Introduction to Motion Analyzer Design Software

For Classroom Use Only!

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Introduction to Motion Analyzer Design Software

Contents

Before You Begin .......................................................................................................................................... 4

About This Lab .................................................................................................................................................................................. 4

Tools & Prerequisites ........................................................................................................................................................................ 4

Start the Software and Open the Project ...................................................................................................... 5

Understanding the Motion Analyzer Profile Editor ........................................................................................ 6

Advanced Index Types in the Profile Editor .................................................................................................................................... 17

Exporting an Index Move to RSLogix 5000 ..................................................................................................................................... 19

Exporting CAM Profiles to RSLogix 5000 Add-On Instructions ...................................................................................................... 24

Importing CAM Profiles from RSLogix 5000 ................................................................................................................................... 28

Using Tuning Simulation ............................................................................................................................. 31

Compliance in Couplings ................................................................................................................................................................ 35

Backlash in Gearboxes ................................................................................................................................................................... 37

Reducing Compliance and Eliminating Backlash ............................................................................................................................ 39

Advanced Tuning Simulation ...................................................................................................................... 41

SolidWorks Integration ................................................................................................................................ 50

BOM Generation ......................................................................................................................................... 73

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Before You Begin

About This Lab

Welcome to the “Introduction to Motion Analyzer Design Software” lab. This session allows you to explore powerful new tools in

Motion Analyzer to quickly evaluate a variety of design options. This mechatronics design software integrates with RSLogix

5000 and SolidWorks to allow control engineers, electrical engineers, and mechanical engineers to see how their design

decisions affect the overall performance of the machine.

As you complete the exercise in this hands-on session, you will:

� Explore how to create a motion profile using Motion Analyzer

� Learn how to export Motion Analyzer profile data to RSLogix 5000

� Understand how to import CAM profile data from RSLogix 5000 into Motion Analyzer

� Analyze why a rotary direct drive motor may outperform a low inertia servo motor

� Interface with SolidWorks to size and select a motor and a drive

This hands-on lab is intended for individuals who:

� Size, select, and optimize motion control applications

� Mechanical engineers and controls engineers designing machines with motion control

� Machine users trying to improve an existing machine with motion control

� System integrators selling motion control

The lab is written to be completed in the order shown; each portion may be broken out and can stand alone too. If you do jump

around, talk to a lab instructor to make sure you have the right programs and files open.

This lab takes approximately 60 minutes to complete.

Tools & Prerequisites

� Motion Analyzer (v5.200)

� RSLogix 5000 (v19)

� SolidWorks 2011 SP4

� Introduction to Motion Analyzer.acd

� MA5.20 Tuning Simulation.mba

� Advanced Tuning Simulation.xlsx

� Hot_Stamper.SLDASM and associated files

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Start the Software and Open the Project

1. Start RSLogix 5000.

From the Start menu, select Programs > Rockwell Software > RSLogix 5000 Enterprise Series > RSLogix 5000.

2. Open the project named Introduction to Motion Analyzer.acd by clicking the Open Project button.

You can find the project in this directory: C:\Lab Files\

3. Start Motion Analyzer.

From the Start menu, Select Programs > Rockwell Automation > Motion Analyzer > Motion Analyzer

4. Accept the terms of use by selecting “I agree”, then click OK.

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Understanding the Motion Analyzer Profile Editor

Upon opening Motion Analyzer, you will be given the option to choose your sizing method. Each has advantages. The

Professional Mode has a new workflow which lets you enter all of your load information before you choose your drive family,

while the Classic Mode is the traditional workflow. The Just Quote Mode is for building a Bill of Materials (BOM) quickly when

you already know what motor and drive your application will use.

1. Click the Start button in the Professional Mode tile.

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2. Click the Application Data button to start entering the data for the first axis.

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3. In this screen you have the chance to choose one of the different load types. Later we will select the From

SolidWorks option, but for this example we’ll select the Linear option.

Click on the Select button in the Linear tile.

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4. This screen would allow you to enter data about the load. You don’t need to enter anything here, since the goal

is simply to export a motion profile to RSLogix 5000.

Click the Proceed to Profile Definition button.

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5. Once you have entered the motion profile, this screen provides an excellent summary.

Click the Edit Profile button to open the Profile Editor.

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6. This simplified version of the Profile Editor can be useful for very simple indexing. To create more complex

moves, the full Profile Editor is used.

Click More Options to load the full Profile Editor.

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7. Let’s get acquainted with the full Profile Editor. This powerful tool will allow you to quickly and easily create

industry-standard index moves, add loads or external forces to specific segments, and define acceleration and

deceleration curves with several different input parameters.

Let’s look at the screen, from left to right, then top to bottom.

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8. Click on the Start Condition button. After opening this pane, you can define your initial starting time, position,

or velocity. For example, if your application axis does not start from rest, you should enter that initial velocity

here.

9. Click the Add button. This is how you will add motion segments to your cycle profile. Let’s highlight some

commonly used segments:

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10. Click on the Accel/Decel segment. This segment will allow you to define motion using a variety of data entry

permutations.

11. Now click the Add button and select the basic Index segment. This segment allows you to vary two parameters

besides the move distance and time.

Changing the Index Type will allow you to define the amount of time spent on acceleration and deceleration, and how steep

those velocity changes are. Select Trapezoidal and notice the sliders that appear on the right hand side and bottom of the

screen. Drag them to view how the segment changes.

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12. Changing the Smoothness will allow you to add S-curve to your profile. Selecting Standard sets the

acceleration and deceleration jerk to 40% of time. At this value, transitions are smooth without greatly increasing

the torque required by the motor.

13. One easily-overlooked feature is the Segment Load button.

Click Segment Load to open the editor.

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14. Click the (pushpin) to lock the Segment Load Editor into place. This is where you add external forces and

payload masses to specific portions of the motion profile.

15. Click the pushpin again to hide the Segment Load Editor.

16. Click the Arrow next to the Delete button and select Delete All to remove the segments you have added during

this Profile Editor exploration.

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Advanced Index Types in the Profile Editor

The Profile Editor in Motion Analyzer contains several index move types. These move types all offer different benefits to

machine builders. In this exercise, you will see the different index move types offered and the benefits of each.

1. In the bottom left corner there is a section called Profile Plot. Click on the Distance and Acceleration buttons to

show those values. This will help you visualize the different profiles. Using the Profile Editor, select Add and

then select Index Advance. Enter the following data:

� Move Distance: 250 mm

� Move Time: 1 second

There are quite a few options in the drop down menu for Advance Index Type. Each of these has advantages in certain

applications. You can look at the graph on the next page to see how that velocity profile changes, depending on what type

of move you use. See the table below for a numerical analysis of the different move profiles. The standard index move has

been included too, so you can compare the advanced index types against a Triangular Index and a Trapezoidal Index. All

of these moves were evaluated for a generic distance of 1 position unit in 1 second.

Move Type Peak

Velocity

Peak

Acceleration

Peak

Jerk

Zero velocity

at boundaries?

Zero acceleration

at boundaries?

Zero jerk at

boundaries?

Standard Index Moves

Triangle 2.00 4.00 Inf Yes No No

1/3

Trapezoidal 1.50 4.50 Inf Yes No No

Index Advance Moves

Index SHM 1.57 4.93 Inf Yes No No

Index 345

Poly 1.88 5.76 60.00 Yes Yes No

Index Mod

Sine 1.76 5.53 69.47 Yes Yes No

Index 2 3

Poly 1.50 6.00 Inf Yes No No

Index 4 5 6

7 Poly 2.19 7.51 52.50 Yes Yes Yes

Index Adj

Sine 2.00 6.28 39.48 Yes Yes No

Index Mod

Trapezoidal 1.99 4.89 63.55 Yes Yes No

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Exporting an Index Move to RSLogix 5000

1. Choose one of the index types that you like (or a few indices if you are feeling adventurous) and build a profile

you can be proud of.

2. Click the Export button on the lower left hand side of the Profile Editor.

3. Click the Next button to continue to the Type of Exports screen shown. Click on the Logix CAM Profile Editor

radio button, and then click Next again.

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4. Select the Motion Axis Time Cam (MATC) radio button and then select Next. The screen will now show the

Logix CAM Profile data calculated from the index input parameters. Depending on the index type you selected,

your data may differ.

5. Click the Next button, select Clipboard, click Next again, and then click the Finish button.

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6. Switch to RSLogix 5000 and open MainRoutine within MainProgram. Ignore the MATC instruction already in

Rung 0 and add a rung with a new MATC instruction (Motion Axis Time Cam) with the following values:

� Axis: Follower

� Motion Control: MATC_Follower

� Direction: 0

� Cam Profile: CAM_01[0]

� Distance Scaling: 1

� Time Scaling: 1

� Execution Mode: Once

� Execution Schedule: Immediate

The rung should look as below:

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7. Click on the for the Cam Profile. This will bring up the Cam Editor. Right click on the in the Master-

Slave distance table. Select Paste as shown below.

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8. Press the button on the toolbar. This will scale the move profile to fit in the Cam Editor window and the

move profile will be shown in the same fashion as the Motion Analyzer Profile Editor. Your graphic may differ

slightly, depending on which move instruction you used.

9. Close the Cam Profile Editor. Do not save the changes. Delete the rung that you just created.

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Exporting CAM Profiles to RSLogix 5000 Add-On Instructions

The Motion Analyzer Profile Editor supports the creation of Add-On Instruction (AOI) ladder code. Rather than creating a single

segment that cannot be easily changed programmatically, this option breaks each section of your motion profile into chunks that

can be easily changed within the logic. When using an index, the distance and time can be changed in the AOI and the new

move will be calculated in RSLogix 5000 without having to export a new Cam Profile from the Motion Analyzer Profile Editor.

1. In the Motion Analyzer Profile Editor, start the export process for the same motion profile again by clicking the

Export button. Click Next and then select the Logix Ladder AOI Instructions radio button.

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2. Click Next and then select Motion Axis Time Cam (MATC). Click Next again and you will see the ladder logic

in neutral text format.

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3. Click Next, select Clipboard, click Next, and then click Finish. Switch back to RSLogix 5000 and your ladder

logic should still be open from the previous section.

4. Double click on the label for the last rung labeled (End).

5. If the drop-down menu next to the text edit field says “In ASCII Text”, change it to “In Neutral Text”. In the text

field to the right of that, paste the clipboard data. You can right-click and select Paste, use Ctrl-V, or use the

Edit Menu to select Paste. Hit Enter on your keyboard to accept the changes to the rung or the green check

box that is highlighted below.

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6. The screen shot below shows the logic after it has been pasted into the routine.

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Importing CAM Profiles from RSLogix 5000

The Motion Analyzer Profile Editor supports the import of some Cam Profiles from RSLogix 5000. At this time, it does not

support two consecutive linear segments (which by definition creates a discontinuity in the velocity profile which cannot be

accurately simulated). In this exercise, you will import the Cam Profile from RSLogix 5000.

1. In the Motion Analyzer Profile Editor, click the arrow next to the Delete button and then select Delete All to

delete any existing segments. Click Add and Logix Elements.

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2. Switch to RSLogix 5000 and select the MATC in rung zero. Click on the for the Cam Profile. Select all of

the segments and then right click to copy all of the segments, as shown. It is important not to select the row

marked with the asterisk, since it will cause errors when pasted into Motion Analyzer.

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3. Switch back to the Motion Analyzer Profile Editor and click the button in the Logix Element Motion Parameters 1

pane labeled Import from Logix Editor. This will pull the data in from the clipboard, assuming that the

clipboard contains RSLogix 5000 Cam Profile data. If you turn off the Acceleration graph by pressing its button

in the lower left, your screen should match this one.

This can now be used to size the motor and drive combination.

4. Close RSLogix 5000 and Motion Analyzer. You don’t need to save the changes.

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Using Tuning Simulation

In this section of the lab, you will use the simulation tools built into Motion Analyzer to verify that the system stands a good

chance of being commissioned successfully. You will analyze three different axes, all of which have already been sized.

The tuning simulation feature in Motion Analyzer is able to show the likely dynamic behavior of a load and motor, being

controlled by a servo drive and a Logix controller. The simulator is able to factor in real world considerations such as tuning

gains, filters, compliance, backlash, and external disturbances.

Running a tuning simulation not only gives a good indication of the system’s stability, it also indicates the probable following error

along the profile. This will help mitigate costly design changes and allow for faster commissioning.

1. Open MA5.20 Tuning Simulation.mba in the C:\Lab Files folder.

After acknowledging the disclaimer, the System View page will load, which shows a system in Motion Analyzer. The three

axes represent the three test cases you will simulate in this exercise:

� Axis 1 – Low inertia motor with coupling to shaft

� Axis 2 – Motor with planetary gearbox

� Axis 3 – Direct drive rotary motor

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2. Double click on Axis 1 and select the Solution tab. You will see that all of the bars are green, indicating that the

system is properly sized, however the inertia ratio is pretty high – almost 50:1, which may cause dynamic

performance issues.

3. In order to determine the dynamic performance of the system, you can click on the Simulation button at the

bottom of the Solution page.

This will launch the tool that allows you to simulate the performance of Kinetix 2000, Kinetix 6000, Kinetix 7000,

and Ultra3000 SERCOS servo drives operating with a Logix controller. When the tool opens, a dialog box will

appear – click the OK button.

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4. Take a moment to familiarize yourself with the screen. On the left hand side, there is information about the

control system including the processor, drive, motor, and load. On the right hand side are the tuning parameters

that would be used in RSLogix 5000. In the center, there is a trend that shows the predicted velocity feedback,

predicted torque feedback, and the predicted position error.

The trends shown here represent the system performance with default tuning gains – that means that the controller has not

adapted the gains to accommodate the load. The dynamic performance in this case is a bit sloppy, which can be readily

seen by the differences in command velocity (grey curve) and actual velocity (green curve) in the uppermost plot. In

RSLogix 5000, the Auto-Tune function will determine the reflected inertia of the load and then adjust the gains as needed.

The Motion Analyzer Auto-Tune function will use the same equations along with the load that was entered to produce the

same results.

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5. Click the Auto-Tune button, and then click the Tune button that will appear. The gains will be adjusted, so you’ll

need to click the Run button in order to see the results of the Auto-Tune. Notice how the performance changed.

6. Click the Auto-Tune button again, but now you should explore the different options available before clicking the

Tune button. You can also customize your tuning by venturing away from one of the tuning modes shown. Be

careful though – some tuning parameters should not be used at the same time, and having more gains active

does not mean better performance!

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Compliance in Couplings

Let’s start with analyzing the coupling that connects the load to the motor of Axis 1. So far our tuning simulation has assumed

that the shaft and screw are directly coupled since we have not entered any data to suggest otherwise. Given this coupling, how

does the simulation perform?

1. Enter the torsional rigidity value of 116 Nm/degree (also known as stiffness) into the proper field. It’s in the

bottom left corner of the simulator window. Run the simulation again. This screenshot was taken after

performing a Basic Auto-Tune.

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2. Use the selection of couplings below to explore which are acceptable for this application. It may be helpful to

change the Auto-Tune Application Type as well. Enter the torsional rigidity and run the simulations:

Note: In servo applications, couplings need to be selected for both torque rating and stiffness. Tuning simulation can help

determine if a particular coupling is suitable.

3. Exit the current simulation by clicking the Return button and then selecting No when the pop-up box appears. If

you choose Yes, you can save your tuning parameters for the commissioning process.

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Backlash in Gearboxes

Note that the motor is only reaching 12% of its peak speed. By adding a gearbox, we can significantly reduce the torque

requirement at the motor and increase its speed, which would allow a much smaller motor and drive.

1. Click on the arrow to the right of the Axis View button, and select the Motor with gearbox. If a dialog box

appears, click OK. This alternative shows the same load and profile, but with a smaller motor, drive, and 7:1

gearbox.

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2. Although correctly sized, it is important to test the dynamic performance of the system. Click on the Simulation

button and then acknowledge that the default gains will be used by clicking OK.

We see below that the “out of the box” results are again a little bit sloppy. If you look at the inertia ratio, you can see that it

is set to 1:0 (since an Auto-Tune has yet to be performed). The Backlash has been set to a default of 6 arc-mins, though

you can change this for your specific gearbox.

3. Click the Auto-Tune button, Tune button, and then the Run button.

Does performance improve? Think about what is happening… Try to fix the problem by adjusting the gains, filters, or

position loop bandwidth.

4. Try the Auto-Tune again, but adjust the Position Bandwidth (labeled as Position BW) to 10 Hz and set the

Application Type to Tracking. All of these options will be visible after clicking Auto-Tune. Then click Tune and

Run again. As you can see, there is a significant change in the performance (the system is more stable now),

but the position error has increased as well.

Note: In servo applications, gearboxes need to be selected for the torque rating and the backlash. Tuning simulation can

help determine if a gearbox is stable before commissioning, and will also help you to prevent noise and potentially harmful

gearbox chatter by entering in your simulated gains.

5. Exit the current simulation by clicking the Return button and then selecting No when the pop-up box appears.

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Reducing Compliance and Eliminating Backlash

1. Switch to the Direct drive rotary axis by clicking on the arrow to the right of the Axis View button, and

selecting the Direct drive rotary. If a dialog box appears, click OK.

This axis shows the same move and load profile, but with an Allen-Bradley Rotary Direct Drive motor; these motors are

specifically designed to reduce compliance and eliminate backlash from the connection. By removing these parasitic

properties from the system, the performance can be improved dramatically.

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2. Click on the Simulation button and click OK to acknowledge that the default gains will be used for the first

simulation.

As before, we need to tune the system in order to get better dynamic response. Look closely though at the out-of-the-box

performance. Since Rotary Direct Drive motors are more immune to large differences between the inertia of the load and

the inertia of the motor, the out-of-the-box gains provided a much closer approximation than for the other axes.

3. Click Auto-Tune and select the Tracking application type from the pull-down menu. Click Tune and Run in

order to see what the system performance will be.

With the direct drive motor, the system does not need to be “de-tuned” to achieve stable performance with very little

following error.

4. Exit the current simulation by clicking the Return button and then selecting No when the pop-up box appears.

5. If continuing on to the Advanced Tuning Simulation section, leave Motion Analyzer open. Otherwise, you can

exit the program without saving your work.

Note: The cost of making a design change in the field is estimated to be 10 times higher than during the machine build, and

100 times higher than in the design stage. Using this Tuning Simulation helps to reduce the risk of design errors, while also

providing information that can help to reduce product cost. Finding an optimal design that is not grossly oversized or too

small to meet the dynamic performance requirements will help you maintain costs.

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Advanced Tuning Simulation

This section is designed to be completed after the Using Tuning Simulation section or by those users that already have a

familiarity with Motion Analyzer; many steps are intentionally covered in less detail than other sections. In this section, you will

learn how to import complex profile data from a Microsoft Excel document. After that, you will be challenged to create the best

control solution from a Total Cost of Ownership perspective – which includes acquisition cost, power consumption, and

commissioning time.

1. If it is not already running, open the file MA5.20 Tuning Simulation.mba, located in C:\Lab Files.

2. From the System View, add a new axis by clicking the button below the existing axes.

3. Acknowledge the dialog box that appears and continue.

This message will inform you that the Integrated Axis Module configuration that had been chosen is no longer valid. Since a

new axis has been added, the converter module of the system will need to be sized again.

4. Click the Application Data button for the new axis.

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5. In the Load Type screen, click on the Select button for Rotary Complex load types.

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6. The defaults for the Rotary Complex are shown. You can use one of the existing templates for entering your

data, but in this case you will use the User-Defined option. This gives you more freedom to analyze your

complex load with 3rd party computational programs or to verify the dynamics of motion that were calculated by

hand.

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7. Open the file C:\Lab Files\Advanced Tuning Simulation.xlsx to see the load that will be entered.

This could represent a vertical crank. Note the graphs on the side that show the inertia and applied torque of the rotary

load. The applied torque is calculated by determining what static holding torque would be required to prevent the load from

falling. In this example, the circular motion of the crank has been broken into 3.6° increments – 100 sections around the

circle.

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8. Select columns A through F and then copy that data to the clipboard.

9. Switch back to Motion Analyzer and click the Clear Data button.

10. Select the only row of data that remains, and then click the Paste button.

In order to select the row without editing it, you need to click on the row number.

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11. Remove the header by selecting that row and clicking the Delete button. Switch the graphics tab on the right

from Image to Graph to see the load profile you just entered. Everything is scaled to 100% of its maximum

value, which is why the Friction Torque looks to be so large compared to the others.

Click the Proceed to Profile Definition button.

12. Click Edit Profile and then More Options to open the full profile editor. This example will model a constant

speed application, taking advantage of the linear sinusoidal motion of crank on the load end.

13. Delete the default segment.

14. Click Add > Accel/Decel. Set the following:

� Time: 1 second

� Velocity: 120 rpm

� Jerk Percentage: 100 % of time

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15. Click Add > Cruise/Dwell and set the following:

� Time: 4 seconds

Click OK. Your completed profile should look something like this example. Click Proceed to Transmissions.

16. At this point in the lab, you have freedom to choose your motor, drive, and transmission combination. A few

things to keep in mind as you move forward:

If you choose one of the Rotary Direct Drive motors, no gearbox or transmission should be selected.

The Kinetix 6000 drive family should be chosen with 3-Phase supply at a nominal 460 Volt input. The other axes in this

system have all been sized to be a part of a single Kinetix 6000 rack, and this new axis would need to share the same

chassis.

Try sorting your solutions list by Cost Factor, Avg Power, and Inertia Ratio. Each will have importance in the Total Cost of

Ownership.

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17. Once a solution has been selected, open it up for more investigation. As shown on the plot, the data points are

varied and represent the complex load throughout its motion profile.

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18. Open the Simulation tool and run the Default Gains simulation. Your simulation may look different, and

depending if the position error is acceptable for the application this is being used for, you may need to tune the

system.

Note: It may take longer than before to open the tool, since there is significantly more profile data to pass.

19. Try an Auto-Tune for the Tracking application type. This will reduce the following error as much as possible.

Run the simulation. What happens?

You may need to reduce the bandwidth, change the checkboxes in the Application Type, reduce your compliance or

backlash (if using transmissions), increase the damping, or add filters.

Also, compare the performance of a motor with a gearbox compared to a direct drive motor. Looking at the position error

graph can help.

Note: Performing this kind of simulation can help you see the advantages and disadvantages of using different types of

mechanics before they are built, for example, how a linear motor could replace a constant speed crank.

20. Close Motion Analyzer and Excel when you are done. You don’t need to save the files.

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SolidWorks Integration

SolidWorks Motion has built in tools that allow for complex inertia estimation and torque estimation. Rather than having the

controls engineers recalculate all of these values for motor sizing, Motion Analyzer ties into SolidWorks so that the controls

engineers and mechanical engineers can use the same models. This allows for consistency in calculations throughout the

design process, as well as design validation.

1. Open SolidWorks. This may take a few moments.

Double-click on the icon on the desktop or, from the Start menu, select Programs > SolidWorks 2011 > SolidWorks 2011.

2. After SolidWorks has opened, click the icon in the menu bar to open a model.

3. Navigate to C:\Lab Files\SolidWorks\Hot_Stamper.SLDASM and open it.

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4. The file will load showing a stamping press. This particular version of the model has been simplified to reduce

calculation time, but this model will still calculate the torque profile for a stamping operation.

5. At the bottom of the screen, there are three tabs: Model, Motion Study-Results and Motion Study-Fresh.

Motion Study-Results will show what your motion study should look like after calculation, while we will use

Motion Study-Fresh for our calculations.

6. Start Motion Analyzer.

From the Start menu, Select Programs > Rockwell Automation > Motion Analyzer > Motion Analyzer

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7. Accept the terms of use by selecting “I agree”, then click OK.

8. Click the Start button in the Professional Mode tile, which simplifies the SolidWorks integration.

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9. Click the Application Data button to start editing the data for the first axis.

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10. In this screen you have the chance to choose one of the different load types. Since we will be getting data from

SolidWorks, we’ll use that method.

Click on the Select button in the From SolidWorks tile.

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11. SolidWorks Motion supports linear motors and rotary motors. The load we are sizing is moving linearly, however

SolidWorks Motion will be calculating all of the mechanical information downstream of the motor. All we need to

do is select the correct motor type. In this case, it is Rotational (Rotary), so select that radio button. Then click

the Proceed to Profile Definition button.

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12. When the Profile Summary screen appears, click the Edit Profile button.

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13. When the simplified Profile Editor displays, click the More Options button so that we can link multiple indices

together.

14. In the full Profile Editor, we can create a few indices. For this operation, make two identical Index Moves. Each

should have the following data:

� Move Distance: 0.5 rev

� Move Time: 0.2 sec

� Index Type: Automatic

� Smoothness: Maximum

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15. Add a dwell at the end of the profile for 0.1 seconds. Then click OK.

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16. Click the Proceed to SolidWorks Load button.

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17. The SolidWorks Load Data screen allows you to compare the actual Motion Analyzer velocity profile and the

SolidWorks velocity profile. In order to pull the data into Motion Analyzer, click the Launch SolidWorks

Simulator button.

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18. Motion Analyzer will launch a new window and display the SolidWorks model that is has connected to. If your

screen differs significantly from this one, please contact an instructor. Click the Next button.

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19. This step will ask you to select a SolidWorks Motion Study for the data. Select Motion Study-Fresh from the

drop-down menu. Then click the Next button.

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20. The Motor Setup screen allows you to verify the SolidWorks Motor setup. Since the orientation of the motor in

this Motion Study is different than Motion Analyzer’s, select the Reverse Direction checkbox. In the case of the

lab, everything else is configured for you already. Click the Next button.

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21. The Summary screen is the last one before calculations take place. You can adjust the granularity of the motion

study by changing the frames per second. Change that value from 25 to 250 Frames/Second for this study,

since we have a short motion profile with fast acceleration and deceleration. When you click the Next button

now, SolidWorks will begin calculating values in the background.

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22. After the calculations are complete, the Results screen will appear showing the velocity and torque profiles

calculated using SolidWorks. If yours do not resemble the graphs shown, contact your lab instructor. Click the

Apply button to close the simulator.

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23. The SolidWorks Load Data screen has the graphs populated now, and it shows that the velocity profiles match.

If they were reversed, this screen would show that discrepancy so that you could correct your model. Click the

Proceed to Transmissions button.

Note: 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.

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24. Since the shaft has a maximum velocity of about 225 rpm in this application, let’s add a gearbox to utilize a

smaller motor at a higher speed. Click the checkbox for a Motor Mounted Gearbox. If you are familiar with

gearbox manufacturers, click the Edit button and select one that you use, and then select the series. If not,

leave the generic data in there. Click the Proceed to Motor button when done.

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25. Check the box for the MPL-Series motors and then click the Proceed to Drive button.

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26. Check the box for AC3ph Supply Type and select 460 as the Nominal Voltage. Click the radio button for the

Kinetix 6000 drive, and then Proceed to Selection.

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27. On this screen you have the option to search through the full database, select the exact model you want by

catalog number, or use the My Preferred search method. This reduced search method will help you maintain

lower spare parts inventories by only looking at the catalog numbers you select as your favorites to use. We’ll

continue with the full database, so click the Search Button.

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28. Once all of the solutions are shown, click on the Cost Factor header to sort by least expensive (lower numbers

are lower cost). If any yellow solutions are shown, uncheck the box for Caution (2). Select the lowest cost

option by double clicking on it. If a dialog box appears, click OK to acknowledge it.

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29. All of the red points on the torque-speed graph are the data points that SolidWorks Motion reviewed. Use the

arrows at the bottom right to look at different solutions from the list, or click back to the solution list.

30. Close Motion Analyzer and SolidWorks. You don’t need to save anything.

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BOM Generation

One of the new modes in Motion Analyzer is the Just Quote mode. This handy tool lets you create Bills of Material that follow the

rules of drive-motor-accessory pairing without having to open up the Motion Control Selection Guide. This can save you time

when you’re putting together a quick BOM.

1. Start Motion Analyzer.

From the Start menu, Select Programs > Rockwell Automation > Motion Analyzer > Motion Analyzer

2. Accept the terms of use by selecting “I agree”, then click OK.

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3. Click the Start button in the Just Quote Mode tile.

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4. Double click on the axis shown to configure its Bill of Material.

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5. The tool is conveniently split into steps.

6. The first step is to determine whether to quote rotary or linear motion. Let’s select Linear Motion.

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7. Next we need to determine whether to use an actuator or a linear motor. For this configuration, let’s select an

actuator – the Heavy Duty Electric Cylinder (MPAI) is one such option.

8. Pick one of the actuators from the list.

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9. Choose one of the drives that are acceptable. Blue listings are compatible, while red listings are not.

10. Select a motor power cable.

11. Select a motor feedback cable.

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12. None of the other steps are required for this application. If they interest you, please review them. To get more

information about any section, click on one of the links for Product Details. This will open the selection guide

page to that part.

13. When you are satisfied with your configuration, click the BOM View in the top menu bar. Explore the tabs and

add accessories.

Note: Though not shown in this lab, this BOM (or any other BOM created in Motion Analyzer) can be exported to Microsoft

Word reports for submission to project plans or quotes.

80 of 80 Publication XXXX-XX###X-EN-P — Month Year Copyright© 2011 Rockwell Automation, Inc. All rights reserved.

Supersedes Publication XXXX-XX###X-EN-P — Month Year