BCN-1534%S2

SPINDLE ORIENT.ATION by ENCODER

TYPE

DL-UE
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from Japamou manual BCN-11341.81

At

MITSUBISHI
ELECTRIC

.......................................................................................................................

I .

Introduction

1.

Specifications

m.

Basic principle ...................................................................................................................

Page
1

..._..___~__ .................................................................................................... 1
2

3_ 1

Bol ck diagram .. ..-..........~..............~................................................................~_

3-2

()perati on expl afiati on ............................................................................................................ 3

......................... 2

Iv.

Parts

V.

S i te adjustments .........____ .........................____ ..................................................................... 6

1 ayout drawing

..................................................................................................... 5

5-l Initial adjustments and adjustments before

start of mass production .............................................................................................

5-2 Adjustment after start of mass producti ~~..-..--.............~.......~........._..._..~.....~ ................ 7

5-3 Setting details for each part ._._____._ ____ ____ __ ___._.__________.___ _ __._ ___ ________ _________ ______ _ __________ __ .____._. 8
5-4 Installation of the encoder . . ..~._..~~___~~....._.................~._~_.~.~.._...~..~................~......---~-------..
M.

13

Detai Is for check terminals and I ight-emi tting diodes------------------ 14

6-l

Li st of the check terminal s ............... .._.....~...~...~......._.~.~....~~._~........._.~.....~.~.._~........._......_~.l

6-2

Detai 1 s for the 1 ight-emi tti ng di o&s. ...........................................................................15

c
M.

MS

Connector composition. card dimensions, and card weight ..-.----. 17

7_ 1

Connector composition __________________________________________~~~.....~......._........~__.~......~...~...-...................

17

7-2

Card dimens i ens _________________i__________________....._~.~~...........~~~.~..........~.-...--~........~......~.....-~-...-...

17

roubie

-shoot

_ ..........................................

External

8-2

Vol

8-3.

Trouble-shooting ...................................... ..... . .................................................................... 18

check

.........................................................................

18

8-1

f-age

c.,eck

ing .............................................................................................................

......................................................................................................................

Exchange _______________ ____ __ _____ __________ __._________..________._ _ _.__........ _.._.__ -..... _-_ -.... I . . . . . . . _ . . . . . . ..- ---_

K.

Card

X .

Elementary

diagram ._...___._._ _.____ _______________ _ ________ _._ _________ _ _____.._ _._ __.............................: . . . . .

18

18

20

21

I .

Introduction

This manual treats the option card

DL-UE

for spindle

orientation function according to the encoder method.

II.

Specifications
1. Used encoder:
2.

Resolution:

R FA-1024-22-1-68
BKO-C-1723

(NIKON >

O.O89"/pulse

'3. Max. spindle speed: 6000 rpm.

4..IN POSITION judqement width: + 0.6" or + 0.3" (switchable)
Standard setting: + 0.6O
5. Output signal contacts:

1A

contacts. Closed with IN-

POSITION

0.2

Contact rating DC 30 V,

A or less

6. Orientation position adjustment: Adjuktment is possible

with the switch on the card
in increments of 0.089" to
max.

-l-

about + ll".

Ill.

Basic principle

3-l.

Block

diagram

The block diagram is shown in

Fig.

3-l.

Stop porition

indication

I N POSITION l-4

oPLG

Racoivor

IN POSITION
sott ing width
4

lbcoiver

Synohroniz- ation
circuit
t

Position
amp1 if iar

Buffer
am01 ifier

~;(~%jY
::c

me-

Suffer

Fig.

3-l

- 2. -

Block

diagram

amplifier

..

---

Speed amp1 if ier

3 - 2 . O p e r a t i o n explanat i o n
The operation is shown in the time chart of Fig. 3-2 .

Speed decided by the gain of

the position amplifier
Counting is
started
yc

Motor speed

Orientation

command

UP TO SPEED

Mark pulse

l-l

rl

IN POSITION OUTPUT

-4-L

200mS

Fig.

'

3-2 Time chart

(1) By orientation command, the motor speed is switched

to orientation speed.
(2) When the motor speed reaches the orientation speed,
the UP TO SPEED signal

rises.

(3) When a mark pulse enters after rising of the UP TO

SPEED

Signal,

the orientation position set by SW801 and

MI802 is read, and counting is started simultaneously.

The motor speed at this time is the orientation speed.
(4) When a point about SO0 before the target point is
reached,

the control loop is switched from the speed

loop to the position loop. At this time, the motor

speed is switched from the orientation speed to the
speed decided by the gain of the position amplifier.

--

(5)

At about 11' before the target point, the linear zone

of the position loop is entered, the motor starts
deceleration, and stop is executed at the target point.

(6) The

IN POSlTlON

signal rises at about 0.3' or about

0.6' respectively before the target point, and the

IN POSlTlON

signal output contacts close about 200 ms

later. Switching between 0.3O and 0.6O can be executed

with the short-circuit pin on the card.
(7) When the orientation.command is cancelled, the motor
returns to the speed of the

S command

given at that

time.
(8)'When reorientation is executed from orientation condition, then the motor turns once and. executes orientation.

-4-

N.

Parts layout drawing

(POSlTl;_td;;ynt

width

Orientation

position

adjustment

(5-3 (3))

H range orientation speed

(5-3 (811

L range orientstion speed

(5-3 (9))

H range posit ion amplifier gain

(5-3

(10))

L rsnge po&t ion amplifier gqin

(5-3 <ll))
H range offset

(5-3 (1))
L range offset

(5-3 (2))

Encoder

revolution

c
Fig.

4-l

Parts layout drawing

-5-

direction

Site adjustments

V.
5-l

I n i t i a l a d j u s t m e n t s and adjustments before start

of mass production.
When machine and
controller are combined for the first
.
time and the controller has not been adjusted for that
machine before shipment from the factory, execute adjustment according to this item.
Sequence'numbers, part numbers, and setting contents are
listed in the following.
1.

PIN802:

Encoder power Supply sellecticn

For details, refer to S-3.(5).

2. PIN.801: Encoder revolution direction
For details, refer to S-3.16).
3. PIN803: IN POSITIoN judgement width
For details, refer to S-3.(7).
4. VP801: H range orientation speed
Set preliminarily to scale graduation 2.
5. vR802: L range orientation speed
Set preliminarily to scale graduation 2.
6. VR803: H range position amplifier gain
For details, refer to S-3.(10).
7. VR804: L range position amplifier gain
For details, refer to S-3.(11).
8. VP 12 (in

SD-W ):

In case of unstable orientation operation

For details, refer to S-3.(4).

9. vR805: H range offset
For details, refer to S-3.(1).
10. VR806: L range offset
For details,. refer to S-3.(2).
-6-

11.

Sw801. SW802:

Orientation position adjustment

Execute ATC without key insertion, and set to a suitable

position. However, it should be noted that an error
may be caused for the fit between spindle and tool
by tool insertion error, position deviation at the time
of insertion, etc.
For details, refer to

S-3.(3).

5-2. Adjustment after start of mass production

The site adjustment items during mass production are
shown in the following.
Note:
For

adjustment execution, confirm that VR801

to VR804 and PIN801 to PIN803 are set correctly

according to "ADJUSTMENT DATA".

Sequence numbers, part numbers, and setting contents

are listed in the following.
1. VR12 (in

SD-SA):

In case of unstable orientation operation

For details, refer to S-3.(4).

2. VR805: H

range

offset

For details, refer to S-3.(1).

3.

VR806:

L range

offset

For details, refer to 5-3. (2).

4 . SW801, SW802:

Orientation position adjustment

Execute ATC without key insertion, and set to a suitable

position. However, it should be noted that an error
may be caused for the fit between spindle and tool
by tool insertion error, position deviation at the time
of insertion, etc.
For details, refer to S-3.(3).
-7-

5 - 3 . S e t t i n g details f o r e a c h p a r t
The setting details for each part are explained in the

by the maker and should not be changed unnece-

(1) vR805: H range

position

amplifier

offset

adjustment

Repeat orientation (Mlg) with H gear MO3, and adjust

VI3805 so that

the lighting condition of

LED801

to

LED808 at the completion of orientation is as shown

in the following figure.

For the meaning of the light-emitting diodes, refer

to item 6-2.(l).
0

LCDaOl

0
0
0

LED802

0
0
0
0

or

LEO803

LED804

0
0
0
0

(2) VR806: L range

o indicates LED illuminated

l

indicates LED not illuminated

LED805
LED806
LED307
~ED808

position

amplifier

offset

adjustment

Execute the same kind of adjustment as in item 1 with

VI3806

for the

L gear

As there is only a difference of 1 pulse between all

LED illuminated and all LED not illuminated, repeated
simultaneous ON/OFF for LED801 to LED808 indicates
that ON/OFF is repeated by an error of 1 pulse, and
this is not abnormal.
Generally, when adjustment for MO3 is executed so that
all LED are out, then in many cases

LED801 to

LED808

all together will tepeat ON/OFF with MO4, or only

LED808

will repeat ON/OFF, and this condition is OK.

-8-

(3) SW8Ol.; SW=: Orientation position adjustment

Orientation position adjustment is executed with SW8Ol
and SW802.

Small

Large 4
SW801

and SW802 have a 2 bit binary code composition.

Number

Movement amount
(about)

r;;z;F;lt amount

Number
1

SW801

(41 (vR12

4
in

11.6O
D-SA) :

0.72"

In case of unstable spindle operation

at

the time of orientation

Turn VR12 in the card SD-SA about 1 scale graduation

in counterclockwise direction.
(5)

PlN802: Setting of the encoder power supply source

(A> Power supply from the spindle controller

Set the pin to position A.

Note:

The standard setting for PIN802 at the time of

shipment is position A. .
Wrong setting of this pin may make orientation
impossible..

-9-

(B) Power supply from. the-NC

-10 the encoder

St the Pin to Position 8.

CAUTION
Before the' pin insertion position is changed,
the power supply must be switched off.
(61 PIN801 :
Start
A or

Setting of the encoder revolution direction

the spindle with SlOO, and insert the pin into

B so that LED811 and LED812 both light up or go

out together with MO3 and M04.

LED811

;o:

LED812

. :o:

MO3

LED811

;o;
0

LED812 ;o:
MO3

MO4

MO4

or

or
MO4

-.

Bad example

Good example

MO4 MO3

MO3

Note:
The standard position for PIN801 at the time of
shipment is position B.

When this pin is inserted wrongly, the spindle will

chatter at the time of orientation and orientation will
not be possible.
Note:
When motor and encoder's rotation is the same
direction, position A is used, and when their
rotation is opposite directions, position B
1 is used.
Note:
I --

Before'the pin insertion position is'chanped,

the power supply must be switched off.
-lO-

(71 PIN803: IN POSITION judgement width setting

PIN803

AB
@I
z When the pin is inserted on side A,

IN

POSITION

is obtained with a width of +- 3 pulses.

AB
c@
LWhen the pin is inserted on side

B, IN POSITION

is obtained with a width of + 6 pulses.

Note:
The standard setting for this pin at the time of
shipment is position B.

* Note:

Before the pin insertion,position is changed, the

power'supply must be switched off.
(8) VR801: H range

orientation

speed

Orientation speed

Time

Try orientation in H gear. When VR801 is turned clockwise, the orientation speed increases as shown in the
figure, but excessive turning will cause overrun.
Visually observe that the servo speed appears suitable
for forward and reverse, and adjust so that orientation
is executed smoothly and quickly.
A spindle speed of about 200 rpm is suitable as

orientation speed.

-1 l-

(9)

VR802:

L range orientation speed

Execute the same adjustment as in item 8 for the L gear.

In this case also, a-spindle speed of about 200

rpm

is suitable as orientation speed.

(10) VR803: H range position amplifier gain
Orientation speed

o As shown in the figure, clockwise turning of this

volume will increase the servo speed and shorten
the orientation time, while simultaneously the
position accuracy is improved.
o However, clockwise turning facilitates overrun.
o With further turning in clockwise direction, the
operation will become unstable, and.finally hunting
will occur.
Adjust so that orientation is executed smoothly and
quickly.
Note:
-

When this volume has been turned, the offset

must be readjusted according to item 1.
(11) V R 8 0 4 : L r a n g e p o s i t i o n a m p l i f i e r g a i n
Execute the same adjustment as described in item 10
for the

gear.
-12-

When this volume has been turned, the offset must be

readjusted according to item 2.

5-4. I n s t a l l a t i o n o f t h e e n c o d e r .
As shown in Fig. 5-1, encoder has one thin line on
. the roter and two thin lines on the stater, respectively.
After the installation to the machine, when orientation
is finished, as shown in Fig. 5'1, the stater's line
coinsides with the skater's line that is in opposition
with the connector.

so,

at

the installation of the encoder, you should set

the machine's spindle to the orientation point required

at first, and then install the encoder of which lines
are in coincidence with each other as shown in Fig. 5-l.
More fine orient point adjust is executed within +ll
degrees electrically. (refer to S-4-3).

rtater 8 I ines

rotbrs

I ines W
coincidexce

of the two lines

+
A

i-

I-

Iorient s t a t e ]

Fig. 5-l Orient point of the encoder

-13-

M.

6-l.

Details for check terminals and light-emitting diodes

List of the check terminals

The check terminals, their functions, the normal values,

and the normal wave forms are listed in the following.
1. (X801: Orientation command confirmation
About +15 V by orientation start command.
2. a-1802: D/A converter output voltage
(1) + 10 v + 10% during continuous revolution.
(2) During orientation
(3) At the time of orientation completion
0 to + 250 mV.
3. CH803: Speed command voltage
+ 10 V/max. speed.
4. CH804: Synchronization oscillator output
m-OAbout 15 V
About 250 kHz
5. CH805: H range orientation speed command voltage
-

About + 1 V to + 3 V.
6. CH806:

L range

orientation speed command voltage

About + 3 V to + 6 V.
7. CH807: UP/DOWN command
L at the time of DOWN COUNT
At the time of UP COUNT: - - - ---I-LED812 lights up at the time of UP COUNT.
8. CH8C8: COUNT PULSE

9.

CH8O9: B phase

pulse check

During continuous revolution:

10. CH810: A phase pulse check

Same as item 10.
11. CH811: Encoder power supply
+5 v +- 10%.
12. CH812: +5 V stabilized power supply output
+5 v + 10%.
13.

CH

813: Common

0 v.
14. CH814: +15 V power supply
+15 v + 3%.
15. CH815: -15 V power supply
-15 v +- 3%.
-

6-2. Details for the light-emitting diodes

__
(1)

POSITION ERROR
LED801

to

LED8Q8

LED801 to LED8O8)

indicate the deviation from the encoder

shaft target position as a.pulse number. As described

above, one pulse corresponds to 0.089'.
LED801.. . . . . . . .o 0 0 0 0 0 0 0 0 0 2
~~~~~~OOOOOOO~O0000000000
~~~8O3OOOO..O..~~~00000~~

25

LED804.'. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2'
~~~8O5OooooooooOOOOOOOOeo

23

LED8060 0 0 0 0 0 0 0 0 0 0 0 0'0 0 0 0 0 0 22

c-

~~D8O7oOOooOOeoOOooOOooOO

2l

L~~8o8oOoOoOoOoOoOoOoOoOo

2.O

-8-7-6-5-4-3-2-l-0+0 1 2 3 4 5 6 7 8 9
(PULSE)

DOWN COUNT C

UP COUNT
I

TARGET POINT

-15-

. LED ILLUMINATED
0 LED NOT ILLUMINATED

(2)

Other light-emitting diodes

Lights up with normal A phase pulse

during motor run
Lights up with normal B phase pulse
during motor run
I ights

up during reverse run

of the motor

0 LiDSO 1
0 LED802
0 LED803

0
0
6
0

LED804
~~~805
LED806

LED807
0 LED808
LED809

Lights up at the time of up COUNT

(From S300 up, this LED lights up
independent of UP COUNT or DOWN COUNT.)

LED810
LED81 1
LED81 2

Lights up with IN POSITION

As the circuit composition provides for UP C@UNT at

the time of reverse and DOWN COUNT at the time of
forward, it is normal that both LED light up and
go out together.
Fig. 6-l

-16-

W.

C o n n e c t o r composition9

card dimensions, and card weight

7-1 . Connector composition

(1) CON54
'1

ORCl

ORLK

ORA

CTL

ORAl

OSB

OR1

,PG

LA1

RI

COM

PG

LA1

RI

10

P12

AC1

Nl5E N12.

AC2

P15E

(2) CON4, CON5

I=

IPA 1

XIPB 1

7-2. Card dimensions

-a:
!------- 7
Weight

About 300 gr.

(not including ,connection connectors).

-1 7-

W. T r o u b l e - s h o o t i n g

8-l. E x t e r n a l c h e c k
First, execute the following visual checks:
o Are there abnormalities in the external appearance?
o Are there any damaged parts?
o Is there attachment of metal chips'or other foreign matter?
o Are there loose connectors?

8-2. V o l t a g e c h e c k
Use a DC voltmeter to check the following check pins:
0 CH811: +5 v + 10%
o CH814: +15 v + 3%
o CH815: -15 v + 3%
. ..I.

At*@iis time, CH813 is used as common for measuring.

8-3. T r o u b l e - s h o o t i n g
(1) Even when an orientation command (M19, Mll,, etc.) is
given, there is no change in the motor operation
(orientation is not possible).
1. The orientation interlock signal is ON.
The signal is ON when pin 5 of K-69 is "L".
Cancel the interlock signal.
2. No orientation signal is given to the card.
When pin 1 of lC-69 is not "L", the signal is not
applied. Treat the outside so that the signal is applied.
(2) When an orientation command is given, the spindle con-

tinues to run with about 200 rpm

1. No pulse signal from the encoder is given as input.
When

LED801 to LED810 all light

up

during

spindle

run, the pulses enter. When they do not light up:

-18-

(1) Check the contact of the connectors CON4 and CON5..

(2) Check the encoder wiring.

(3) Exchange the encoder.

(3) Overrun occurs at the time of orientation, and orientation
is executed to a completely different place

1. The orientation speed is high.

Turn VR801 (H range) and/or VR802 (4 range) for
about 1 scale graduation in counterclockwise direction.
(4) The spindle operation at the time of orientation is
not smooth
1. High gain of,the speed loop
Turn VR12 in the card SD-SA for about 1 scale
graduation in counterclockwise direction.
2. High gain of the position loop

Turn VR803 (H range) and/or VR804- (L range) for

i --

about 1 scale graduation in counterclockwise direction.

Note:
After turning of VR12, VR803, and VR804, refer
to 5-3.(l) and (2) and execute offset adjustment.

5) Orientation is executed to the correct position, but

the IN POSITION signal is not put out
1. Deviation of the offset adjustment
Refer to S-3.(1) and (2) and execute offset adjustment.

(6) The IN POSITION signal drops off immediately when

the machine grasps the tool, and ATC operation stops.
1. The offset adjustment has deviated, the position

deviates slightly by external force at the moment

when the tool is grasped, and IN POSITION drops

-19-

off.

Refer to 5-3.(l) and (2) and execute offset adjustment.

2. Because of deviation of the orientation position
adjustment, a large external force is applied at
the moment when the tool is grasped, the position
deviates, and IN

POSITION drops

off.

Refer to 5-3.(3) and execute orientation position

adjustment.

K. Card Exchange
9-l. Pin a n d volume s e t t i n g
Set

PIN801

to

P1~805

and

VI3801

to

VR804 to

the same positions

as on the cart? to be exchanged.

Set SW801 and SW802 also to the same positions.
9-2. Offset adjustment
Adjust VI3805 and VR806 under reference to 5-3.(l) and (2).
g-3.

Confirmation of the orientation position

Execute

ATC

without key insertion, try manual key insertion,

and if manual insertion is not possible, confirm that a

position is reached where the taper part will enter with
application of hydraulic pressure.
In case of position deviation, adjustSW801 and SW802
according to 5-3.(3).

-2 o-