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© 2011 Eaton Corporation. All rights reserved.
1119 A/B - Enhancing close loop axis solution with new AxisPro valves
Nalin Shah, Kevin Alstrin, John Blomster
EDM 2011
2 2 © 2011 Eaton Corporation. All rights reserved.
AGENDA
• Introduction of AxisPro Valves and Closed loop modes
• Centralized VS. Distributed Architecture
• Overview of Pro-FX configuration ( Live Demo )
• Overview of DS408 Drive Position Control (DPC)
• Applications review
3 3 © 2011 Eaton Corporation. All rights reserved.
KBS1-PLC Closed loop position controlled Axis Panel 1
KBS1
New KBS1 (level 1) valve offers:
• M12 CAN-enabled com port
• Configurable command input
+/- 10VDC/4-20,+/-10,+/-15 mA
• Configurable “Enable option”
• Valve diagnostics over M12 port
• Diagnostics LEDs visible through
light port : Power, fault codes
• Backward compatible to existing
KBS series valve
CAN IN
Mach. Controller
Motion controller in PLC
4 4 © 2011 Eaton Corporation. All rights reserved.
CANopen DS408
• DPC – Drive Position Control – Used for control of cylinder position
• DSC – Drive Speed Control – Used to control the speed of a hydraulic motor or cylinder
• DFPC – Drive Force / Pressure Control – Used to control the force produced by a cylinder or the torque produced by a hydraulic motor.
• DPQ – Drive Pressure / Flow control (Eaton Custom)– Used to control flow (speed) until a threshold is reached then to control pressure.
5 5 © 2011 Eaton Corporation. All rights reserved.
KBS2-DS408/DSC Distributed Motor Speed Control axis Panel 2
New KBS2 (level 2) valve offers:
• Hard Coded axis motion
controller per DS408 standard
• Control and CAN-open
communication to Prop valve
• Closed loop (speed) feedback to
the valve
• Parameterize application on PC.
Download to the KBS2 valve via
CAN.
Mach. Controller
6 6 © 2011 Eaton Corporation. All rights reserved.
KBS3-DS408/DPQ: PQ axis distributed control Panel 3
New KBS3 (level 3) valve offers:
• Control and CAN open
communication to PROP valve
• Integrated pressure sensors (4
ports) connected to OBE controller.
• Pressure monitoring and/or control
on board - Pressure control hard
coded, configurable per DS 408
• Position control with cylinder
position signal to the valve.
• Parameterize application on PC.
Download to the KBS3 valve via
CAN.
External spring load illustrating
force control.
External spring load
Mach. Controller
7 7 © 2011 Eaton Corporation. All rights reserved.
KBS4 & KBS3:Two axis synchronized motion control Panel 4
KBS4 KBS3
New KBS4 (level 4) valve offers:
• White space, freely programmable in CoDeSys
• Local (additional) CAN bus for slave cylinder
• Master-slave and motion control on the valve.
• Master control KBS4 (CoDeSys) and slave KBS3 – DS 408.
External spring load on one cylinder shows parallel motion in
spite of uneven load.
External spring load
CAN IN
Mach. Controller
8 8 © 2011 Eaton Corporation. All rights reserved.
Moeller PLC & SmartWire-DT Panel 5
Moeller PLC to start motor
SmartWire-DT
9 9 © 2011 Eaton Corporation. All rights reserved.
Distributed Axis Control Architecture
Machine Control Architecture Centralized Versus Distributed
Axis-Pro supports all machine control architectures
Centralized Axis Control Architecture
10 10 © 2011 Eaton Corporation. All rights reserved.
On-Board Application Control Synergy with F(x) and IAB Portfolio
Application Software
Pro-FX® Control
Hydraulics
Gen. Purpose Controllers & I/O
High Performance Controllers
Human Machine Interface
Hydraulics
Gen. Purpose Controllers & I/O
High Performance Controllers
Human Machine Interface
Advanced Mobile Valves CC Piston Pumps
EFX Controllers Mobile
I/O
Exte
nders
SFX Controllers
VFX Displays Ultronics / JFX
Directional / Proportional Valves HydroKraft Pumps
Mobile Systems Stationary Systems
Config. Software
Pro-F(x)® Configure
Software
Control F(x)®
11 11 © 2011 Eaton Corporation. All rights reserved.
Summary of Recent Name Changes
Saturn Valve AxisPro Valve
Valve F(x) Pro-FX Configure
Control F(x) Control F(x)
Pro-FX Control
CoDeSys V2
CoDeSys V3
12 12 © 2011 Eaton Corporation. All rights reserved.
On-Board Application Control
DS408 Device Profile for
Proportional Valves and
Hydrostatic Transmissions
•Level 2, 3, and 4 Valves
•“Hard coded” motion
control algorithms
•Parameterized using Pro-FX
Configure
•Level 4 Valves
•“White Space”
•Programmable using Pro-
FX Control
DPC – Drive Position Control
DSC – Drive Speed Control
DFPC – Drive Force/Pressure Control
DPQ – Drive Pressure/Flow Control
pQ pump control / pQ cylinder control
Load sensing pump control
Single axis position, flow, or pressure control
Pres and temp compensated flow control
Synchronous axis control (master/slave)
Twin spool Meter in / Meter out control
Machine Prognostics & Diagnostics
13 13 © 2011 Eaton Corporation. All rights reserved.
Pro-FX Configure Versus Pro-FX Control
Pro-FX
Control
Used to program
the white space in
on Level 4.
Pro-FX
Configure
Used to
configure
Level 1, 2,
3, and 4.
14 14 © 2011 Eaton Corporation. All rights reserved.
Overview of Pro-FX Configure
15 15 © 2011 Eaton Corporation. All rights reserved.
Pro-FX Configure: Control Window
16 16 © 2011 Eaton Corporation. All rights reserved.
Pro-FX Configure: Monitor Window
17 17 © 2011 Eaton Corporation. All rights reserved.
Pro-FX Configure: Data Plotting
18 18 © 2011 Eaton Corporation. All rights reserved.
Pro-FX Configure: Diagnostics Window
19 19 © 2011 Eaton Corporation. All rights reserved.
Hard-Coded, Configurable Controls Drive Position Control (DPC)
Offset
Cylinder Setpoint Spool Setpoint
Cylinder Feedback
Saturation 4-Quadrant
Ramp
x
y
Scale
-1
Sign
Inversion
d
dtDerivative
d
dtDerivative
d
dtDerivative
LPF
Low Pass
Filter
Kv_ff
Velocity
Feed Forward
1
SIntegrator
Kp
Proportional
Gain
Ki
Integral
Gain
Kv
Active
Damping
Ka
Active
Mass
Saturation
-1
Sign
Inversion
Directional
Dependent
Gain
+
-
+
-
+
+
++
++
+
+
Demand
Value
Generator
Feed Forward
Controller
State Feedback
Controller
Actual Value
Conditioning Condition Feedback
Controller Output Conditioning
20 20 © 2011 Eaton Corporation. All rights reserved.
Hard-Coded, Configurable Controls Drive Position Control (DPC)
Offset
Cylinder Setpoint Spool Setpoint
Cylinder Feedback
Saturation 4-Quadrant
Ramp
x
y
Scale
-1
Sign
Inversion
d
dtDerivative
d
dtDerivative
d
dtDerivative
LPF
Low Pass
Filter
Kv_ff
Velocity
Feed Forward
1
SIntegrator
Kp
Proportional
Gain
Ki
Integral
Gain
Kv
Active
Damping
Ka
Active
Mass
Saturation
-1
Sign
Inversion
Directional
Dependent
Gain
+
-
+
-
+
+
++
++
+
+
Feed Forward
Controller
State Feedback
Controller
Actual Value
Conditioning Condition Feedback
Controller Output Conditioning
21 21 © 2011 Eaton Corporation. All rights reserved.
Hard-Coded, Configurable Controls Drive Position Control (DPC)
Offset
Cylinder Setpoint Spool Setpoint
Cylinder Feedback
Saturation 4-Quadrant
Ramp
x
y
Scale
-1
Sign
Inversion
d
dtDerivative
d
dtDerivative
d
dtDerivative
LPF
Low Pass
Filter
Kv_ff
Velocity
Feed Forward
1
SIntegrator
Kp
Proportional
Gain
Ki
Integral
Gain
Kv
Active
Damping
Ka
Active
Mass
Saturation
-1
Sign
Inversion
Directional
Dependent
Gain
+
-
+
-
+
+
++
++
+
+
State Feedback
Controller
Actual Value
Conditioning Condition Feedback
Controller Output Conditioning
22 22 © 2011 Eaton Corporation. All rights reserved.
Hard-Coded, Configurable Controls Drive Position Control (DPC)
Offset
Cylinder Setpoint Spool Setpoint
Cylinder Feedback
Saturation 4-Quadrant
Ramp
x
y
Scale
-1
Sign
Inversion
d
dtDerivative
d
dtDerivative
d
dtDerivative
LPF
Low Pass
Filter
Kv_ff
Velocity
Feed Forward
1
SIntegrator
Kp
Proportional
Gain
Ki
Integral
Gain
Kv
Active
Damping
Ka
Active
Mass
Saturation
-1
Sign
Inversion
Directional
Dependent
Gain
+
-
+
-
+
+
++
++
+
+
State Feedback
Controller
Actual Value
Conditioning Condition Feedback
23 23 © 2011 Eaton Corporation. All rights reserved.
Hard-Coded, Configurable Controls Drive Position Control (DPC)
Offset
Cylinder Setpoint Spool Setpoint
Cylinder Feedback
Saturation 4-Quadrant
Ramp
x
y
Scale
-1
Sign
Inversion
d
dtDerivative
d
dtDerivative
d
dtDerivative
LPF
Low Pass
Filter
Kv_ff
Velocity
Feed Forward
1
SIntegrator
Kp
Proportional
Gain
Ki
Integral
Gain
Kv
Active
Damping
Ka
Active
Mass
Saturation
-1
Sign
Inversion
Directional
Dependent
Gain
+
-
+
-
+
+
++
++
+
+
State Feedback
Controller
Condition Feedback
24 24 © 2011 Eaton Corporation. All rights reserved.
Hard-Coded, Configurable Controls Drive Position Control (DPC)
Offset
Cylinder Setpoint Spool Setpoint
Cylinder Feedback
Saturation 4-Quadrant
Ramp
x
y
Scale
-1
Sign
Inversion
d
dtDerivative
d
dtDerivative
d
dtDerivative
LPF
Low Pass
Filter
Kv_ff
Velocity
Feed Forward
1
SIntegrator
Kp
Proportional
Gain
Ki
Integral
Gain
Kv
Active
Damping
Ka
Active
Mass
Saturation
-1
Sign
Inversion
Directional
Dependent
Gain
+
-
+
-
+
+
++
++
+
+
Condition Feedback
25 25 © 2011 Eaton Corporation. All rights reserved.
Hard-Coded, Configurable Controls Drive Position Control (DPC)
Offset
Cylinder Setpoint Spool Setpoint
Cylinder Feedback
Saturation 4-Quadrant
Ramp
x
y
Scale
-1
Sign
Inversion
d
dtDerivative
d
dtDerivative
d
dtDerivative
LPF
Low Pass
Filter
Kv_ff
Velocity
Feed Forward
1
SIntegrator
Kp
Proportional
Gain
Ki
Integral
Gain
Kv
Active
Damping
Ka
Active
Mass
Saturation
-1
Sign
Inversion
Directional
Dependent
Gain
+
-
+
-
+
+
++
++
+
+
26 26 © 2011 Eaton Corporation. All rights reserved.
Pro-FX Configure: Graphical Configuration Window
27 27 © 2011 Eaton Corporation. All rights reserved.
Demand Value Generator Configuring the 4-Quadrant Ramp
Define the 4 ramp rates
in units of um/sec
28 28 © 2011 Eaton Corporation. All rights reserved.
Testing the 4-Quadrant Ramp Using Data Plotter
29 29 © 2011 Eaton Corporation. All rights reserved.
Testing the 4-Quadrant Ramp Using Data Plotter
30 30 © 2011 Eaton Corporation. All rights reserved.
Demand Value Generator Configuring the Saturation Limit
31 31 © 2011 Eaton Corporation. All rights reserved.
Blow Molding: Parison Control
Application: Plastic Blow Molding M / C
• DS408-DPC / Drive Position Control in KBS2
• Position accuracy reqd. with in ~ +/- 0.001 in.
• CAN-open communication to Prop valve
• Closed loop (position) feedback to the valve
KBS2
M/ C Controller
32 32 © 2011 Eaton Corporation. All rights reserved.
Press Brakes Application
KBS3
Application: Press Brake (200T – 3000T)
• DS408-DPQ: Drive P / Q Control in
KBS3
• Sync. position accuracy reqd. with in ~
+/- 0.0004 “
• Control flow (speed) until a threshold
is reached then switch to pressure
control
Sensor
33 33 © 2011 Eaton Corporation. All rights reserved.
Wind Turbine: Pitch adjustment of rotor Blades
M/ C Controller
Application: Wind Turbine-Blade
pitch Control
• DS408-DPC: Drive Position Control
in KBS2
• Set point command are generated
as a function of wind speed, wind
dir. And rotor speed and fed to KBS2
• Position sensor output is typ. 4-20
mA
34 34 © 2011 Eaton Corporation. All rights reserved.
Flattening machines:- Roll Gap Control
P T
KBS4 KBS3 M/ C Controller
Application: Flattening Machine
• Control thickness in manufacturing of foils
or floor coverings
• Synchronized motion control of two
cylinders to maintain accuracy ~ 0.0004 in.
• Control algorithms in white space of KBS4
35 35 © 2011 Eaton Corporation. All rights reserved.
Hydro forming Press Application
Application: Hydro forming press
• DS408-DPQ: Drive P / Q Control in KBS3
• Pressure on cap end and position of cylinders
maintained to allow no leakage of fluid during
intensified forming pressure
DIE
PART
KBS3 KBS3
Intensified Forming
Pressure
36 36 © 2011 Eaton Corporation. All rights reserved.
Welding – Steel bands
KBS2 KBS2
KBS2
KBS2
KBS2 KBS2
Controlled
Gap
Application: Welding bands
• DS408-DPC Drive position
control in KBS2
• Bands are aligned in Y dir.
• Bands are positioned in X dir.
to control gap
Y Dir.
X Dir.
37 37 © 2011 Eaton Corporation. All rights reserved.
Mold Oscillator – Continuous Casting Plant
Application: Mold Oscillator in
Continuous Casting Plant
• DS408-DPC: Drive Position Control
in KBS2
• Mold is oscillated to keep material
in molten state
KBS2
M/ C Controller
38 38 © 2011 Eaton Corporation. All rights reserved.
Journal Bearing Closed Loop Application - Kirloskar Oil engine Limited, India
•To Check Journal Bearing Half – Dim.
Accuracy
•External motion control in the PLC
• Open Loop Velocity (Q) Mode
• Closed Loop Force (p) Mode
with 400 Kg +/- 18 Kg accuracy
• Total Cycle Time – 0.9 sec
• KBS level 1
KBS 1 KBS 1
39 39 © 2011 Eaton Corporation. All rights reserved.
Car Sear Belt Assembly Anchorage Test Rig – Calspan, USA
•Test Rig to test Car Seat Head Rest, Seat
Back and Anchoring capacity
•External motion control in the PLC
• Closed Velocity (Q) Mode
• Closed Loop Force (p) Mode
• KBS level 1
40 40 © 2011 Eaton Corporation. All rights reserved.