towards manufactured parts. Highly critical parts need stringent inspection. For these kinds of applications Easy Vision brings huge benefits, since it is easily applicable, provides instant information without additional equipment and helps to stick to your budget for inspection equipment. Michael Glassl: Any concrete examples where Easy Vision has really helped your manufacturing process? Mario Backhaus: Some critical parts for the car and furniture industry needed adequate lubrication. The use of the ZFV immediately led to positive results. Besides this, we managed to improve
Lucian Dold Marketing Manager Sensing and Safety Omron Europe
our processes even further by introducing colour inspection for filtering out contrast more easily. So one improvement lead us to a better understanding and resulted in a major improvement action.

tesas experience

Lucian Dold: We understand that discrete production has its headaches in terms of inspection, but applying Zero Defect in a continuous process such as adhesive tape production must be a real challenge. Nico Liebert: At tesa we produce adhesive tapes at extremely tight thickness tolerances and at speeds sometimes exceeding 400 metres per minute. The thickness of the adhesive layer has a direct impact on the quality of the adhesive bond. Inspection systems are mainly used to check the application of paste. Core applications include the inspection of transparent stamps. The main difficulties lie with detection of hole positions in areas which are difficult to illuminate, and the small scanning range of just 2 to 3 cm per image, due to the extremely high line speed. Another major hurdle is that the product is transparent and therefore almost invisible. Hence border detection for proper material alignment while winding is somewhat tricky. Michael Glassl: Does it mean that such high requirements are met only by complex inspection systems? Nico Liebert: Not necessarily. At the beginning we used a high-end vision
system that required considerable expertise. When the system stopped, only a few people could help. However Zero Defect is only successful when the operator can also contribute to the process improvement when necessary. Thus for many inspection tasks Easy Vision can do the job. Lucian Dold: From a users point of view, what would you find essential in a good inspection system? Mario Backhaus: Colour and resolution are important elements which have been improved in the newer generations. Detecting free falling parts and identifying low contrast still represent important challenges. However, one should seriously consider the usability aspect. A feature packed system which leaves the user in the dark when malfunctions occur, or which requires a PC and a dedicated software just for diagnosing a fault, isnt quite realistic. The real challenge for a Zero Defect production process is really to bring the initiative to the shop-floor operator. Nico Liebert: I guess inspection system suppliers must balance performance and flexibility with ease of use. There are many inspection tasks that vision systems still have to solve. However, as users we are confronted with the reality of the shop-floor and always look at the total cost of ownership of the product. This means cost, usability and maintainability of the product. For us, achieving Zero Defect production is also a balance between failure-free production and sustainable cost. The Omron Easy

Teach & Go inspection systems. With its ZFV Vision Sensor family, Omron is again revolutionising vision by making it easy and intuitive.

Target, Teach & Go!

The concept behind the ZFV is Target, Teach & Go! It provides the right balance between user-friendliness and capability, by offering functionalities
Pattern recognition The PATTERN tool verifies if a symbol printed on a package is present and complete by comparing it with a previously taught reference. Position verification The correct cap position (closure) of a shampoo bottle is inspected using the POSITION tool which detects object edges.
Character recognition The CHAR tool verifies if a lot code, date code or product code is correctly printed on a label.
Width inspection The WIDTH tool measures an object, in this case a label, to verify that it is not folded or cut.
Area inspection The AREA tool verifies the size of an object, in this case sweets in a blister pack, to check their presence.
Object counting The COUNT tool verifies the number of pins on an IC by counting the edges within an area.
that users can understand and an easy intuitive method that saves time. The ZFV comes with a complete user interface, so a PC is unnecessary. The user interface consists of a crisp colour LCD screen and a few buttons. A simple menu guides you through the set-up procedure. To minimise installation effort, the sensor head comes with an integrated light with a field of view of up to 150 mm.
on the ZFV colour for connection to an external device or to a PC. The PC tool is of course available for the colour version for configuration and monitoring.
Colour the virtual third dimension
The ZFV family also includes a colour model, which is extremely useful in processes where colour coding or tagging is used, such as assembly of electronics and packaging. In terms of inspection functionality, the ZFV colour offers similar features to the ZFV grey scale but as it acquires a colour image, it uses the colour information in the image as a virtual 3rd dimension giving additional security and stability to your application.

Live image

The ZFV is the first vision sensor that offers live images of the inspected object on an LCD screen. The plain image of the inspected object, the inspection status (OK or NOT OK) and detailed results are simultaneously displayed. This eliminates the need for an additional monitoring device such as a PC or industrial terminal. In case the information needs to be remotely monitored, a USB port is available

The ZFV is the first vision sensor that offers live images of the inspected object on an LCD screen.
Target, teach, go and enjoy! Set-up in minutes
For all its simplicity, the ZFV is far from basic. The ZFV family offers a toolbox containing up to 8 built-in inspection tools, enabling you to address the majority of inspection tasks in minutes. With the ZFV familys focus on usability, Omrons ambition is to reduce the complexity of vision sensing. Everybody should be able to use a vision sensor without expert knowledge and without prior, extensive training. The ZFV vision sensor enables you to do exactly that.

www.never-fail.info

N e v e r f a i l. i n p r a c t i c e a t L O r a l
German Application Award 2005 winners:
1. Prize: Klaus Arhelger, Carl Cloos Schweitechnik GmbH, Haiger 2. Prize: Ralf Heikens, Hauni Maschinenbau AG, Hamburg 3. Prize: Bjrn Rinke, Rmerwall Naturbrunnen und Getrnke GmbH & Co. KG, Duisburg
In the eyes of a customer, your package is your brand. Missing or misplaced labels, spilled products, damaged seals may derail your best efforts to build up brand image and make your business grow.
German Sensor Application Award 2005
Hauni, the global market and technology leader in machine building for the international tobacco industry was awarded with the German Sensor Application Award 2005 at the automation technology exhibition SPS/IPC/Drives in Nrnberg, Germany. The innovative application with Omrons laser measurement sensors convinced the jury of well-known representatives of Media, Science and Industry and brought Hauni the second place in the nationwide competition. The German Sensor Application Award for the most effective, most economical, most creative or most unusual sensor application was founded in 2002 by an initiative of the Ruhr-University Bochum, Fraunhofer Institut Physikalische Messtechnik, Sensorspecialist Turck and the magazines elektro Automation and KEM.
A company like LOral is well aware of this fact: Striving for Excellence Perfection is our goal is one of its corporate values. And in the Karlsruhe production plant one of LOrals largest European production sites outside France Omrons ZFV teach & go vision sensors are supporting that value. Along with other products, at Karlsruhe, LOrals PURE ZONE, deep controlbottles are filled, labelled, packed and shipped throughout Europe. After each container is filled and closed, two labels are attached one on the front of the container, one on the back. The package represents

Your package is your brand
Never fail. in practice at LOral
LOrals brand, so accurate placement of these labels is crucial. This is where the ZFV comes in. It makes sure that the correct label is attached to the correct side by verifying a unique feature on each label using the (Pattern) Match function. This unique feature is typically one of the printed elements on the label to be inspected such as a symbol or a name, and since both sides of the object are inspected, 2 ZFV sensors are used. in the ZFVs bank storage and are switched via digital input signals, so theres no need to re-teach when the product type is changed. intuitive, easy-to-use product concept. Without needing specially-trained personnel, vision specialists or external support, LOral was able to
The line speed of 110 objects per minute is no problem for the ZFV since it is able to handle those cycle times per second.
The line speed of approximately 110 objects per minute is also no problem for the ZFV since it is able to handle those cycle times per second. Its no surprise that, beside its functionality, one of the key reasons for LOral buying the ZFV was its solve all the challenges presented by the application in an extremely short period of time. Target! Teach! Go! A good example of how Omrons ZFV helped to ensure LOrals brand image.
No problems with different product types
Although more than 1 variant of the product is processed on this machine, this is no problem for the ZVF. The settings for each variant are stored
By Axel Kalf, Product Manager Vision, Omron Europe
Omron technology supports Mechatronics center of excellence at the Finnish university
Mechatronics is now an essential discipline in the industrial automation world since modern machines are using extensively motion and servodrive technology. The School of Information and Communication of
Technology (ICT) Seinjoki Polytechnic in Finland has cooperated with Omron Electronics Oy to build a modern Mechatronics center geared to provide a complete curriculum on this subject.
Omron Business School because we care
For organisations to excel in the economically challenging global environment, its crucial that they have the competence to accept change, and then adapt to it as a core part of their corporate culture, while maintaining an implicit focus on the needs of their customers. As part of Omrons commitment to this ethos, the Omron Business School (OBS) has been established. The OBS is a dedicated European Training Centre. Its mission is to develop a coherent understanding throughout the organisation of what Omron deems to be of value to the customer, and how the company wants to approach and operate within its market. Programmes focus on motivation, coaching, performance and change management with external expertise used as appropriate. To date, the OBS has trained in excess of 150 employees the response from whom has been extremely encouraging. Roberto Maietti, European Sales Director, sees this success as a direct result of.placing the emphasis on programmes which both enhance our corporate knowledge and competence and deliver value that employees can use on a daily basis. We strongly believe that the combined effect ultimately gives sustainable value to our customer base.

Robert van Geffen Web Content Coordinator

www.omron-industrial.com

Providing you with expertise online
Omrons new, improved website enables you to access our knowledge banks, whether you are looking for a new product or are already using an Omron solution. The product selector on our homepage is your guide to the right product. Simply select from our product ranges and scroll down. Every click gives you more details. Once you arrive at the correct product page, the information at your fingertips includes: Detailed product specifications Brochures, manuals, datasheets to download Dedicated software and accessories Application stories And much more. If you have a question, or would like to request a quotation or brochure, simply click on the appropriate button on the product pages. We will follow up your enquiry quickly and efficiently.
Corrie de Bruijn New Media Coordinator
New Download center Sharing knowledge 24/7
A new Download center is now available from www.omron-industrial.com around the clock and in your own language. What is particular about this essential tool is its reliability, user-friendliness and multi-language capability. Based on Documentum the new tool allows you to search documents using familiar terms for products. Hence entering terms like HMI, MMI or simply Touch will invariably lead you to the range of our HMI terminals. There you have all document categories (manuals, brochures, datasheets) and an overview of languages in which it is available.
N e v e r s t o p. To t a l f r e e d o m i n m o t i o n c o n t r o l
Josep Marti Product Manager Omron Yaskawa Motion Control
With the ever-increasing demand for higher throughput, manufacturing processes nowadays operate more and more on a continuous basis. This has resulted in a marked shift from traditional step-by-step sequencing automation to continuous sequencing. This is now commonly called multi-axes control. In Omron we see it as our mission to popularise continuous sequencing and to bring it back to the customer level. Coming from that angle, it is hardly surprising that we designed Trajexia to be intuitive, transparent, open and functional.
Easy and powerful motion platform
At the heart of Trajexia lies Omrons new TJ1-MC16 high-performance multi-tasking motion coordinator. It is specifically designed to meet todays most demanding continuous-path motion control tasks, controlling up to 16 axes over a Mechatrolink-II with independent control of position, speed or torque for each axis. The use of the Mechatrolink-II motion bus significantly reduces wiring, space, installation complexity and breakdowns while increasing the system reliability and offering information transparency throughout the system. A common challenge facing machine manufacturers has been the high engineering costs of developing motion-control systems that meet the varying requirements of different machines with differing needs. With Trajexia, however, easy scalability from low to high axis-count creates the possibility to re-use motion solutions over several machine versions, providing significant savings in development time and costs. Moreover, even once a machine is in the field, the flexibility of the Trajexia platform allows a wide range of production adjustments to quickly and easily meet constantly changing and sometimes unexpected manufacturing requirements with minimum or even zero system down time.

ZS-H Multi-tasking at sub-m accuracy
Highest demand in quality control can be satisfied by the ZS-H expansion of the popular ZS-L series. The ZS-H controller is capable to run up to 4 measurement tasks in parallel. Solve applications with the unique 1500 mm sensing head or ensure 0,25 m precision at 0,05% linearity. You can be confident that the ZS solves your application because this family works reliably on almost all surfaces, from glass and metal to black rubber.
E5CSV - The easy way to perfect temperature control
The E5CSV temperature-controller series is the enhanced successor to our E5CS series. The new series shares many of the outstanding features that made its predecessor such a success including easy setting up using DIP and rotary switches, a large 7-segment LED display and choice of ON/OFF or PID control with Self-Tuning. However, the new E5CSV series offers much more, like an Auto-Tune function and multiple input types. The enhanced display enables the E5CSV to show a larger range, extending up to 1999 C. The series also complies with the IP66 Standard and the depth has been reduced to a mere 78 mm.
ZFV Colour Easy vision, teach & go
Omrons new ZFV smart vision sensor is an image processing system in a sensor format. It consists of two separate components, a camera head with an integrated light source and a processing unit. The latest addition to the ZFV family is the ZFV colour sensor. Using this instead of the conventional monochrome sensor widens the choice of applications and increases the stability of your inspection. Through its automatic colour filter function, image contrast is optimised, making measurements more reliable. There are 7 colour filters in total; the one that obtains the most suitable contrast is automatically selected, so theres no need to worry about colour setting parameters. Parameter settings and lighting control are available at the touch of a button. A smart user interface allows parameter setting using a few buttons and the built-in colour LCD monitor. During operation, the display gives direct feedback showing results and images in real time. Easy vision teach & go, for applications which can be solved in minutes not hours or days.

Features at a glance

Brilliant colour display Real-time result and image display Intuitive user interface One button teach teach and go Up to 8 inspection tools Adjustable inspection area and distance Integrated, adjustable LED light Up to 250 inspections per second

Quality FIRST with smart testing
To meet the tight timescale without compromising on Omrons legendary reliability, the development team also had to devise faster testing methods that could be used during development. Manual testing is too slow and automatic testing can be expensive. For this a completely new
N e v e r s t o p. L o g i c P A K r e l i e s o n Tr a j e x i a
When LogicPAK decided to design the new LPK sleeving machine, they insisted on working with a system that gives them total control on development, servicing and upgrading of the machine. This is key for safeguarding their unique know-how in high-speed sleeving machines. They decided for Trajexia.
From the technical aspect, the LPK had to be developed in less than 6 months, it had to be smaller, and be able to handle more product variety with a change-over time reduced by a factor of 3. where it is heat-shrunk. The Sleeve process is now closed and final inspection can eventually take place.
Motion and vision fully integrated
To achieve 160 cycle/min a non-stop operation had to be adopted, thus all axes had to be perfectly synchronised. The machine uses 10 rotary and 2 linear servo-axes, all coordinated via Mechatrolink motion bus. On-the-fly orientation mechanism is performed by precise synchronisation of ZFV vision sensors and a sophisticated servo-based mechanism. Final inspection is performed by an F160 unit. A CJ1 PLC takes care of the machine sequencing and management tasks while an NS screen is used for visualisation. The whole automation system is fully integrated allowing access to all devices via one Ethernet connection, thus achieving easy tele-servicing.
A beautifully synchronised operation
Products are transported into the machine over an inlet line, at which point a sensor identifies their presence and triggers the sleeve device to provide a foil. After the product has passed the inlet line it will reach the main drive. While the product moves further through the main drive, the foil, which is provided by the Sleeve device, will be pushed over the product. After this the product with the foil reaches over the outlet line the rotating device. The flow of the product through the rotating device goes beneath an electrically operated heating duct

Shrinking foil, prepared from sleeve device

Product

Inlet line

Main drive

Outlet line

Rotating device

Heating unit
Safety Guide featuring AN SEN MAN
Your companion in machine safety
While machine safety has gained a wide recognition in the industrial automation world, it is commonly acknowledged that the safety language is still a reserved domain of the specialist. Unfortunately, users are either confused by product suppliers due to the tendency to sell more complexity than to genuinely advise, or are simply overwhelmed by abstract regulations when they turn to notified safety specialists. Recognising that, Omron created an easy safety guide having the AN SEN MAN character as mascot. AN SEN MAN your guide through safety regulations and applications
AN SEN is the Japanese expression for safety. It is a guide dedicated to gain transparency for non-specialists. It addresses safety issues related to users as well as machine operators. It gives you valuable advice when designing a new machine or renovating an old one and provides you with
valuable background on safety standards and regulation. AN SEN MAN also covers international regulations like OSHA and standards from the US while giving hints and advice when exporting outside the EU. AN SEN MAN comes in a 12-language CD and is freely available from your nearest Omron office.
Realizing new opportunities in industrial automation
Automation Competence Centres
Turning ideas into proven solutions
Todays machines as well as their related automation components and networking systems are subject to ever-changing and challenging development leaps. Understanding the complexity while at the same time getting the simplicity of operating Omron systems across to potential users is no longer just a matter of fairs and exhibitions. Seminars and showrooms have been a method of knowledge transfer in the past, but with its new Automation Competence Centre (ACC) project, Omron is making way for a new kind of industrial automation dialogue.
The end result will be a number of Automation Competence Centres distributed throughout Europe, connected and interfacing with our existing application centres. Here, visitors will be able to find solutions to any of their specific problems, or thrilling inspiration for their future automation tasks. With a single visit, youll get a completely new perspective on possible savings and increased productivity opportunities. Each new Automation Competence Centre will comprise a number of key elements.

test and train in a hands-on way any process for which they want a smarter solution. Upon predetermination of your requirements, an environment can be set up to exactly match and evaluate your needs and present a suitable solution.
concept. They will be able to see for themselves how CX-One software offers a single connection point to communicate with, configure and monitor Smart Platform devices such as PLCs, HMIs, drives, servos and temperature controllers.
Omrons Automation Competence Centre project a new kind of industrial automation dialogue.
Designed to make machine automation easy, Smart Platform provides seamless, drag-and-drop integration of all automation components in your machine. Moreover, built-in distributed intelligence in Omron devices means that you spend less time programming and troubleshooting. Visitors will be able to discover the many benefits of Smart Platform by experimenting with CX-One software, which is an integral part of the Smart Platform
B. Expert Area Knowledge transfer from a manufacturers core competence
This area features the latest product presentations, including related application examples, plus an inspiring expert demo that demonstrates the possibilities of the latest and future technologies. Actual applications in your business field, linked to Omron-specific
A. Integrated Machine Area Proof for Smart Platform Concept
This area will feature a real machine testing environment with three manufacturing stations: Retrieval, Production, Distribution. A key objective of each ACC is to allow a visitor to configure, commission,
technology background and customer references accompany this knowledge transfer point in the ACCACC, so youll be able to benefit from Omrons huge knowledge base. The Technology part of the Expert Area is likely to continually change to keep up-to-date with the rapid pace of technological evolution, but topics already pencilled in are nano automation; high-resolution, line and wide distance laser systems; 100% inline machine vision systems; flexible open systems motion control; gradient temperature control and advanced

process control; LCIA; and integrated safety solutions.

C. Lab Area

In the Lab Area, visitors will be able to try out products, test them and even build a possible solution for their specific requirements. Here, Smart Platform will be a major focus. This area will offer the opportunity to simulate your specific environment and find a solution for your application task. Equipment such as a conveyor bench, high-speed turntable, tripod system, multi-axis desktop system, motor set-ups etc. can be combined
and networked or set up as standalone scenarios to demonstrate an individual solution. Omron specialists will of course be on-hand to provide specific support and advice.

Denmark first

The first ACC will be opened in Copenhagen, Denmark in Spring 2006, followed by centres in central Europe. Automation Competence Centres will be continuously networking with the existing Technology Application Centres of Mechatronics (Spain), Sensing (Germany) and Software (UK).
J u st c rea te. w i t h O m ro ns i n te l l i g e n t re m ote I /O so l u t i o n s
Omron remote I/O intelligence in any environment
Omron offers remote I/O solutions for industrial automation, suited for a wide range of environments. What they all have in common is built-in intelligence that will reduce engineering time, help to plan maintenance, and give you better control over your machine performance. You decide the network and the type of I/O to best suit your application.
From centralised to distributed control
The function of the Programmable Logic Controller is gradually changing from centralised control system to the brains and communication core of modern machines. Traditional PLC I/O units are being replaced by remote I/O islands connected to the PLC by bus systems. The increase in initial hardware expense is easily outweighed by savings in wiring, commissioning and troubleshooting. The change is also driven by a trend towards modular machine design. By splitting production machinery into logical sections, machine builders can adapt to customer requirements more easily. By linking standard machine sections by a single bus instead of conventional parallel wiring, such machines can be assembled rapidly from prefabricated sections.

IP20 In-cabinet I/O

For mounting remote I/O in a protected environment (i.e. inside machines or in control cabinets), IP20 protection is sufficient. In IP20 class, Omron offers compact I/O blocks as well as modular I/O systems for DeviceNet, CompoNet and Profibus-DP.

Interlocking bus block

SmartSlice is Omrons modular remote I/O system. With bus couplers for DeviceNet and Profibus-DP, and other open networks like CompoNet and Ethernet/IP in preparation, it offers the most flexible and intelligent I/O solution yet. Its internal bus structure is based on CompoNets CIP message system, allowing seamless integration with all CIP-based networks and with Profibus DPV1. This means that data in each individual I/O module can be configured and monitored through multiple network layers, without additional PLC or HMI programming.
Hot-swappable electronics module Universal 12-pt terminal block
Omrons remote I/O units offer:
right protection for any environment Open bus interfaces to suit any application Clever design for easy installation Built-in intelligence for reduced engineering Smart monitoring for planning machine maintenance
Theo Mattaar Product Marketing Manager PLCs at the Control Business Unit Omron Europe

IP54 field-mount I/O

For field-mounting in relatively clean environments, Omron now offers an alternative to IP67 I/O in a new range of CompoNet IP54 I/O units. Their dustproof enclosure can be subjected to the occasional splash of water, which offers sufficient protection in most areas where human workers operate. The IP54 housing design allows quick connection of standard I/O wiring, avoiding the need for prefabricated cable-connector assemblies as used in IP67 systems. A new quick-connect network system makes it easy to branch off the main line at any place in the production line. With the freedom of topology that CompoNet offers, this makes the IP54 solution ideally suited for warehousing and conveyor applications.
IP67 harsh environment I/O
Omrons IP67 I/O line was developed in close cooperation with Japanese car manufacturers to withstand the harsh environment of car production lines. Resistant against dust, water and welding spatter, they are aimed at providing maximum availability under all circumstances. Rugged M12 connections and power supply through the DeviceNet cable provide fast and faultless installation.

Smart Platform

What all of Omrons I/O systems have in common is the intelligence built into each device. By distributing the burden of data pre-processing, signal validation and error logging, the programming efforts for PLCs, HMIs and supervisory software can be reduced. Furthermore, all Omron remote I/O have features that help to plan machine maintenance. Each unit keeps track of its power supply status, the operation time of each single sensor or actuator, the number of operations, and even monitors machine response time locally. With this data, Omrons Smart I/O can warn maintenance personnel that a machine part is about to reach the limits of its operational life. Maintenance can then be performed at a convenient time, thereby reducing the risk of machine breakdowns causing costly production downtime. All this built-in functionality can be used without having to program a PLC or HMI, and without having to worry about data transfer across network transitions. Using the Smart Active Parts and Function Block Libraries in Omrons CX-One software, access to this information is a matter of One Software One Connection One Minute.

Supported networks

Omrons main network architecture is based on CIP, the Common Industrial Protocol of DeviceNet. Its mix of cyclic and acyclic communication services allows fast I/O response plus reliable messaging for on-line parameterisation and monitoring of intelligent field devices. Omron also supports CIP-equivalent messaging over Profibus-DP, using DPV1 acyclic services. To help you build best-in-class machines with minimal effort, Omron now introduces CompoNet, a new member of the CIP family. Ideal for networking finely distributed sensors and actuators, it combines easy set-up with sub-millisecond response and smart messaging.
Just create. Smart Platform in practice at Ecolean
The Swedish company Ecolean was founded in 1996. The company focuses on developing functional, efficient and environmentally-friendly packaging materials for foodstuffs. In other words: sustainable packaging.
Earlier this century, Ecolean developed a packaging material based on calcium carbonate, or chalk as it is commonly known. The chalk is bound by polyolefins to create a unique packaging material with very low environmental impact. For example, no chemical processes are necessary to extract the raw material, and only limited amounts of energy are required. Furthermore, Ecolean packaging is completely recyclable. It is easily sorted and can either be reused or burned as fuel to provide heat. An extra customer benefit is that the packaging machines are smaller and less expensive than those of competitors like TetraPak, which is making them especially attractive in the markets of the Far East. Ecolean also develops complete packaging systems, covering everything from smart packaging to filling machines. The filling system for fluid foodstuffs is based on a highly practical stand-up bag, or soft-bottle as Ecolean calls it. A second system is LeanCover, which is a wrap-around film for butter and margarine. LeanCover can be used in most existing packaging machines and provides consumers with the perfect packaging.

International growth

So successful is this product which is sold worldwide to discerning customers in many segments of the foodstuffs industry that Ecolean is now experiencing the exciting development of moving from being an innovation company to an international industrial company. A professional management team has been brought in and the company has come under stable ownership. Ecolean now has 200 employees worldwide, with production taking place in Helsingborg, Sweden, and Tianjin, China.

Wrong! Omron, the pioneer and market leader in the field of modern relay technology, sees industrial relays as one of its core businesses and has heavily invested in developing a revolutionary line of 6 mm plug-in relays suited for industrial automation. The G2RV is a clear indication from Omron that it intends to play big in this market, says Boudewijn Hoogma, European Product Manager.

G2RV likes it rough

With the industrial environment in mind, the G2RV is a real plug-in relay designed with strong mechanical pins
that tolerate roughness. Also remarkable is that both socket and relay have been designed from the start as one smart unit, taking into account labelling, marking, and ease of wiring with its push-in terminals. In spite of its slim design, the G2RV includes all the features of a true industrial relay like mechanical flag, transparent housing, 6 A and 400 VAC switching voltage, and it sustains an electrical life of 100,000 operations.
to 230 VAC. A wide range of accessories is available, ranging from labels and cross-bars to a PLC interface unit to reduce wiring. The G2RV will expand further to cover more applications and more models.

Features and benefits:

Strong mechanical pin Slim design Indication (mechanical flag and LED) Screw and push-in terminal Max. current 6 A Max. switching voltage 400 VAC.

Family concept

The G2RV comes in 6 different models covering input voltages from 12 VDC

RoHS OK!

The European RoHS Directive on the restriction of the use of certain hazardous substances such as lead, cadmium and mercury in electrical and electronic equipment, comes into force from July 1st 2006. Its aim is to contribute to the protection of human health and the environment. Therefore Omron has decided to follow this directive even though our range of industrial products is currently outside the scope.
Omron is committed to going beyond the RoHS requirements and covers not only the 6 RoHS substances but over 220 other potentially harmful substances. Since 1999 Omron has been actively working on removing such hazardous materials from its products. This meant replacing electronic components by RoHS compatible alternatives in many of our products and changing some of our key manufacturing processes, such as lead-based soldering. This involved the introduction of new reflow-ovens to allow lead-free soldering. Omron is one of the pioneers in environmentally-friendly product design and manufacturing and has built up extensive expertise in these areas. Combined with Omrons key focus on quality, this allowed us to introduce these changes without compromising the functionality and reliability of our products. For our customers, all this means you can rely on Omron as an environmentally conscious supplier and we intend to comply with the EU directive before it comes into effect. We have thoroughly tested all products incorporating replacement materials, so you can be sure that our customary high quality standards are met. By offering RoHS compliant products, Omron is showing its leading position in terms of care for the environment and good corporate citizenship. Another example of this approach is Omrons environmental charter. Initiated in 1994, it has been extended into the 21st century with Green Omron 21 which specifies a well-defined environmental action plan incorporating RoHS compliancy.

Trajexia system...... 6

2.1 2.2 2.3 2.4 2.5 2.6

BASIC commands...... 15

3.1 3.2
Communication protocols...... 179
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8
Examples and tips..... 212

5.1 5.2

Troubleshooting...... 293
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 Voltage and analysis tools......293 TJ1-MC__.......293 TJ1-PRT........296 TJ1-DRT........297 TJ1-CORT.......297 TJ1-ML__.......298 GRT1-ML2.......298 TJ1-FL02.......301
GRT1-ML2 timing...... 302
Revision history....... 307
Safety warnings and precautions

Intended audience

WARNING Never short-circuit the positive and negative terminals of the batteries, charge the batteries, disassemble them, deform them by applying pressure, or throw them into a fire. The batteries may explode, combust or leak liquid. WARNING Fail-safe measures must be taken by the customer to ensure safety in the event of incorrect, missing, or abnormal signals caused by broken signal lines, momentary power interruptions, or other causes. Not doing so may result in serious accidents. WARNING Emergency stop circuits, interlock circuits, limit circuits, and similar safety measures must be provided by the customer as external circuits, i.e., not in the Trajexia motion controller. Not doing so may result in serious accidents. WARNING When the 24-VDC output (I/O power supply to the TJ1) is overloaded or short-circuited, the voltage may drop and result in the outputs being turned off.As a countermeasure for such problems, external safety measures must be provided to ensure safety in the system. WARNING The TJ1 outputs will go off due to overload of the output transistors (protection).As a countermeasure for such problems, external safety measures must be provided to ensure safety in the system.
This manual is intended for personnel with knowledge of electrical systems (electrical engineers or the equivalent) who are responsible for the design, installation and management of factory automation systems and facilities.

General precautions

The user must operate the product according to the performance specifications described in this manual. Before using the product under conditions which are not described in the manual or applying the product to nuclear control systems, railroad systems, aviation systems, vehicles, safety equipment, petrochemical plants, and other systems, machines and equipment that can have a serious influence on lives and property if used improperly, consult your OMRON representative.

Safety precautions

WARNING Do not attempt to take the Unit apart and do not touch any of the internal parts while power is being supplied. Doing so may result in electrical shock. WARNING Do not touch any of the terminals or terminal blocks while power is being supplied. Doing so may result in electric shock.

OFFPOS

Name VERIFY VFF_GAIN VP_SPEED Description Selects different modes of operation on a stepper output axis. Contains the speed feed forward control gain. Contains the speed profile speed.

/i Name FALSE OFF ON PI

Constants
Description Equal to the numerical value 0. Equal to the numerical value 0. Equal to the numerical value 1. Equal to the numerical value 3.1416. Equal to the numerical value -1.

/i Name

Communication commands and parameters
Description Sends FINS Read Memory and Write Memory to a designated FINS server unit. Executes a specific Host Link command to the Slave. Reads data from the Host Link Slave to either VR or TABLE variable array. Represents the status of the last Host Link Master command. Defines the Host Link Master timeout time. Writes data to the Host Link Slave from either VR or TABLE variable array. Defines the Slave unit number for the Host Link Slave protocol. Sets the serial communications.
FINS_COMMS HLM_COMMAND HLM_READ HLM_STATUS HLM_TIMEOUT HLM_WRITE HLS_NODE SETCOM

/i Name AIN AOUT GET IN

I/O commands, functions and parameters
Description Holds the value of the analog channel. Holds the value of the analog channel. Waits for the arrival of a single character and assigns the ASCII code of the character to variable. Returns the value of digital inputs. Parameter defines the default input device. Waits for a string to be received and assigns the numerical value to variable. Returns TRUE or FALSE depending on if character is received. Waits for a string and puts it in VR variables. Sets one or more outputs or returns the state of the first 24 outputs. Defines the default output device. Outputs a series of characters to a serial port. Turns on an output when a predefined position is reached, and turns off the output when a second position is reached. Returns the value of the digital outputs.
INDEVICE INPUT KEY LINPUT OP OUTDEVICE PRINT PSWITCH READ_OP
Mathematical functions and operands
Description Adds two expressions. Subtracts two expressions. Multiplies two expressions. Divides two expressions. Takes the power of one expression to the other expression. Checks two expressions to see if they are equal. Assigns an expression to a variable. Checks two expressions to see if they are different.
Name FRAC IEEE_IN IEEE_OUT INT LN MOD NOT OR SGN SIN SQR TAN XOR
Description Returns the fractional part of an expression. Returns floating point number in IEEE format, represented by 4 bytes. Returns single byte extracted from the floating point number in IEEE format. Returns the integer part of an expression. Returns the natural logarithm of an expression. Returns the modulus of two expressions. Performs a NOT operation on corresponding bits of the integer part of the expression. Performs an OR operation between corresponding bits of the integer parts of two expressions. Returns the sign of an expression. Returns the sine of an expression. Returns the square root of an expression. Returns the tangent of an expression. Performs an XOR function between corresponding bits of the integer parts of two expressions.

3.2.45 CAMBOX

Axis command
Arguments start_point The address of the first element in the TABLE array to be used. end_point The address of the end element in the TABLE array. table_multiplier The Table multiplier value used to scale the values stored in the TABLE. As the TABLE values are specified in encoder edges, use this argument to set the values for instance to the unit conversion factor (set by UNITS parameter). link_distance The distance in user units the link axis must move to complete the specified output movement. The link distance must be specified as a positive distance. link_axis The axis to link to. link_option See the table below.
link_option value Description 4 Link starts when registration event occurs on link axis. Link starts at an absolute position on link axis (see link_position). CAMBOX repeats automatically and bidirectionally. This option is cancelled by setting bit 1 of REP_OPTION parameter (REP_OPTION = REP_OPTION OR 2). Combination of options 1 and 4. Combination of options 2 and 4.
link_position The absolute position where CAMBOX will start when link_option is set to 2. Note: When the CAMBOX command is executing, the ENDMOVE parameter is set to the end of the previous move. The REMAIN axis parameter holds the remainder of the distance on the link axis.
/i Example ' Subroutine to generate a SIN shape speed profile ' Uses: p is loop counter ' num_p is number of points stored in tables pos 0.num_p ' scale is distance travelled scale factor profile_gen: num_p=30 scale=2000 FOR p=0 TO num_p TABLE(p,((-SIN(PI*2*p/num_p)/(PI*2))+p/num_p)*scale) NEXT p RETURN This graph plots TABLE contents against table array position. This corresponds to motor POSITION against link POSITION when called using CAMBOX. The SPEED of the motor will correspond to the derivative of the position curve above. fig. 8 fig. 7
/i Example A pair of rollers feeds plastic film into a machine. The feed is synchronised to a master encoder and is activated when the master reaches a position held in the variable start. This example uses the table points 0.30 generated in the example above: start=1000 FORWARD AXIS(1) WHILE IN(2)=OFF CAMBOX(0,30,800,80,15,2,start) WA(10) WAIT UNTIL MTYPE=0 OR IN(2)=ON WEND CANCEL CANCEL AXIS(1) WAIT IDLE The arguments of the CAMBOX command are: 0 is the start of the profile shape in the TABLE 30 is the end of the profile shape in the TABLE 800 scales the TABLE values. Each CAMBOX motion therefore totals 800*2000 encoder edges steps. 80 is the distance on the product conveyor to link the motion to. The units for this parameter are the programmed distance units on the link axis. 15 specifies the axis to link to. 2 is the link option setting. It means: Start at absolute position on the link axis. The variable start holds a position. The motion will execute when this position is reached on axis 15. fig. 9

Description Following error (this is the real FE when ATYPE=40 is used) Feedback speed (With ATYPE=41 Units=Max Speed/40000000H, with other ATYPE Units= reference units/s) Command speed (units same as in Feedback Speed) Target speed (units same as in Feedback Speed) Torque (Force) reference (With ATYPE=42 Units=Max Torque/40000000H, with other ATYPE Units= % over nominal Torque Monitor selected with Pn813.0 Useful to monitor servo monitors (Unxxx) Monitor selected with Pn813.1 Useful to monitor servo monitors (Unxxx) /i Bit no.
Servo Driver input signal Sigma-II P_OT N_OT DEC PA PB PC EXT1 EXT2 EXT3 BRK Reserved Reserved IO12 Sigma-V P_OT N_OT DEC PA PB PC EXT1 EXT2 EXT3 BRK HBB Reserved IO12 Junma P_OT N_OT /DEC Not used Not used Not used /EXT1 Not used Not used /BRK E-STP Not used Not used G-Series / Accurax G5 P_OT N_OT DEC Not used Not used PC EXT1 EXT2 EXT3 BRK E-STP SI2 PCL
Forward limit switch Reverse limit switch Zero point return deceleration Encoder A phase signal Encoder B phase signal Encoder C phase signal First external latch signal Second external latch signal Third external latch signal Brake output Emergency stop switch General input 2 General input 12 (Sigma-II and Sigma-V), Torque limit input in positive direction (GSeries and Accurax G5)
N/A DRIVE_CONTROL AXIS(2) = 256 In this example, OUT 0 is switched on for axis 2, connected using the TJ1FL02.
Bit no. Servo Driver input signal Sigma-II IO13 Sigma-V IO13 Junma Not used G-Series / Accurax G5 NCL General input 13 (Sigma-II and Sigma-V), Torque limit input in negative direction (GSeries and Accurax G5) General input 14 (Sigma-II and Sigma-V), General input 0 (G-Series and Accurax G5) General input 15 (Sigma-II and Sigma-V), General input 1 (G-Series and Accurax G5) Description Description This parameter contains the monitored data of the Servo Driver connected to the system via the MECHATROLINK-II bus. The data to be monitored is selected using DRIVE_CONTROL and can be displayed in the Trajexia Studio scope or used inside a program. The monitored data is updated each SERVO_PERIOD. The command is executed on the driver for the base axis set by BASE. The base axis can be changed with the AXIS modifier, as with all the other axis commands and parameters. N/A No example. N/A

Not used

3.2.90 DRIVE_READ
/i Type Axis command DRIVE_READ(parameter, size, VR) The DRIVE_READ function reads the specified parameter of the Servo Driver connected to the Trajexia system via the MECHATROLINK-II bus. Upon successful execution, this command returns -1 and puts the read value in the VR memory location specified by the VR parameter. If the command cannot be executed, the value 0 is returned. The command is executed on the driver for the base axis set with BASE. It can be changed using the AXIS modifier, like with all the other axis commands and parameters. Note: This command waits for the response of the axis, therefore its execution is slow and the time variable. Do not use this command together with other commands that require quick execution. Note: Executing a DRIVE_READ will temporarily disable the Servo Driver Front Panel display. Note: DRIVE_READ returns -1 on success. It also returns -1 with no parameter read if the parameter number does not exist or has the wrong size.

3.2.101 ENCODER_RATIO

/i Type Syntax Description Axis parameter ENCODER_RATIO(numerator, denominator) This command allows the incoming encoder count to be scaled by a non integer number, using the equation: MPOS = (numerator / demoninator) x encoder_edges_input Unlike the UNITS parameters, ENCODER_RATIO affects commands like MOVECIRC and CAMBOX, since it affects the number of encoder edges within the servo loop at the low level. It is necessary to change the position loop gains after changing encoder ratio in order to maintain performance and stability. Note: Large ratios should be avoided as they will lead to either loss of resolution or much reduced smoothness in the motion. The actual physical encoder count is the basic resolution of the axis and the use of this command may reduce the ability of the Motion Controller to accurately achieve all positions. Note: ENCODER_RATIO does not replace UNITS. Only use ENCODER_RATIO where absolutely necessary. For all other axis scaling use UNITS.

3.2.100 ENCODER_ID

/i Type Syntax Axis parameter (read-only) ENCODER_ID
Arguments denominator A number between 0 and 16777215 that is used to define the denominator in the above equation. numerator A number between 0 and 16777215 that is used to define the numerator in the above equation.

3.2.103 ENCODER_TURNS

/i Type Syntax Description Axis parameter (read-only) ENCODER_TURNS The ENCODER_TURNS parameter returns the number of multi-turn count from the encoder. This is applicable only to Flexible axis absolute Tamagawa axis with ATYPE value 46 and Flexible axis absolute EnDat axis with ATYPE value 47. The multi-turn data is not automatically applied to the axis MPOS parameter after initialization. The application programmer must apply this from the program using OFFPOS or DEFPOS commands as required. If applied to axis of ATYPE value other than 46 or 47, the parameter returns 0. N/A PRINT ENCODER_TURNS AXIS (1) This command will print absolute encoder multi-turn counts for axis 1. AXIS, ENCODER, ENCODER_BITS.
' 7200 is the closest to the encoder resolution that can be devided by an ' integer to give degrees. (7200/20=360) ENCODER_RATIO(8192,7200) UNITS=20 ' axis calibrated in degrees, resolution is 0.05 deg. A rotary table has a servo motor connected directly to its centre of rotation. An encoder is mounted to the rear of the servo motor and returns a value of 8192 counts per revolution. The application requires the table to be calibrated in degrees, but so that one degree is an integer number of counts. N/A

/i Type Syntax Description Task parameter PROC_STATUS The PROC_STATUS parameter returns the status of the process or task specified. The parameter is used with the PROC modifier and can return values listed in the table below.
PRINT "CAPITALS and lower case CAN BE PRINTED" Consider VR(1) = 6 and variab = 1.5, the print output will be as follows: PRINT 123.45, VR(1)-variab 123.4500 4.5000 length: PRINT "DISTANCE = ";mpos DISTANCE = 123.0000 In this example, the semi-colon separator is used. This does not tab into the next column, allowing the programmer more freedom in where the print items are placed. PRINT VR(1)[ 4,1 ]; variab[ 6,2 ] 6.0 1.50 params: PRINT "DISTANCE = ";mpos[ 0 ];" SPEED = ";v[ 2 ]; DISTANCE = 123 SPEED = 12.34 PRINT "ITEM ";total" OF ";limit;CHR(13); >> PRINT HEX(15),HEX(-2) F FFFFA $ (HEXADECIMAL INPUT), OUTDEVICE.
/i Value /i Arguments Example See also N/A WAIT UNTIL PROC_STATUS PROC(3)=0 PROCNUMBER, PROC. Description Process stopped Process running Process stepping Process paused

Example Example

Example Example See also

3.2.210 PROC

Task command PROC(task_number)

3.2.212 PROCESS

/i Type Syntax Description Arguments Example See also Program command PROCESS The PROCESS command displays the running status of all current tasks with their task number. N/A No example. HALT, RUN, STOP.
PROFIBUS function 2 configures the TJ1-PRT for data exchange with the PROFIBUS-DP master unit and defines areas in the VR memory where I/O exchange takes place. PROFIBUS function 4 returns the data exchange status of the TJ1-PRT. Refer to the table below for the description of the bits in the data exchange status word.
/i Bit 0 Value Description Failed configuration of I/O data exchange I/O data exchange configured successfully I/O data not available I/O data available Data exchange active in OPERATE mode Data exchange active in CLEAR mode

3.2.213 PROCNUMBER

/i Type Syntax Description Task parameter (read-only) PROCNUMBER The PROCNUMBER parameter contains the number of the task in which the currently selected program is running. PROCNUMBER is often required when multiple copies of a program are running on different tasks. N/A MOVE(length) AXIS(PROCNUMBER) PROC_STATUS, PROC.
/i Arguments unit_number Specifies the unit number of the TJ1-PRT in the Trajexia system. VR_start_outputs The starting address in VR memory of the controller where the output data from the PROFIBUS-DP master is located. no_outputs The number of output words from the PROFIBUS-DP master in VR memory. VR_start_inputs The starting address in VR memory of the controller where the input data for the PROFIBUS-DP master is located. no_inputs The number of input words to the PROFIBUS-DP master in VR memory.

3.2.214 PROFIBUS

LABEL expected Program not found

Number Message 67 68

Number Message 138 Device error: Command not supported by device Device error: CRC error Device error: Error writing to device Device error: Invalid response from device Firmware error: Cannot reference data outside current block Disk error: Invalid MBR Disk error: Invalid boot sector Disk error: Invalid sector/cluster reference File error: Disk full File error: File not found File error: Filename already exists File error: Invalid filename File error: Directory full Command only allowed when running Trajexia Studio # expected FOR expected INPUT/OUTPUT/APPEND expected File not open End of file
/i Arguments Example See also N/A >> PRINT RUN_ERROR PROC(5) 9.0000 BASICERROR, ERROR_LINE, PROC.
LABEL must be at start of line Cannot nest one line IF LABEL not found LINE NUMBER cannot have decimal point Cannot have multiple instances of REMOTE Invalid use of $ VR(x) expected Program already exists Process already selected Duplicate axes not permitted PLC type is invalid Evaluation error Reserved keyword not available on this controller VARIABLE not found Table index range error Features enabled do not allow ATYPE change Invalid line number String exceeds permitted length Scope period should exceed number of AIN parameters

3.2.235 RUNTYPE

/i Type Syntax Description Program command RUNTYPE "program_name", auto_run [ , task_number ] The RUNTYPE command determines whether the program, specified by program_name, is run automatically at start-up or not and which task it is to run on. The task number is optional, if omitted the program will run at the highest available task. The current RUNTYPE status of each programs is displayed when a DIR command is executed. If any program has compilation errors no programs will be started at power up. To set the RUNTYPE using Trajexia Studio, set the Priority property of the program. program_name The name of the program whose RUNTYPE is being set. auto_run 0 = Running manually on command; 1 = Automatically execute on power up. All non-zero values are considered as 1. task_number The number of the task on which to execute the program. Range: [1, 14].
>> RUNTYPE progname,1,3 This line sets the program progname to run automatically at start-up on task 3. >> RUNTYPE progname,0 This line sets the program progname to manual running. AUTORUN, EPROM, EX.

3.2.236 S_REF

/i Type Syntax Description Axis parameter DAC S_REF This parameter contains the speed reference value which is applied directly to the Servo Driver when the axis is in open loop (SERVO=OFF). The range of this parameter is defined by the number of available bits. For MECHATROLINK-II axes, S_REF takes 32 bits, so the available range is [-2147483648, 2147483648], which corresponds to a voltage range [-10V, 10V]. For Flexible axis axes, S_REF takes 16 bits, so the available range is [-32768, 32767], which corresponds to a voltage range [-10V, 10V]. These ranges can be limited by using the OUTLIMIT parameter. The value currently being applied to the driver can be read using the S_REF_OUT axis parameter. N/A WDOG = ON SERVO = OFF square: S_REF AXIS(0) = 2000 WA(250) S_REF AXIS(0) = -2000 WA(250) GOTO square These lines can be used to force a square wave of positive and negative movement with a period of approximately 500ms on axis 0. AXIS, S_REF_OUT, OUTLIMIT, SERVO.

3.2.251 SRAMP

/i Type Syntax Description Axis parameter SRAMP The SRAMP parameter contains the S-curve factor. The S-curve factor controls the amount of rounding applied to the trapezoidal profiles. A value of 0 sets no rounding. A value of 10 sets maximum rounding. The default value of the parameter is 0. SRAMP is applied to the FORWARD, MOVE, MOVEABS, MOVECIRC, MHELICAL and REVERSE commands. Notes: Using S-curves increases the time required for the movement to complete. The S-curve factor must not be changed while a move is in progress. N/A No example. AXIS. Example

3.2.252 STEP

3.2.253 STEP_RATIO
Axis command STEP_RATIO(numerator, denominator) See also
Two axes are set up as X and Y but the axes ' steps per mm are not the same. Interpolated moves require identical UNITS values on both axes in order to keep the path speed constant and for MOVECIRC to work correctly. The axis with the lower resolution is changed to match the higher step resolution axis so as to maintain the best accuracy for both axes. ' Axis 0: 500 counts per mm (31.25 steps per mm) ' Axis 1: 800 counts per mm (50.00 steps per mm) BASE(0) STEP_RATIO(500,800) UNITS = 800 BASE(1) UNITS = 800 N/A

3.2.254 STEPLINE

/i Type Syntax Description Program command STEPLINE [ "program_name" [ , task_number ]] The STEPLINE command executes one line (i.e., "steps") in the program specified by program_name. The program name can also be specified without quotes. If STEPLINE is executed without program name on the command line the current selected program will be stepped. If STEPLINE is executed without program name in a program this program will be stepped. If the program is specified then all occurrences of this program will be stepped. A new task will be started when there is no copy of the program running. If the task is specified as well then only the copy of the program running on the specified task will be stepped. If there is no copy of the program running on the specified task then one will be started on it. Example Example See also program_name The name of the program to be stepped. task_number The number of the task with the program to be stepped. Range: [1,14].
program_name The name of the program to be stopped. task_number The number of the task with the program to be stopped. Range: [1,14].

3.2.271 TSIZE

/i Type Syntax Description System parameter (read-only) TSIZE The TSIZE parameter returns the size of the TABLE array, which is one more than the currently highest defined TABLE element. TSIZE is reset to 0 when the TABLE array is deleted using DEL "TABLE" or NEW "TABLE" on the command line. N/A
Example The following example assumes that no location higher than 1000 has been written to the TABLE array. >> TABLE(1000,3400) >> PRINT TSIZE 1001.0000 DEL, NEW, TABLE.

3.2.274 UNTIL

See REPEAT.UNTIL.

3.2.275 VERIFY

/i Type Syntax Description Axis parameter VERIFY The verify axis parameter is used to select different modes of operation on a stepper encoder axis. VERIFY=OFF Encoder count circuit is connected to the STEP and DIRECTION hardware signals so that these are counted as if they were encoder signals. This is particularly useful for registration as the registration circuit can therefore function on a stepper axis. VERIFY=ON Encoder circuit is connected to external A,B, Z signal Note: On the TJ1-FL02 when VERIFY=OFF, the encoder counting circuit is configured to accept STEP and DIRECTION signals hard wired to the encoder A and B inputs. If VERIFY=ON, the encoder circuit is configured for the usual quadrature input. Make sure that the encoder inputs do not exceed 5 volts. Arguments Example See also N/A VERIFY AXIS(3)=ON N/A

3.2.272 UNITS

/i Type Syntax Description Axis parameter UNITS The UNITS parameter contains the unit conversion factor. The unit conversion factor enables the user to define a more convenient user unit like m, mm or motor revolutions by specifying the amount of encoder edges to include in a user unit. Axis parameters like speed, acceleration, deceleration and the Axis commands are specified in these user units. Note: The UNITS parameter can be any non-zero value, but it is recommended to design systems with an integer number of encoder pulses per user unit. Changing UNITS will affect all axis parameters which are dependent on UNITS in order to keep the same dynamics for the system. N/A A leads crew arrangement has a 5mm pitch and a 1,000-pulse/rev encoder. The units must be set to allow moves to be specified in mm. The 1,000 pulses/rev will generate 1,000 x 4 = 4,000 edges/rev. One rev is equal to 5mm. Therefore, there are 4,000/5 = 800 edges/mm. UNITS is thus set as following. >> UNITS = 1000*4/5 AXIS, ENCODER_RATIO.

3.2.276 VERSION

/i Type Syntax Description System parameter (read-only) VERSION The VERSION parameter returns the current firmware version number of the current system installed in the TJ1-MC__.

You can use these BASIC commands:
/i BASIC command HLM_COMMAND HLM_READ HLM_STATUS HLM_TIMEOUT HLM_WRITE SETCOM Description HLM_COMMAND executes a specific Host Link command to the slave. HLM_READ reads data from the Host Link slave to either VR or TABLE memory. HLM_STATUS gives the status of the last command of the Host Link master. HLM_TIMEOUT defines the Host Link master timeout time. HLM_WRITE writes data to the Host Link slave from either VR or TABLE memory. SETCOM configures the serial communication port and enables the Host Link protocols.

Serial protocol

The TJ1-MC__ TJ1-MC__ has a DB-9 connector that contains two serial ports: Port 1: RS232 Port 2: RS422 or RS485, depending on the switch settings See the Trajexia Hardware Reference manual for details. Both ports can independently support these protocols: Host Link master Host Link slave User defined protocol
Note The serial port (port 1) CANNOT be used for programming the unit.

Host Link master

If the TJ1-MC__ is the Host Link master, you can send BASIC commands to a Host Link slave, for example a PC. When you send a BASIC command to a Host Link slave, the execution of the next BASIC command waits until the Host Link slave sends a response.

PROGRAMMING MANUAL 183

Commands
These Host Link commands are supported for the Host Link Master protocol:
/i Type I/O memory reading Header code RR Name Function

Type I/O memory writing

Header code WR

Name CIO AREA WRITE

Function Writes the specified data in word units beginning with the designated CIO/IR word.
CIO AREA READ Reads the specified number of words beginning with the designated CIO/IR word. LR AREA READ Reads the specified number of words beginning with the designated LR word. Reads the specified number of words beginning with the designated HR word. Reads the specified number of words beginning with the designated DM word. Reads the specified number of words beginning with the designated AR word. Reads the specified number of words beginning with the designated EM word. CPU unit status Testing PC model code reading Host Link communications processing
LR AREA WRITE Writes the specified data in word units beginning with the designated LR word. HR AREA WRITE DM AREA WRITE AR AREA WRITE EM AREA WRITE STATUS WRITE TEST PC MODEL READ ABORT (command only) Writes the specified data in word units beginning with the designated HR word. Writes the specified data in word units beginning with the designated DM word. Writes the specified data in word units beginning with the designated AR word. Writes the specified data in word units beginning with the designated EM word. Changes the operating mode of the CPU unit. Returns, unaltered, a single block that was sent from the master. Reads the model code of the CPU unit Aborts the operation that is performed by a Host Link command, and returns to the initial status.

Note If you use an OMRON DeviceNet master, it is advised to select either input_count or output_count with a value of 4,8,16, or 32 for the VR variables. After you have executed the command DEVICENET(unit_number, 2,.), data arrays are automatically exchanged. The data exchanged between the TJ1-DRT and the DeviceNet master is in 16-bit integer format. Each word exchanged ranges from -32768 to 32767.
A VR variable can hold a 24-bit number, and it can also hold fragments. The exchange with the DeviceNet master does not support values outside the range -32768 to 32767 or fragments. Configure the DeviceNet network To configure the OMRON CJ1W/CS1W-DRM21 DeviceNet master to exchange VR variables with the Trajexia system, do these steps: 1. Start the CX-Integrater in the CX-ONE software tool. 2. Select Network from the Insert menu. 3. Select DeviceNet from the Select Network screen. The Network view shows.

fig. 10

4. Select CJ1W-DRM21 from the OMRON Communication adapter list.

fig. 11

5. Drag and drop the CJ1W-DRM21 to the Network window.

fig. 12

6. Install the EDS file from the CX-Integrator. 7. Select No from the dialog window. The icon is not needed.
8. Register the slave to the master, right click on the #01TJ1-DRT icon. 9. Double click on the Master Icon. 10. Select the TJ1-DRT device.

fig. 14

11. Click Advanced Setup. 12. Click Connection tab. 13. Click User Setup. 14. Click Use Poll Connection. 15. Select Con.Path. 16. Select the number of variables that has been selected for the DeviceNet communication. 17. Click OK to confirm all dialog boxes. 18. Select Work Online from the Network menu. 19. Select Parameter from the Component menu. 20. Right click on the Master icon. 21. Select Parameter Download.

fig. 15

TJ1-DRT can provide status information to both the TJ1-MC__ and the DeviceNet master. You can retrieve the status information in BASIC with the command DeviceNet (unit_number,4,0). The result provides the following information:
/i Bit 0 Value 1 4-Description DeviceNet (unit_number, 2,.) not executed yet DeviceNet (unit_number, 2,.) executed without error No DeviceNet I/O connection DeviceNet I/O connection running VR variables in the output data range have been updated VR variables in the output data range have not been updated yet DeviceNet I/O connection size matches the DeviceNet(unit_number,2,) command DeviceNet I/O connection size does not match the DeviceNet(unit_number,2,) command Always zero Network power OK Network power failure No BUSOFF occurred BUSOFF occurred No node address duplication error Node address duplication error Reserved

Caution To make sure that the absolute position is always correct, you must make sure that
(Pn205 + 1). encoder_resolution < 2

and that

(Pn205 + 1). encoder_resolution. Pn203 Pn202 < 232
Note that this is not obvious for the high-resolution encoders of the Sigma-V motors.

Example 3

The mechanical system uses a servo motor with an 17-bit absolute encoder. The mechanical gear ratio of the gearbox is 1:6.31. One rotation of the pulley moves the moving part on the belt 320 mm. The total length of the belt, and therefore the total moving range of the motion part, is 4160 mm. The mechanical measurement units must be mm. This means that all axis parameters and commands given to Trajexia are expressed in mm. Using the same procedure as in example 1, the equation expressing the relationship between user units and encoder counts is:
Pn202 Pn203 2. encoder_counts 6.31. motor_revolution 1. pulley_revolution = 1. motor_revolution 1. pulley_revolution 320mm

fig. 21

Total length (perimeter) of belt: 4160
17-bit absolute encoder 1:6.31 Gear
r = 320/(2*PI) 1 turn = 320mm move

UNITS =

17 2. 6.31 encoder_counts

Therefore:

17 2. 6.31

2 1000

631 8.125

631 125

One solution is:
UNITS = 2 = 512 Pn202 = 631 Pn203 = 125
Note that we have not used the pulley radius in the calculation. This is to avoid the use of , which cannot be expressed as a fractional number). In toothed pulleys, the number of teeth and mm per tooth is commonly used. The calculation of the multiturn limit setting is:
m. motor_revolution = n. machine_cycle m. motor_revolution = n. machine_cycle = n. 13 6. 31 motor_revolution 1 pulley_revolution 4160. pulley_revolution 320. machine_cycle = n. 13. pulley_revolution
= n. 82.03. pulley_revolution

m = n. 82.03

The smallest integer m for which this equation is valid is 8203. This results in Pn205 = 8202. In addition, to limit the motion units range to the moving range of the motion part, the following axis parameters must be set: REP_DIST = 4260, and REP_OPTION = 1. With these settings, executing MOVE(38) moves the moving part 38 mm in forward direction. The range of possible MPOS and DPOS values is 0 mm to 4160 mm.

Pn202 Pn12

One possible solution is:
50 Pn202 = 5 Pn203 = 6 Pn205 = 4
Because 217/50 is a number with an infinite number of decimal digits, we can choose the following:

Pn202 UNITS Pn203 =2

10 50. 12

10 600

Therefore, the parameters are:
UNITS = 2 = 32768 Pn202 = 1 Pn203 = 15 Pn205 = 4 REP_DIST = 50 REP_OPTION = 1
With these settings, executing MOVE(50) moves the moving part 50 mm, or one station.

Example 6

The mechanical system consists of a ball screw. It uses a servo motor with a 17-bit absolute encoder. The mechanical gear ratio of the gearbox is 1:3. The screw pitch of the ball screw is 10mm per revolution. The total travel distance of the ball screw is 540 mm. The mechanical measurement units must be mm. With the same procedure as in example 1, we have:
Pn202 Pn203 2. encoder_counts 3. motor_revolution 1. ballscrew_revolution = 1. motor_revolution 1. ballscrew_revolution 10mm

fig. 24

17-bit absolute encoder 1:3 Gear 540mm

17 2. 3 encoder_counts

Pn202 Pn203 UNITS = 2

3 2. 5

UNITS = 2 = 65536 Pn202 = 3 Pn203 = 5
The calculation of the multiturn limit setting parameter Pn205 is not needed in this case because the ball screw is a system with a fixed (limited) axis. It is enough to set this value large enough to have the overflow of the counter out of the effective position. Also, because of the axis is finite, it is not important to set the REP_OPTION parameter, because REP_DIST must be set large enough so it is outside of the maximum effective position (540 mm). One solution is: REP_DIST = 1000 and REP_OPTION = 0. With these setting, executing MOVE(17) moves the ball screw 17 mm in forward direction.
Mapping Servo Driver inputs and outputs
The Trajexia controller has got a digital I/O space that consists of 256 digital inputs and 256 digital outputs. The digital outputs range has four parts: Digital outputs 0 - 7. These outputs do not physically exist on the TJ1-MC__. If you write these outputs, nothing happens. If you read these outputs, they return 0. Digital outputs 8 - 15. These outputs physically exist on the TJ1-MC__. You can physically access them on the 28-pin screwless connector on the front side of the TJ1-MC__ (see the Hardware Reference Manual for details). If you write these outputs, they become active and give a 24 VDC signal. If you read these outputs, they return their current status. Use the command OP to write and read these outputs. Digital outputs 16 - 31. These outputs are software outputs only. They do not physically exist on the TJ1-MC__, but you can write them and read their correct status. You use these outputs mostly in BASIC programs to accomplish some control sequences that require outputs which do not need to be physical. Use the command OP to write and read these outputs. Digital outputs 32 - 255. These outputs are physically present only if additional digital I/O units are connected to the TJ1-MC__ via MECHATROLINK-II bus. Writing and reading them if they do not physically exist (when the I/O units are not connected) has no effect. Use the command OP to write and read these outputs. All outputs are unique to the controller. They are not accessed per axis. The digital input range has three parts: Digital inputs 0 - 15. These inputs physically exist on the TJ1-MC__. You can physically access them on the 28-pin screwless connector on the front side of the TJ1-MC__ (see the Hardware Reference Manual for details). These