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In this blog post, I’ll walk you through how to easily program a timed pressing operation using our MEXE02 universal product support software. This example works for any products in the AlphaStep AZ Series family, which also includes other series that utilize the same technology and software.
When it comes to programming line by line, it’s helpful to break down the steps chronologically. However, the MEXE02 software doesn’t follow a chronological order. Instead, it allows users to create point-to-point motion profiles that can be linked in various ways. Let’s consider what tasks the motor needs to perform in a timed pressing operation. For this example, we’re using a DRS2 Series compact electric cylinder, which leverages the AlphaStep AZ Series technology. Some of the great features of the AlphaStep AZ Series can only be accessed with the MEXE02 support software.
For instance:
1. Approaching the load at a high speed, such as 50 mm/s, and then slowing down as it gets closer to prevent damage. This can be achieved with a basic positioning operation.
2. Once the actuator crosses the dotted line and triggers the sensor, we want the system to switch to a slower push motion operation to continuously apply pressure to the load.
3. During the push motion operation, we want the actuator to push against the load for 5 seconds at a lower torque setting, then move back -0.1 mm.
4. After the push motion operation, the actuator should return to its original home position at 50 mm/s to be ready for the next load.
Now that we’ve outlined the motor’s tasks, we need to translate these requirements into specific functions and parameters to program the desired operation. While connecting motion profiles can sometimes be tricky, the MEXE02 software and our AlphaStep AZ Series products can significantly reduce the burden typically associated with traditional PLCs.
Visualizing the setup can be beneficial for programmers. In this example, we use a switch to initiate the motion sequence. The sensor’s output is connected to the driver’s R0 input.
A flowchart can help illustrate the process. Our flowchart also includes the actual functions required to make this operation happen, such as "positioning operation" and "push motion operation."
One of the advantages of using a DRS2 Series actuator is its ability to leverage both the AlphaStep hybrid control and absolute positioning capabilities from the AlphaStep AZ Series family of absolute closed-loop stepper motor products. This eliminates the need for external home sensors, limit sensors, and encoders, reducing the number of cables and increasing reliability.
The most challenging aspect of this motion sequence involves the driver detecting an external input signal (from the sensor) and jumping from one running motion profile to another that applies a preset torque percentage. This can be achieved using the Event Jump function, but we’ll also cover other essential functions required to complete this operation.
Before diving into these functions, let’s take a look at the MEXE02 software. Here’s a screenshot of the software after selecting a product series. Clicking on the menu items on the left changes the stored data parameters section on the right. The three yellow boxes highlight the specific functions we need to use.
We’ll zoom in on the same image to focus on the three key functions: Operation I/O Event, Direct-IN, and Operation Type (where you select push motion operation). Double-clicking the operation type opens its full menu of choices.
The Event Jump function, or Operation I/O Event, is designed to branch operations based on the ON/OFF status of the signal set in the Event Trigger I/O of an Operation I/O Event. It’s a function that can switch the operating mode of a running motor using an external or internal signal as a trigger. For example, the Event Jump function can act as an IF/THEN statement to get the motor out of a repetitive motion loop to perform another task.
Here, you can see the parameters you can set with the Operation I/O Event, which include Name, Link, Next data number, Dwell time, Event trigger I/O, Event trigger type, and Event trigger count.
The Push Motion function is a standard feature in most closed-loop stepper motor and servo motor systems. It describes a function where a motor intentionally stalls against a load to provide a continuous torque or push force. Push motion is useful in pressing operations, stamping operations, and even measurement operations.
To use push motion, you must select one of the following Operation Types:
- Continuous (push motion)
- Absolute push motion
- Incremental push motion (based on command or feedback position)
Remember to adjust the Operating current [%], as it controls the torque of the motor. Push motion won’t work if the Operating current is left at 100%.
The "Direct-IN" function assigns specific external or internal I/O signals to trigger certain operations. The driver needs to know which inputs it should be detecting.
Are you ready to see the solution? Below, we’ll show you what the data should look like within the MEXE02 support software. In the image below, we’ll mark the left menu again. The 1, 2, and 3 labels indicate the parameters we need to access.
In the Operating Data window, four motion profiles will need to be programmed (starting from #0). We’ll need two "absolute positioning" profiles, one "incremental push-motion (based on command position)" profile, and one "incremental positioning (based on feedback position)" profile. Remember to set the operating current to 20.0% (torque is proportional to current).
FYI, up to 256 motion profile slots are available. For applications requiring more than 256 motion profiles, please contact our technical support engineers for assistance.
In the Operation I/O Event window, we’ll need to program #0 and #1 in the following manner. We’ll need one "continuous sequential operation" and one "automatic sequential" operation. Ensure you select the "event trigger I/O", "event trigger type", and "event trigger count". For #0, we chose the ON edge for the event trigger type, and for #1, we used ON (msec). In the event trigger count, 5000 msec equals 5 seconds.
In the Direct-IN Function window, we need to set up two inputs. Simply tell the driver which inputs you want to assign to DIN0 and DIN1. In this case, it’s R0_R and TLC.
And that’s it! It might take some time to get comfortable with the MEXE02 software and the various methods to link motion profiles. The good news is that this programming example works for any AlphaStep AZ series family product and MEXE02 software, including the DRS2 Series compact electric cylinders, EZS Series linear slides, EAC Series linear cylinders, L Series rack and pinion, EH Series grippers, and DG2 Series rotary actuators.
If you’d like to learn more about the MEXE02 software, here’s a blog post and video introducing it.
Ready to see the MEXE02 software in action? Check out the video below demonstrating a round trip operation (back and forth move) combined with push motion.
Would you rather skip the intro and dive straight into programming? Here are instructional videos for AZ Series, AR Series, and RKII Series.
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Unfortunately, we don’t have a video specifically showing a timed pressing operation or an event jump operation. But here’s a video demonstrating a round trip operation plus push motion.
Feel free to reach out if you have any questions or need further assistance!