operationalfunctions.a. Application & EquipmentThe Part Feeder Station is the first stage of an overallapplication based on various Motion Control systems.The first and second stage are controlled with SureStepStepper Systems using ADC products, with the final stagebased on AutomationDirect’s SureServo Servo System.To the right is a list of topics covered in this video.f. Operational Demonstration00:55b. Wiring (Schematic Diagram)c. Hardware Setup (Jumper & Dip Switches)d. DirectSOFT5 Ladder Logic & IBoxese. C-more Micro-Graphic Panel (HMI)“Links” pointing to available technical information fromAutomationDirect have been included, such as theexample on the SureStep User Manual shown below.Link to SureStep Stepping Systems User Manual: http://bit.ly/r5dgUO

Motion Control Video Rundown and References (cont’d)02:30This handout can be used to follow along with the video, and can also be useful as a refresher to thesteps required to create a working Motion Control System using a DirectLOGIC DL05 PLC with DCoutputs, programmed with the PLC’s built-in High Speed Pulse Output using Mode 30, controllingan AutomationDirect SureStep Stepper System, interfaced with a C-more Micro-Graphic panel,monitored with ADC sensors, and constructed using ADC wiring components.For additional information on AutomationDirect’s products that are a good choice for a MotionControl application, please refer to the Automation Notebook article titled ‘Starting with Steppers’under the Tech Thread, Part 1 of 2 published in Issue 21 (Fall 2011), and Part 2 of 2 published inIssue 22 (Spring 2012). Various stepper motor control methods are discussed in this article. Linksto Part 1 & 2 are shown below.The eight part video series titled ‘Motion Control – DirectLOGIC Micro PLC/CTRIO Module toSureStep Stepping System with C-more Micro-Graphic Panel (HMI)’ is another excellent resourcedetailing Motion Control System information.8 Part Video Series: http://bit.ly/17OhoYULink to “Starting with Steppers” Part 1: http:/bit.ly/J5U0tNLink to “Starting with Steppers” Part 2: http:/bit.ly/IQSjUb

Application – Part Feeder StationThe Part Feeder Station was designed to dispense one part at atime into a tube that carries the sequenced parts to the nextstation. The parts in this example application consists of sixdifferent colored marbles, steel balls, and brass balls. Theparts are all approximately 14mm in diameter. The parts arestored in a cylindrical polycarbonate hopper. A slottedpolycarbonate disk, coupled to an AutomationDirect NEMA 17stepper motor, is used to rotate the disk. The slot in the diskallows one part at a time to drop into the slot as it rotates.The part then falls into the exit tube when it is positioned overthe opening.The Part Feeder mechanism is built using T-slotted 80/20framing. It includes a part hopper, slotted disk driven with aSureStep stepper motor, and a coupled Koyo encoder toprovide speed control and jam detection. There is also a fiberoptic photoelectric sensor to detect when the exit tube is full,and a capacitive proximity sensor to determine when the parthopper is empty.03:27Part Feeder Station

Application – Control Panel EnclosureThe Part Feeder Station controls are housed in a non-metallicJIC NEMA 4X enclosure with a window through the door. AC-more Micro-Graphic panel and the master control powercircuitry push buttons are mounted through the enclosure’swindow.Located on the enclosure’s panel are the DirectLOGIC DL05PLC, AcuAMP DC current sensor, 24 VDC power supply usedfor the PLC’s DC inputs and also 24 VDC power to the AcuAMP,and the master control power circuitry relay.The SureStep stepper motor drive and stepper motor powersupply are also mounted to the enclosure’s panel.AutomationDirect’s terminal blocks, wire duct, DIN rail, andmachine tool wire are used to construct and wire the controlpanel enclosure.AutomationDirect multi-wire connector and multi-conductorflexible control cable is used to connect the control panelenclosure to the Part Feeder Station.Control Enclosure04:42

Application - Schematic DiagramsThe next two slides represent the schematic diagrams of thePart Feeder Station.The first schematic diagram shows the power circuitry whichincludes the Master Control circuitry with relay, ‘Power On’push button and ‘Emergency Stop’ push button.The ADC Rhino 24 VDC power supply used to provide power tothe PLC’s DC inputs, and power to the AcuAMP DC currentsensor is also shown on the first schematic diagram.The second schematic diagram includes the DirectLOGIC DL05PLC, SureStep stepper system motor, power supply and drive,Koyo incremental encoder, AcuAMP DC current sensor, 4-20mA analog current input module, fiber optic photoelectric andcapacitive proximity sensors, and C-more Micro-Graphic panel.The wiring for the Part Feeder controls uses different coloredmachine tool wires for the various conductors to help identifyindividual circuits, whereas wire numbering could have beenjust as easily used. Follow the codes for your application.Control Enclosure Panel05:50

05:58Schematic DiagramPart Feeder StationPower WiringSheet 1 of 2

06:19Schematic DiagramPart Feeder StationDL05 PLC,Stepper System& HMISheet 2 of 2

F0-04AD-1 Analog Input Module Jumper SettingsTo detect if the Part Feeder is jammed, the current from the SureSteppower supply to the SureStep drive is monitored using an AcuAMP DCCurrent Sensor.The 4-20mA signal from the DCT100-42-24-F AcuAMP Current Sensor iswired into channel 1 of the F0-04AD-1 Analog Current Input l Analog Current Input Module determines the input signal level.The chooses are 4–20mA or 0–20mA. The module ships with the jumpernot connecting the two pins, so that in this position, the expected inputsignal is 4–20mA.F0-04AD-1F0-04AD-106:50

STP-DRV-6575 Microstepping Drive – Block DiagramFeatures: Low cost, digital step motor driver in compact package Operates from Step & Direction signals, or Step CW & StepCCW (jumper selectable) Enable input & Fault output Optically isolated I/O Digital filters prevent position error from electrical noise oncommand signals; jumper selectable: 150 kHz or 2MHz Rotary switch easily selects from many popular motors Electronic damping and anti-resonance Automatic idle current reduction to reduce heat when motor isnot moving; switch selectable: 50% or 90% of running current Switch selectable step resolution: 200 (full-step); 400 (halfstep); 2,000; 5,000; 12,800; or 20,000 steps per revolution Switch selectable microstep emulation provides smoother, morereliable motion in full and half step modes Automatic self test (switch selectable) Operates from a 24 to 65 VDC power supply Running current from 0.5 to 7.5ALink to Microstepping Drive Data Sheet: http://bit.ly/17mkQLQ07:42

STP-DRV-6575 Microstepping Drive – WiringExternal wiring to the STP-DRV-6575 Microstepping Drive is accomplished byusing the two separate pluggable screw terminal connectors. The powerconnections for the supplied DC power and the stepper motor leads share a sixposition connector. The digital inputs and one output share an eight-positionconnector.Also seen in the diagram to the right are the Status LEDs, the Rotary Switch usedto select the Stepper Motor based on part number or current rating, and the8-position Dip Switch used to select the drive’s operating parameters.STP-DRV-657507:58STP-DRV-6575

STP-DRV-6575 Microstepping Drive – Motor Selection08:36Use the Rotary Switch to select the motor being used basedon either the stepper motor’s part number, or set by thestepper motor’s current rating. In this example the steppermotor used is part number STP-MTR-17060D, so the RotarySwitch is set to position 8.STP-MTR-17060D

STP-DRV-6575 Microstepping Drive – S3 & S4 Jumper SettingsIn most cases the S3 & S4 jumpers for the STP-DRV-6575Microstepping Drive can be used per the factory defaults, but canbe adjusted as shown here:Jumper S3 – Step Pulse Type Jumper in “1-2” position – Step & Direction(factory default) Jumper in “1-3” position – Step CW / Step CCWJumper S4 – Step Pulse Noise Filter Jumper in “1-2” position – 2MHz Jumper in “1-3” position – 150 kHz(factory default)STP-DRV-657509:04

STP-DRV-6575 Microstepping Drive – Dip Switch Settings – 1 of 309:46SW 1 & 2: Reduce power consumption and heat generation by limiting motor running current to 100%, 90%, or80% of maximum. Current should be increased to 120% if microstepping. (Torque is reduced/increased by thesame %.)SW 4: Reduce power consumption and heat generation bylimiting motor idle current to 90% or 50% of running current.(Holding torque is reduced by the same %.)SW 3: Anti-resonance and damping feature improvemotor performance. Set motor and load inertia range to0–4x or 5–10x.

STP-DRV-6575 Microstepping Drive – Dip Switch Settings – 2 of 311:01SW 5, 6 & 7: For smoother motion and more precise speed, set the pulsestep resolution to 20000, 12800, 5000, 2000, 400 smooth, 400, 200smooth, or 200 steps/rev.SW 8: The Self Test function, Dip Switchposition 8, when in the ‘On’ positionautomatically rotates the motor backand forth two turns in each direction inorder to confirm that the motor isoperational.

STP-DRV-6575 Microstepping Drive – Dip Switch Settings – 3 of 3The STP-DRV-6575 Drive Dip Switches forthe Part Feeder Station are set as follows: Current Reduction – 80%Application does not require full torque,so 80% is used to reduce heat. Load Inertia – 0-4XApplication has little loading,so lower inertia can be used. Idle Current Reduction – 50%Reduce power consumption to 50%,which reduces heat produced at idle. Step Resolution – 400 steps/rev SmoothProduces the best running results for theapplication. Self Test - OffSTP-DRV-657511:35

STP-DRV-6575 Microstepping Drive – Alarm Codes11:55In the event of a drive fault or alarm, the green LED will flash one or two times, followed by a series of red flashes.The pattern repeats until the alarm is cleared.

DirectSOFT5 – Setting Up HSIO Mode 30 Pulse Output – 1 of 1512:24The first steps in programming theHigh-Speed Pulse Output Mode 30function that is built into the DL05PLC requires loading parameters intothe assigned V-memory registers.Constant value K30 is loaded intoV7633 to enable Mode 30 forgenerating output pulses.The octal address, O2320, is loadedinto V7630 to designate the beginningof the Profile Parameter Table.Pulse and direction is selected byloading constant K103 into V7637.Rung 1

DirectSOFT5 – Setting Up HSIO Mode 30 Pulse Output (cont’d) – 2 of 1513:45Continuing the setup of the High-Speed Pulse Output Mode 30 function, additional parameters are loaded intothe Profile Parameter Table:The constant K2000 is loaded into Vmemory address V2320 to select a VelocityProfile move.Constant K80000000 is loaded intodouble word size V-memory addressV2321/2322 to select CCW direction.The stepper motor SPEED is set with aninitial velocity of 100 pulses per secondby loading constant K10 into V-memoryaddress V2323. The loaded value ismultiplied by a factor of 10.Rung 2

DirectSOFT5 – Cycle Control Start/Stop Logic – 3 of 1514:48The rung shown here is used to latch in the ‘Feeder Run’ signal using the ‘F1’ and ‘F2’ function keys locatedon the C-more Micro-Graphic panel. ‘F2’ is the ‘Start’ pushbutton and ‘F1’ is the ‘Stop’ pushbutton.Memory address V2010 is assigned in the C-moreMicro-Graphic panel as the LED Control Word forthe Function Key and LED object. Out BitB2010.2 controls the LED on Function Key 3.Rung 3

DirectSOFT5 – Hopper Empty & Exit Tube Full Delay Timers – 4 of 1515:36Timer ‘T0’ allows the Part Feeder slotteddisk to continue to run for 10 secondsafter no more parts are detected in thehopper. The Hopper is Empty detector is aCapacitive Sensor.The timer resetsanytime parts are detected.A Fiber Optic Photo Sensor is used todetect if the Parts back up in the Exit Tube.Timer T1 is used so that every part thattriggers the Fiber Optic photo sensordoesn’t stop the Part Feeder slotted disk,and the part has to block the photo sensorfor one second before the action ispaused.Rung 4/5

DirectSOFT5 – Execute HSIO Mode 30 Parameters, Out Y0 – 5 of 1516:47The rung shown here controls the execution of the Velocity Profile that was setup with the HSIO Mode 30parameters in rungs 1 and 2. Out Y0 produces the step pulses that are wired into the stepper drive.Rung 6Contact C4 is the Feeder Runsignal that is shown in rung 3.Timers T0 and T1 contactsenable the rung when theHopper is not Empty and the ExitTube is not Full respectively.Contact C7 is the contact fromthe circuit that detects if there isno motion from the steppermotor, indicating a jam or motorfailure.

DirectSOFT5 – Slotted Disk Fast/Slow Speed Circuit – 6 of 1517:24The encoder that is coupled to the Stepper Motor is used for several functions. In this rung the encoder’smarker pulse, labeled Z-channel, which occurs once per revolution, is used to switch the Velocity Profile toa higher rotational speed to increase how many parts per time period are dispensed.The marker pulse provides a one-shot signal that islatched in through internal relay C1 for Fast Speed.The latch is held-in while counter CT0 is used tocount a pre-set amount of the encoder’s A-channel100 pulses per revolution to determine at whatrotational position to switch back to the Slow Speed.Rung 7

DirectSOFT5 – Slotted Disk Fast/Slow Speed Encoder Pulse Counter – 7 of 1518:00Counter CT0 counts the encoder’s A-channel pulses via DL05 PLC input X3 to determine how long thestepper motor stays in High Speed before switching back to Slow Speed.A pre-set of 85 counts is used in the application,which calculates to be .85 times 360 degreesequals 306 degrees in High Speed and 54 degreesin Slow Speed, which is over the point the part isdropped into the Exit Tube. Of course the countpre-set can be adjusted to produce differentresults.The Z-channel marker pulse occurrence point inthe slotted disk’s rotation is adjusted by looseningthe set screws on the stepper motor and holdingthe encoder in position while rotation the slotteddisk, then tightening the set screws.Rung 8

DirectSOFT5 – Slotted Disk Fast/Slow Speed Change Logic – 8 of 1519:02The logic shown here determines the running velocity of theStepper Motor. It switches between Slow Speed at 100 pulsesper second and Fast Speed at 300 pulses per second.With the Fast Speed internal relay C1 de-energized, theconstant K10 is loaded into the Profile Parameter Tablememory register V2323. This value, times a multiplier of 10,produces a Slow Speed velocity of 100 pps. With C1energized, the constant K30 is loaded into memory registerV2323 to produce a Fast Speed velocity of 300 pps.SlottedDiskRung 9/10

DirectSOFT5 – Analog Input IBox Instruction – 9 of 1519:24The current from the Stepper Motor Power Supply tothe Stepper Motor Drive is monitored using an AcuAMPDC current sensor. The output signal from the AcuAMPis 4 to 20 mA and represents 0 to 50 Amps as setup onthe sensor.The 4 to 20 mA signal is wired into a F0-04AD-1 analoginput module located in the expansion slot of the DL05PLC.To increase the current input resolution, ten turns arewrapped through the current sensor’s aperture, allowing5 Amps to produce full scale output.The ANLGIN IBox instruction is used to configure themodule with the Pointer Setup method as shown. Baseequals K0, Slot # is K1, there are four input channels,thus K4 is used, Input Data Format in binary equals K1,and Data Address assigned to V2000.Rung 11

DirectSOFT5 – Jam Detected via Stepper Motor Over Current – 10 of 1520:26The measured current that is drawn from the stepper motor power supply by the stepper motor drive isconstantly updated in memory register V2000 as was setup using the Analog Input Module Pointer SetupIBox instruction shown in the previous slide.Rung 12The Driver Current is compared in the rung shownhere to a Set Point value entered in memory registerV2100 through the C-more Micro-Graphic panel. Ifthe Driver Current is equal to or greater than the OverCurrent Set Point, then internal relay C5 is energized.This condition indicates that a Jam has occurred andsignals the next set of rungs to reverse the direction ofthe Stepper Motor with the intensions of clearing theJam.

DirectSOFT5 – Jam Detected via Reverse Timer – 11 of 15Rung 1321:00This rung looks for the C5 Jam signal as aresult of the Stepper Motor Power Supplycurrent that goes to the Stepper Motor Drivehas exceeded the Set Point value.The signal is used as a one shot and latchesin the circuit through internal relay C6, JamDetected.Timer T2, programmed for 10 seconds, isused to set how long the Stepper Motor isran in the reverse direction to clear thepotential jam. When Timer T2 times out, theReverse Rotation circuit is de-energized, andthe Stepper Motor returns to running in itsnormal direction.

DirectSOFT5 – Stepper Motor Forward/Reverse Logic – 12 of 1521:25The logic shown here determines the direction of theStepper Motor. It switches between the normalCounter-Clockwise direction to a Clockwise direction.With the Reverse Rotation internal relay C6 energized,via a rising edge one shot, the constant K0 is loadedinto the Profile Parameter Table memory registerV2321/2322 to produce a CCW direction. With C6de-energized, via a falling edge one shot, the constantK80000000 is loaded into memory registerV2321/2322 to produce a CW direction.Rung 14/15

DirectSOFT5 – No Motion Detection via Encoder Pulses – 13 of 1522:01Timer T3 is used to detect if the Stepper Motor isjammed, or has stalled, by means of monitoring theB-channel pulses that are produced by the encoderwhen the Stepper Motor is rotating.The Timer is enable by the Step Drive Run signal‘Y0’, and is programmed with a time of 0.2 seconds.The encoder pulses, input ‘X4’ are programmed intothe Timer’s reset, and causes the Timer to beconstantly reset as long as the Stepper Motor isrotating.Rung 16

DirectSOFT5 – Detect No Stepper Motor Motion – 14 of 1522:49If Timer T3 times out, indicating no Stepper Motor rotation, internal relay C7 is latched in through itself,and a normally closed C7 contact is used in the Step Drive Run ‘Y0’ output circuit to stop the StepperMotor from running.The No Step Motion circuit is reset by taking the CycleControl, internal relay C4, out of Feeder Run mode.Press the Feeder Stop push button (F1 Key) on theC-more Micro-Graphic panel to reset.Once the situation for the loss of motion is corrected,the Part Feeder can be put back into normal operationby pressing the Feeder Start push button (F2 Key) onthe C-more Micro-Graphic panel.Rung 17

DirectSOFT5 – Documented Project – 15 of 1523:27The DirectSOFT5 ladder logic program as shown in this video is not overly complicated. The commentedproject is a good example of the various programming elements that are available to the end user. Amajority of the programming basics that are a part of DirectSOFT5 are covered in the example project,including, a ‘control program’ that is used to configure the Mode 30 pulse output by loading parametersinto predefined memory locations, timers to allow detection of parts and encoder pulses, a counter toaccumulate rotary encoder pulses for motion detection, value compare logic instructions, outputsaddressed by bit of word, logic latching internal relays, assigned contacts from the C-more Micro-Graphicpanel, and an IBox instruction to configure the analog current input module.NOTE: A complete commented DirectSOFT5project for the Motion Control demopresented here is availa