Size, Select and Configure Kinetix 5500 Using

Motion Analyzer and Studio 5000

For Classroom Use Only!

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Size, Select and Configure Kinetix 5500 Using Motion Analyzer and Studio 5000

Contents
Before You Begin .......................................................................................................................................... 4
About This Lab .................................................................................................................................................................................. 4
Tools & Prerequisites ........................................................................................................................................................................ 4
Starting the Software and Opening the Project ............................................................................................ 5
Understanding the Motion Analyzer Profile Editor ........................................................................................ 6
Advanced Index Types in the Profile Editor .................................................................................................................................... 13
Exporting an Index Move to Logix Designer in Studio 5000 ........................................................................................................... 14
Importing CAM Profiles from Microsoft Excel ................................................................................................................................. 19
Importing CAM Profiles from Logix Designer in Studio 5000 .......................................................................................................... 21
Building a System in Motion Analyzer ......................................................................................................... 23
Create an Integrated Drive Motor Application in Motion Analyzer .................................................................................................. 23
Configure an Axis with an Intergrated Drive Motor ......................................................................................................................... 28
Configure a Power Supply for Your Axes ....................................................................................................................................... 32
Configuring an AC Supply and DC Bus Sharing for a Kinetix 5500 Drives Group ..................................... 34
Using the Motion Analyzer Tuning Simulation ............................................................................................ 38
Compliance in Couplings ................................................................................................................................................................ 42
Backlash in Gearboxes ................................................................................................................................................................... 44
Reducing Compliance and Eliminating Backlash............................................................................................................................ 47
Appendix A: Using the Motion Analyzer Tuning Simulation (Advanced) .................................................... 50
Appendix B: Importing Profile Data into Motion Analyzer Using a .csv File ............................................... 58

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Before You Begin

About This Lab
Welcome to the Size, Select and Configure Kinetix 5500 Using Motion Analyzer and Studio 5000 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 Logix Designer in Studio 5000 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 exercises in this hands-on session, you will:
Explore how to create a motion profile using Motion Analyzer
Export and Import CAM profiles between Motion Analyzer and Logix Designer
Create an Integrated Drive Motor application
Configure AC and DC bus sharing for the Kinetix 5500 drive
Utilize the new Tuning Simulator
This hands-on lab is ideal 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. If you would like to skip sections, talk to a lab instructor to make sure you
have the right programs and files open.
This lab takes approximately 90 minutes to complete.

Tools & Prerequisites

Motion Analyzer (v7.00)
Studio 5000 (v21)
Introduction to Motion Analyzer.acd
K5500 Power Sharing.mba
MA Tuning Simulation.mba
Advanced Tuning Simulation.xlsx

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Starting the Software and Opening the Project

1. Start Studio 5000. From the Start menu, select All Programs > Rockwell Software > Studio 5000.
2. Open the project named Introduction to Motion Analyzer.acd by clicking the Existing Project button. You can
find the project in this directory: C:\Lab Files\.
3. Start Motion Analyzer. From the Start menu, select All 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 prompted to choose your Application Mode. The Size and Select Mode helps you to
size, select and optimize your control system and then create a Bill of Materials. The Just Quote Mode is for building a Bill of
Materials quickly when you already know what motor and drive your application will use.

1. Click the Start button in the Size and Select Mode tile.

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2. The image below highlights some of the new menu and navigation options available in Version 6.00 of Motion
Analyzer. In the Axis View you have the chance to choose one of the different load types. For this example well
select the Linear option. Click on the Select button in the Linear tile.

3. This screen would allow you to enter data about the load. You dont need to enter anything here, since the goal
of this portion of the lab is simply to export a motion profile to Logix Designer in Studio 5000. Click the Next
button.

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4. Once you have entered the motion profile, this screen provides an excellent summary. As you can see, no
motion profile has been entered yet. Click the Edit Motion Profile button to open the Profile Editor.

5. The Less Options Profile Editor Mode can be useful for simple indexing. To create more complex moves, the
More Options Profile Editor Mode is used. Click More Options to load the More Options Profile Editor Mode.

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6. Lets get acquainted with the More Options Profile Editor Mode. This powerful tool allows 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 input parameters. Lets explore some of the features of the
Profile Editor. (If you are already familiar with the Profile Editor, you can skip these steps and move on to the
next section.)

6a. Click on the Profile button. With this button, you can copy an axis or go to a motion profile from another
axis in your project.

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6b. 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 the
initial velocity here.

6c. Notice the Segment Load pane to the right of the Start Condition pane. This is where you add external
forces and payload masses to specific portions of the motion profile. Click the pushpin to hide the Segment
Load Editor.

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6d. Click the Add button. This is how you will add motion segments to your motion profile. Lets explore some
commonly used segments:

6e. Click on the Accel/Decel button to add an acceleration or deceleration segment. This segment will allow
you to define motion using a variety of data entry options.

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6f. Now click the Add button and select the 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 motion profile graph. Drag them to
view how the segment changes.

6g. Changing the Smoothness will allow you to add S-curve to your motion 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.

6h. 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. The various move types 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. Check the Position and Acceleration checkboxes
to show those values. This will help you visualize the different motion profiles. Using the Profile Editor, select
Add and then select Index Advance. Enter the following for the move parameters:

Distance: 250 mm

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 below to see how the velocity profile changes, depending on
what type of move you use. See the table below for a numerical analysis of the different motion 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
Standard Index Moves
Triangle
1/3 Trapezoidal
Index Advance Moves
Index SHM
Index 3 4 5 Poly
Index Mod Sine
Index 2 3 Poly
Index 4 5 6 7 Poly
Index Adj Sine
Index Mod Trapezoidal

Peak
Velocity

Peak
Acceleration

Peak Jerk

Zero velocity at
boundaries?

Zero acceleration
at boundaries?

Zero jerk at
boundaries?

2.00
1.50

4.00
4.50

Inf
Inf

Yes
Yes

No
No

No
No

1.57
1.88
1.76
1.50
2.19
2.00
1.99

4.93
5.76
5.53
6.00
7.51
6.28
4.89

Inf
60.00
69.47
Inf
52.50
39.48
63.55

Yes
Yes
Yes
Yes
Yes
Yes
Yes

No
Yes
Yes
No
Yes
Yes
Yes

No
No
No
No
Yes
No
No

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Exporting an Index Move to Logix Designer in Studio 5000

1. Choose one of the index types that you like (or a few indices if you are feeling adventurous) and build a motion
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. Well be using the Logix CAM Profile
Editor, so click Next again.

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4. Well be using the Motion Axis Time CAM (MATC), so click 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
will probably differ.

5. Click the Next button. Well copy the data to the Clipboard, so click Next again, and then click the Finish
button.

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6. Switch to the Logix Designer in Studio 5000 and open MainRoutine within MainProgram. Ignore the MATC
instruction in Rung 0. Enter the following values into the MATC instruction in the second rung:

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

Lock Position: 0

Lock Direction: None

Instruction Mode: Time Driven Mode

The rung should look like this:

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7. Click on the
button for the CAM Profile in the rung you just modified. This will bring up the CAM Editor.
Right click on the
button in the Master-Slave distance table. Select Paste as shown below.

If you receive this error:

You have removed the exported data from the clipboard. If this is the case, you will need to return to the
Motion Analyzer Profile Editor and repeat steps 2-5 above in order to re-copy the motion profile data to the
clipboard.

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8. Press the
button on the toolbar. This will scale the CAM profile to fit in the CAM Editor window and the
CAM profile will be shown in the same fashion as the Motion Analyzer Profile Editor. Your plot may differ,
depending on which index type you used.

9. Close the CAM Profile Editor. Delete the rung that you just modified.

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Importing CAM Profiles from Microsoft Excel

The Motion Analyzer Profile Editor also supports the import of time and position data from an Excel spreadsheet.

1. Click the arrow next to the Delete button. Select Delete All to delete the move you just created.
2. Start Microsoft Excel. From the Start menu, select All Programs > Microsoft Office > Microsoft Excel 2010.
3. Open Simple Move.xlsx located in C:\Lab Files.
4. The Simple Move spreadsheet follows the format required to import CAM profile data into the Motion Analyzer
Profile Editor: Time Data in the first column, position data in the second column, and type in the third column.

Note: When importing a CAM profile, the two options for move type are Linear and Cubic. In the Motion
Analyzer Profile Editor, the type data is case sensitive.

5. Highlight the data only (not the column labels), right click on the highlighted data and select Copy.

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6. Return to the Motion Analyzer Profile Editor and click the Import button.

7. Click the Next button to continue to the Source Location for Import screen shown. Well be using the data
from the Clipboard, so click Next again.

8. Keep the default import type of Logix CAM Profile Editor by clicking Next in the Type of Import screen.
9. You should see the Excel data populate the Import Options Logix CAM screen. Make sure that the first line
corresponds with your first line of data. Click Next, and then click Finish. The CAM profile from Microsoft Excel
will appear in the Segment Plot window.
Note: For an explanation of how to export a Motion Profile template to Microsoft Excel in order to create and
modify a CAM profile based on values other than position (ex. Torque or Inertia), refer to Appendix B.

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Importing CAM Profiles from Logix Designer in Studio 5000

The Motion Analyzer Profile Editor supports the import of some CAM Profiles from Logix Designer. At this time, it does not
support two consecutive linear segments (by definition this creates a discontinuity in the velocity profile which cannot be
accurately simulated). In this exercise, you will import the CAM Profile from Logix Designer.

1. In the Motion Analyzer Profile Editor, click the arrow next to the Delete button. Select Delete All to delete any
existing segments. Click Add and Logix Elements.

2. Switch to Logix Designer and select the MATC in rung zero. Click on the
the segments and then right click to copy all of the segments, as shown.

for the CAM Profile. Select all of

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 still contains the CAM Profile data from
Logix Designer. The profile data can now be used to size the motor and drive combination.

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Building a System in Motion Analyzer

Create an Integrated Drive Motor Application in Motion Analyzer
In this portion of the lab, you will select a drive and motor using the CAM profile imported from Logix Designer and then create
two Integrated Drive Motor or IDM axes.

1. In the Profile Editor window, accept the motion profile that you just imported from Logix Designer by clicking OK.
2. Click Next to move on to select the Linear Mechanism for your application.
3. Select the Linear Stage as the Mechanism Type for your application.

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4. The next screen displays a summary of the Application Requirements and gives you the option to configure
options for the Linear Stage. Click Next.

5. In the Linear Stage tab, select the MPAS Direct Drive Linear Stage, then click Next.

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6. In the Drive tab, select the Kinetix 6000 Drive Family. Check the AC3ph box under Supply Type and then
select 480 for the Nominal Voltage. Click Next.

7. In the Selection tab, click Search to generate a list of solutions for your application.
8. At the bottom of the window, acknowledge the Alert regarding configuration of the Drive Module by clicking
Accept.

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9. Sort the solution list by clicking on the Cost Factor column label, and highlight the most cost effective option on
the list, the MPAS-A8014E-ALMS2C. Notice that the Linear Stage that you just selected now appears in the
Explorer View. You will need to widen the window to see the full catalog number.

10. Right click on My New Axis in Slot 1 and select Rename. Rename My New Axis to Linear Axis.
11. Click on the Life Estimate tab for the Linear Stage. The Life Estimate tab provides information on the life and
bearing load utilizations for linear stages and electric cylinders. Notice that based on the default Operating
Conditions (8 hours a day and 5 days a week) the Linear Stage has an estimated life of greater than 25 years for
the Motion Profile which we have selected.

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12. Click the Change Operating Conditions button and enter 12 Hours per Day and 7 Days per Week for the new
Operating Conditions. Click OK.

13. Notice now that the Strip Seal and Cable Track Life Estimate has been reduced to about 16.5 years.

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Configure an Axis with an Intergrated Drive Motor

The Integrated Drive-Motor (IDM) is a high performance food-grade servo motor integrated with a Kinetix servo drive. The
Kinetix 6000M system is designed to integrate seamlessly with the popular Kinetix 6000 and Kinetix 6200 multi-axis servo drive
systems. The 460 volt Kinetix 6000M Power Interface Module mounts directly to a Kinetix 6000 power rail and connects to the
sercos fiber optic motion network in the control enclosure. We will now add an Integrated Drive Motor to the power rail.

1. Right click on Slot 2 in the Power Rail and select Add Axis. Right click on My New Axis and rename the axis to
IDM Axis 1.
2. Notice that the Axis View window for IDM Axis 1 appeared when this axis was added to the power rail. Select
Rotary for the Load Type.
3. Enter 0.1 kg-m2 for the Primary Inertia and click Next.

4. In the Profile tab, click Edit Motion Profile. We will use a simple trapezoidal move, so when the Profile Editor
appears, click OK and then click Next.
5. Click Next in the Transmissions tab.

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6. Select the new MDF-Integrated Drive Motor Series and click Next.

7. You defined a Kinetix 6000 Drive and the voltage requirements for the Linear Axis. Since the IDM axis shares
the power rail with the Linear Axis, this drive information populates automatically. Click Next in the Drive tab.
8. Click Search in the Selection tab. When the solution list appears, highlight the MDF-SB1304F, which is the first
solution on the list. Again notice that the Integrated Drive Motor that you just selected is now listed under My
New IPIM in the Explorer View.

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9. Now well quickly copy and paste this new axis to create a second axis for the IPIM. Highlight My New IPIM in
Slot 2 and click the Add Axis button on the Home tab of the Ribbon Bar.

10. The following dialog box will appear indicating that since another axis will place demands on the IPIM, Motion
Analyzer will re-evaluate the IPIM to make sure it provides enough power for the two axes. Click OK to
acknowlege the information.

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11. Highlight IDM Axis 1 and click the Copy button on the Home tab of the Ribbon Bar.

12. Highlight the axis you just created (My New Axis) and click Paste on the Home tab of the Ribbon Bar. Notice
that Motion Analyzer has verified that MY New IPIM is sufficient for the two axes, so it is no longer listed as
Incomplete but instead now displays a green check box.
13. Rename IDM Axis 1 (1) to IDM Axis 2.

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Configure a Power Supply for Your Axes

1. Notice that the Kinetix 6000 Power Rail is indicating that its configuration is incomplete. Highlight the Power
Rail and click the Power Supply/Accessories button on the Home tab of the Ribbon Bar to select a power
supply for this application.

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2. Click on the IAM & Shunt tab in the Power Supply/Accessories View and click Search.

3. The following dialog box will appear. Motion Analyzer recognizes that it is most efficient to arrange the drives in
order of decreasing power requirement. Since an IPIM cannot be placed in slot 1, we must accept the current
arrangement with the linear thruster in slot 1. Click the Perform Search button.

4. Click Yes in the next dialog box. Notice that Slot 1 now contains the selected Integrated Axis Module, 2094BC01-MP5-S.

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Configuring an AC Supply and DC Bus Sharing for a Kinetix 5500 Drives Group
The Kinetix 5500 is a new drive developed by Rockwell Automation, providing full EtherNet/IP Integrated Motion and universal
voltage input with a small cabinet footprint and reduced wiring. The Kinetix 5500 features an innovative design which combines
power and feedback signals in a single cable and connects to the new Kinetix VPL servo motors with a single SpeedTEC
connector. The Kinetix 5500 is also configurable as either a stand-alone drive or within a drive group, allowing for the sharing of
both the AC supply and the DC Bus. We will now configure the power structure for a Kinetix 5500 drives group that shares AC
and DC power.

1. Click File -> Open and open the file K5500 Power Sharing.mba located in C:\Lab Files. There is no need to
save the preivious file.
2. In the explorer view on the left, you will see seven Kinetix 5500 axes.

3. Double click on Axis 1 and navigate to the Motor Tab. Select the Detailed View.

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4. Scroll to the VPL Motor to find more information about this new motor

5. Navigate to the Drive Tab. Click OK on the pop-up saying that Shunt Selection will need review. Again select
the Detailed View.

6. Scroll down to the Kinetix 5500 to find out more infomration about this new drive.

7. Select Axis 1 in the Explorer View, then, while holding down the Shift key, click on Axis 7 to select all of the
axes.

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8. Under the Home tab, click the Group button

9. On the same tab, click Power Supply / Accessories.

10. Here, we are presented with two options, DC Sharing or AC Sharing Only. For our application, we would like to
share boh the AC supply and the DC Bus. The AC Supply will be fed into both Axis 1 and Axis 2. Together,
these drives will convert the AC to DC, feeding a shared DC bus that is connected to the rest of the drives. This
will save wiring and installation costs.

In the Axes Power Sharing Configuration, select DC Sharing and check the box under Axes Sharing Input AC
Supply for Axis 2.

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11. Click on the Converter and Shunt tab. Here, Motion Analyzer will determine if the internal capactiance and
shunts in the system are sufficient to manage the power needed by the system. Press the Calculate Utlizations
button.
12. Motion Analyzer has calculated that the the total application continuous shunt power is 160% of the shunt
wattage and is too large for the system to manage, as indicated by the red bar. Change the shunt on Axis 1, 2
and 3 from the Internal Shunt to 2097-R6. Acknowldege the dialog box that appears.

13. Press the Calculate Utilizations button again to see the result. The bar should no longer be red, indicating that the
shunt is properly sized.
14. Note that the system is using 19% of the maximum continous current and 32% of the maximum peak current
supplied to the DC bus from Axis 1 and Axis 2.

Go back to the Power Configuration tab and add Axis 3 to AC sharing by clicking the box under Axes Sharing
Input AC Supply. Acknowldege the dialog box that appears. Now return to the Converter and Shunt tab and
click Calculate Utilizations. You will notice that the continuous and peak current has decreased to 13% and 21%.
By sharing the AC Supply, the additional drive is able to add to the current capacity of the system.

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Using the Motion Analyzer 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 systems stability, it also indicates the probable following error
along the motion profile. This will help mitigate costly design changes and allow for faster commissioning.

1. Open the MA Tuning Simulation.mba in the C:\Lab Files folder. There is no need to save the current Motion
Analyzer project file. 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 various
Kinetix drives operating with a Logix controller.

4. Take a moment to familiarize yourself with the screen. On the left hand side, there is information about the
control system including the controller, drive, motor, and load. Click on the caret to see more detailed
information about the Simulation Inputs.

5. On the right hand side are the tuning parameters that would be used in Logix Designer.

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6. In the center, there are three plots where the Motor Position, Velocity and Torque values and their associated
target values are displayed after running a simulation. Click the Run Simulation button.

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 the command values (green curves) and actual values
(red curves) in the Motor Position and Velocity plots. In Logix Designer, the AutoTune function will determine the
reflected inertia of the load and then adjust the gains as needed. The Motion Analyzer AutoTune function will
use the same equations along with the load that was previously entered to produce the same results.

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7. Click the AutoTune button, and then click the Run Simulation button. Notice how the performance changed.

8. Explore the different tuning options available. 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
Lets 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. Change the Coupling type from Rigid to Compliance.

2. Enter the stiffness value of 116 Nm/degree (also known as torsional rigidity) into the proper field. Select the
Basic Application Type for the AutoTune and click the AutoTune button. Then click Run Simulation.

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3. Use the selection of couplings below to explore which are acceptable for this application. It may be helpful to
change the AutoTune Application Type as well. Enter the torsional rigidity (stiffness) and run the simulations:

Note: In servo applications, couplings need to be selected for both torque rating and stiffness. The tuning simulation
can help determine if a particular coupling is suitable.

4. Exit the current simulation by clicking the OK button.

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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. Double click on the Motor with gearbox axis in the Explorer View pane.

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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 click the Run Simulation button.
We see below that the out of the box results are again a little bit sloppy. Expand the Simulation Inputs window
by clicking the caret and notice that the Backlash has been set to a default of 6 arc-mins, though you can change
this for your specific gearbox.

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3. Click the AutoTune button and then the Run Simulation button.
Does performance improve? When the simulation completes, notice that the Position Lock Tolerance has been
exceeded.
4. Try the AutoTune again, but adjust the Position Bandwidth to 10 Hz. This parameter is located under More
Options in the AutoTune Options section of the screen in the upper right hand side.

Set the Application Type to Tracking. Then click AutoTune and Run Simulation again. As you can see, there
is a significant change in the performance (the system is more stable now), and the position error is no longer
exceeded.
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 OK button.

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Reducing Compliance and Eliminating Backlash

1. Switch to the Direct drive rotary axis by double clicking the Direct drive rotary axis in the Explorer View pane.
This axis shows the same motion 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 then click the Run Simulation button.

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

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3. Select the Tracking application type. Click the AutoTune button, and then click the Run Simulation button 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 OK button.

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.

5. If continuing on to the Advanced Tuning Simulation section, leave Motion Analyzer open. Otherwise, you can
exit the program without saving your work.

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Appendix A: Using the Motion Analyzer Tuning Simulation (Advanced)

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 load 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 MATuning Simulation.mba, located in C:\Lab Files.
2. From the Axis View, add a new axis by double clicking Slot 5 (the first empty slot below the existing axes).

3. Acknowledge the dialog box that appears by clicking OK.

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.

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

5. The defaults for a Rotary Complex load 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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6. 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.

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

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

9. 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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10. Remove the header by selecting the first 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 Next button.

11. Click Edit Motion Profile and then More Options to open the More Options Profile Editor Mode. This example
will model a constant speed application, taking advantage of the linear sinusoidal motion of crank on the load
end.
12. Delete the default segment.
13. Click Add > Accel/Decel. Set the following:

Time: 1 second

Velocity: 120 rpm

Jerk Percentage: 100 % of time

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

Time: 4 seconds

Click OK. Your completed motion profile should look something like this example. Click Next.

15. 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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16. 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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17. Open the Simulation tool and click the Run Simulation button. 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.

18. Try an AutoTune 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 selection for 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.

19. Close Motion Analyzer and Excel when you are done. You dont need to save the files.

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Appendix B: Importing Profile Data into Motion Analyzer from Microsoft Excel
This Appendix explains how to export a Motion Profile template to Microsoft Excel in order to create and modify a CAM profile
based on values other than position (ex. Torque, Speed, Inertia, etc.). Once you have created the Profile template, you can
modify the profile parameters for your application within Microsoft Excel and then import the final Profile Data into Motion
Analyzer.

Create a Microsoft Excel File Template to Import Profile Data into Motion Analyzer
1. In the More Options Profile Editor screen in Motion Analyzer, delete any existing Profile segments by clicking
the arrow next to the Delete button and selecting Delete All.
Note: In this demonstration we will be using a linear load, but the process applies to a rotary load as well.

2. Click the Add button and select the Accel/Decel segment.

Note: For demonstration purposes, we will use the default Data Entry Permutation selection of Time
Velocity and the Incremental data entry type.

The following process would be the same if you were to select any of the other data types.

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

4. Click the Next button to continue to the Type of Exports screen shown. Select the User Defined Export type
and click Next.

5. In the Export Options User Defined screen select SI Units and click Next.

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6. Select File as the Target Location and click Browse. Name the file Profile, browse to the desktop, and save the
file as a .txt file.

7. Click Next in the Target Location for Export screen and then click Finish.
8. Start Microsoft Excel. From the Start menu, select All Programs > Microsoft Office > Microsoft Excel 2010.
9. Open the Profile.txt file that you saved to the desktop. You will need to change the file type to All Files (*.*) in
order to see the .txt file.
10. In the Text Import Wizard that appears in Microsoft Excel, click Next, Next, and Finish. The file should be
similar to this:

This file can now be used as a template for creating or modifying your Motion Profile within Microsoft Excel.

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Import Profile Data into Motion Analyzer from a Microsoft Excel Template
1. Open the Microsoft Excel file C:\Lab Files\Advanced Profile Import.xlsx. This file contains a sample profile
that contains velocity, time, and force data.
2. Copy the data in Column B (do not include the column labels) in the Advanced Profile Import spreadsheet into
Cell D7 in the Profile template that was created.
3. Copy the data in Column C in the Advanced Profile Import spreadsheet into Cell F7 in the Profile template.
4. Copy the data in Column D in the Advanced Profile Import spreadsheet into Cell H7 in the Profile template.
5. Copy the data in Column E in the Advanced Profile Import spreadsheet into Cell Q7 in the Profile template.
6. Fill Columns A-C with the text contained in row 8 for the respective columns.

7. Fill the remaining columns in the profile template that do not yet contain data with zeros (i.e. Columns E, G, I-P
and R-T). Your spreadsheet should look similar to this:

Note: Column O contained a - in row 8. A zero or a - may be used interchangeably in the unused
columns. Zeros were used in this demonstration for consistency.

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8. Save the file, and select Yes when the following dialog box appears.

9. Close the Profile.txt file. If a dialog box appears as you are closing the spreadsheet, select Dont Save. Return
to the Profile Editor in Motion Analyzer.
10. Delete any existing Profile segments by clicking the arrow next to the Delete button and selecting Delete All.
11. Click the Import button on the lower left hand side of the Profile Editor.

12. Click the Next button to continue to the Source Location For Import screen shown. Select the File option,
navigate to the Profile.txt file that you saved to the desktop and click Open.

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13. In the Source Location for Import screen click Next.

14. In the Type of Import screen select User Defined and TAB Delimiter. Click Next.

15. Click Next in the Import Options User Defined screen and then click Finish.
16. The imported profile will appear in the Profile Plot window. Select the Velocity and Applied Force checkboxes
to compare the plots in the Profile Editor to the plots in the Advanced Profile Import.txt file.

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Notes

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

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

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Copyright 2013 Rockwell Automation, Inc. All rights reserved.