Documentation eXtended Transport System Start-Up · installation of the XTS in a machine or system,...

Documentation

eXtended Transport System Start-Up

1.22016-02-18

Version:Date:

Table of content

Table of content1 Foreword .................................................................................................................................................... 5

1.1 Notes on the documentation............................................................................................................. 51.2 Documentation issue status.............................................................................................................. 61.3 Intended use ..................................................................................................................................... 6

2 Guidelines and Standards ........................................................................................................................ 7

3 Safety.......................................................................................................................................................... 83.1 General safety instructions ............................................................................................................... 8

3.1.1 Personnel qualification.......................................................................................................... 83.1.2 Description of safety symbols ............................................................................................... 8

3.2 Special safety instructions ............................................................................................................... 93.3 Using in Ex environments ............................................................................................................... 10

4 Handling ................................................................................................................................................... 114.1 Transport ........................................................................................................................................ 114.2 Packaging ....................................................................................................................................... 114.3 Storage ........................................................................................................................................... 124.4 Maintenance / Cleaning .................................................................................................................. 12

4.4.1 Replacement of the guide rollers ........................................................................................ 134.5 Disposal .......................................................................................................................................... 14

5 Product identification.............................................................................................................................. 155.1 Scope of supply .............................................................................................................................. 155.2 Type label ....................................................................................................................................... 155.3 Type key ......................................................................................................................................... 16

6 Technical description.............................................................................................................................. 186.1 General technical data.................................................................................................................... 18

6.1.1 Dimensions ......................................................................................................................... 196.1.2 Connection diagram XTS-Infeed......................................................................................... 206.1.3 Connection overview........................................................................................................... 21

6.2 Configuration ................................................................................................................................. 226.2.1 Basic functions.................................................................................................................... 226.2.2 Use of the basic functions................................................................................................... 236.2.3 System length and curve function....................................................................................... 23

6.3 Overview ........................................................................................................................................ 246.4 Overview of the components .......................................................................................................... 26

7 Installation................................................................................................................................................ 287.1 Mechanical installation.................................................................................................................... 287.2 Overview of the tightening torques ................................................................................................. 297.3 Mounting the movers on the guide rail............................................................................................ 317.4 The positioning system................................................................................................................... 33

7.4.1 Zero point of the encoder system ....................................................................................... 337.4.2 Teaching the encoder system............................................................................................. 347.4.3 Application simulation ......................................................................................................... 40

7.5 Collision avoidance......................................................................................................................... 417.5.1 Operating principle of collision avoidance........................................................................... 41

8 Technical data.......................................................................................................................................... 458.1 AT9011-0050-0550......................................................................................................................... 458.2 Technical drawing AT9011-0050-0550........................................................................................... 45

eXtended Transport System Start-Up 3Version: 1.2

Table of content

9 Support and Service................................................................................................................................ 46

eXtended Transport System Start-Up4 Version: 1.2

Foreword

1 Foreword

1.1 Notes on the documentationThis description is only intended for the use of trained specialists in control and automation engineering whoare familiar with the applicable national standards.It is essential that the following notes and explanations are followed when installing and commissioningthese components.

The responsible staff must ensure that the application or use of the products described satisfy all therequirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

The documentation has been prepared with care. The products described are, however, constantly underdevelopment.For that reason the documentation is not in every case checked for consistency with performance data,standards or other characteristics.In the event that it contains technical or editorial errors, we retain the right to make alterations at any timeand without warning.No claims for the modification of products that have already been supplied may be made on the basis of thedata, diagrams and descriptions in this documentation.

Trademarks

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC®and XTS® are registeredtrademarks of and licensed by Beckhoff Automation GmbH.Other designations used in this publication may be trademarks whose use by third parties for their ownpurposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications andpatents:EP1590927, EP1789857, DE102004044764, DE102007017835with corresponding applications or registrations in various other countries.

The TwinCAT Technology is covered, including but not limited to the following patent applications andpatents:EP0851348, US6167425 with corresponding applications or registrations in various other countries.

EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,Germany

Copyright

© Beckhoff Automation GmbH & Co. KG, Germany.The reproduction, distribution and utilization of this document as well as the communication of its contents toothers without express authorization are prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of apatent, utility model or design.


Foreword

1.2 Documentation issue statusIssue Comment1.2 Chapter update:

4.2; 4.5; 6.1.1; 6.1.2; 6.2.3; 6.4; 7.2; 7.5.1; 7.5.2New and deleted chapter:New: 4.4.1; 6.1.3Deleted: 7.3

1.1 Chapter update:3.2; 6.1; 6.1.1, 7.3New chapter:Technical data

1.0 First edition

1.3 Intended useThe linear eXtended Transport System (XTS) is designed for machines and equipment with the highestdemands on dynamics and positioning accuracy. All components of the eXtended Transport System (XTS)are exclusively intended to be programmed and commissioned using the TwinCAT automation softwarefrom Beckhoff Automation GmbH & Co. KG.

WARNING

Caution - Risk of injury!Electronic equipment is not fail-safe. In case of failure of the drive system, the machinemanufacturer is responsible for ensuring that the connected components of the eXtendedTransport System (XTS) and the machine are brought into a safe state.

WARNING

Commissioning of the eXtended Transport System (XTS)The eXtended Transport System (XTS) must be commissioned based on the requirementsof the currently valid EU Machinery Directive. Furthermore, the client must ensure that allcomponents installed in the system have a valid serial number.

All components of the eXtended Transport System (XTS) are installed exclusively in electrical systems ormachines. They may only be commissioned in connection with components of the eXtended TransportSystem (XTS) and the previously designed plant. Furthermore, it is essential to take into account allenvironmental conditions defined in this document before the eXtended Transport System (XTS) iscommissioned.


Guidelines and Standards

2 Guidelines and Standards

CAUTION

Danger for persons, the environment or equipmentThe components of the XTS are not products within the meaning of the EC Machinery Di-rective. Operation of the XTS components in machines or systems is only permitted oncethe machine or system manufacturers has provided evidence of CE conformity of the com-plete machine or system.


Safety

3 Safety

3.1 General safety instructions

3.1.1 Personnel qualificationThis description is only intended for trained specialists in control, automation and drive engineering who arefamiliar with the applicable national standards.

3.1.2 Description of safety symbolsThe following safety symbols and associated safety instructions are used in this document. These safetyinstructions must be read and followed.

DANGER

Serious risk of injury!Failure to follow the safety instructions associated with this symbol directly endangers thelife and health of persons.

WARNING

Caution - Risk of injury!Failure to follow the safety instructions associated with this symbol endangers the life andhealth of persons.

CAUTION

Personal injuries!Failure to follow the safety instructions associated with this symbol can lead to injuries topersons.

Attention

Damage to the environment or devices!Failure to follow the safety instructions associated with this symbol can lead to damage tothe environment or equipment.

Note

Tip or pointerThis symbol indicates information that contributes to better understanding.


Safety

3.2 Special safety instructionsThe safety instructions are designed to avert danger and must be followed during installation,commissioning, production, troubleshooting, maintenance and trial or test assemblies. The XTS can operateindependently. Installation in a machine or system is not mandatory. During independent commissioning orinstallation of the XTS in a machine or system, the documentation and safety instructions provided by themachine manufacturer must be read and applied.

WARNING

Caution - Risk of injury!The XTS may only be installed by trained and qualified personnel. The qualified personnelmust know the national accident prevention regulations and be able to apply them.When working on the XTS, personal protective equipment (PPE) must be worn. In particu-lar, safety boots must be worn!

WARNING

Caution - Risk of injury through electric shock!Bring the electrical environment (XTS, cabinet, etc.) into a safe, de-energized state beforeinstalling or working on the XTS.

DANGER

Acute risk of injury due to improper earthing!The XTS must be earthed in accordance with the statutory provisions. Non-compliant earth-ing can cause acute injuries or death by electric shock.

Attention

Intended use!The XTS starter kit may only be put into operation under consideration of currently valid EUdirectives and standards, as well as the EC Machinery Directive in force at the time of com-missioning.

Attention

Destruction of the XTS starter kit!Ensure adequate ventilation and proper earthing of the cabinet. The permissible ambientconditions are specified in the “Technical data” section. Failure to observe the specifiedambient conditions and improper earthing may cause damage to components of the XTSstarter kit. Furthermore, EMC problems can arise.

CAUTION

Risk of burns from hot surfaces!The XTS issues a warning via TwinCAT if the operating temperature exceeds 65 °C. If thetemperature exceeds 75 °C, the system switches off automatically. In the event of an auto-matic shutdown, the surface temperature of the coils may exceed 105 °C. Acute risk ofburns!Do not touch the components of the XTS during operation and shortly after operation. Waituntil all components have cooled sufficiently.Use a thermometer to check the surface temperature of the components.In cases that require touching of components directly after operation, use suitable safetygloves to protect from burns. Wear heat-resistant clothing.

Danger from magnetic fields!The Beckhoff XTS is equipped with permanent magnets at the guide rails and movers. Thefield strength of the XTS results solely from the magnetic fields of these components. Alimit range of < 0.5 mT is reached in energized state at a radius of 150 mm, in non-ener-gized state at a radius of 130 mm. The magnetic field poses a danger to persons and theenvironment. Observe the regulations for magnetic fields in air transportation (IATA Pack-ing Instruction 902). This applies to already installed magnets. Permanent magnets mustbe stored in humid conditions. The use of permanent magnets in humid conditions (up to95% relative humidity) can lead to corrosion and destruction of the permanent magnets.


Safety

Danger from magnetic fields!In particular, the magnetic field poses a danger to:

• Persons with cardiac pacemakers (the magnetic field may cause the pacemaker toswitch to test mode and thus cause a cardiac arrest!)

• Persons with magnetically conductive implants• Magnetic data storage devices• Chip cards with magnetic strips, and• Electronic devices• Also keep in mind that the magnetic fields can influence implanted defibrillators and

make external defibrillators inoperable.• Ensure a safety distance of 500 mm to all magnetic parts. Also, make sure that there is

no direct contact with magnetic components near parts that are susceptible to interfer-ence. The national regulations and guidelines applicable in other countries must be followed!Also note the requirements of BGV B 11 in connection with magnetic fields (BGV B 11Section 14).

Note

Liability for further transport!Please note that all components of the XTS starter kit may only be forwarded in the originalpackaging supplied by Beckhoff. The use of other packaging for further transport wouldvoid all liability and warranty claims against Beckhoff Automation GmbH & Co. KG.

3.3 Using in Ex environments

WARNING

The use of the XTS in potentially explosive atmospheres – Directive 94/9/EC– is not permitted!


Handling

4 Handling

4.1 Transport• The XTS starter kit may only be transported by qualified personnel and in the manufacturer's original

packaging.• Avoid shocks, particularly at the corners of the packaging.• If the packaging is damaged, check the XTS starter kit for visible damage. Inform the transport

company and, if necessary, the manufacturer.

CAUTION

Damage to the device due to improper transport!When transporting the XTS starter kit ensure that all specifications are met. In particular,jerky and fast movements should be avoided.

4.2 Packaging• Motor modules in recyclable cardboard packaging*• Magnet holders in recyclable cardboard packaging with foam inserts*• Movers in recyclable cardboard packaging with bubble wrap*

*only single packaging.

Shipping of the XTS starter kit

Contents of the Starter Kit include• Fully Assembled and tested XTS (item 4)• Control Cabinet with all necessary equipment

(item 3)

Both are secured in the shipping crate to preventmovement during transport.

Warning Pinch Point!When opening/closing the case keep hands clear ofthe area between the lid of the crate (1) and the sideof the crate (2) two People are required to lift/lowerthe lid!


Handling

4.3 StorageRequirement Characteristic valueClimate category 2K3 according to EN 60721Storage temperature -25°C to +85°CPermissible relative humidity 15% - 95%, no condensation

Store only in the original recyclable manufacturer's packaging.

4.4 Maintenance / Cleaning

Maintenance

The XTS motor modules are maintenance-free!

WARNING

Observe the ambient commissioning conditions!Make sure that the XTS is stored and electrically operated only under the specified condi-tions.

The XTS movers are not maintenance-free!

WARNING

Destruction of the rails!The guide rollers of movers must be checked at regular intervals. Remove any dirt or otherforeign material that may have accumulated on the guide rollers during operation. Failure tocomply with regular maintenance can lead to increased wear of the guide rollers, as well asdamage to the rails.

Note

Rail maintenanceThe rails can be lubricated lightly. This increases the life of the guide rollers. The followinglubricants are suitable for this purpose:

• Vaseline according to DAB 10 (German Pharmacopoeia 10)• Vaseline spray• Silicone spray• PTFE spray• If the rails are cleaned for maintenance, re-lubricate them with one of the lubricants

listed above. For further specifications please contact the Beckhoff applications depart-ment.


Handling

Cleaning

The XTS modules are sealed according to protection class IP65. They are not protected against aggressivesubstances. Clean the modules regularly to protect them against rust and corrosion. Use only Isopropanol.

WARNING

Damage to motor modulesIf damage to the motor modules has occurred, please contact Beckhoff Automation GmbH& Co. KG immediately!

WARNING

Damage to the guide rollersMake sure that the rails are free from dirt and metallic particles. A dirty rail can significantlyreduce the service life of the guide rollers.

4.4.1 Replacement of the guide rollersInstallation manual

Loosen the roller axel nut• Use a 1.5mm Allen Key hold to hold the screw

in place. (2)• Loosen and remove the nut using a 5.5mm

socket wrench/spanner (1)The Screw (2) must be held in place to prevent itfrom turning with the Socket.

Removal of the components• Pull out the screw that is the shaft of the roller

(2) and take with it• the Roller (4)• the washer (5)• the nut (1)

Caution! When removing the screw (2) be sure topull it straight out from the hole in the mover body (6)in order to prevent damage to the threads. Do not tiltit.


Handling

Exchange the RollerAfter all the components have been removed, fromthe mover body, the roller can be replaced.

Reassemble the Components• Insert the screw (2) through• the Roller (4) then• the washer (5)• Push the screw through the hole of the mover

body and fix it in place with the nut (6)Caution! To prevent damage to the threads, takecare to insert the screw (2) straight into the moverbody (6). Do not tilt the screw.

Tighten the Roller axel nut.• Use a 1.5mm Allen key hold the screw (2) in

place.• With a 5.5mm Socket tighten the nut (1) to a

torque of 2.4NmThe screw (2) must be held in place to prevent it fromturning with the nut.

4.5 DisposalIn accordance with the WEEE 2002/96/EC Directives we take old devices and accessories back forprofessional disposal, provided the transport costs are taken over by the sender. Send the devices with thenote “For disposal” to:

Beckhoff Automation GmbH & Co. KGService-CenterStahlstraße 3133415 Verl


Product identification

5 Product identification

5.1 Scope of supplyCheck the completeness of the delivery against your delivery note.Missing parts or damage should be recorded immediately and reported to the carrier, the insurance and/orBeckhoff Automation GmbH & Co. KG.

The standard scope of supply includes:• XTS-Starter Kit• Control cabinet• Connection cables• Control PC• Switch mode power supply units for 24 V and 48 V• Software licenses (TwinCAT/TC3/XTS Extension)• Commissioning of the XTS (this manual)

5.2 Type label



5.3 Type key

*Content of the XTS-Starterkit



*Content of the XTS-Starterkit


Technical description

6 Technical description

6.1 General technical dataEnvironmental influences XTSAmbient temperature -10 °C – +40 °C

If ambient temperatures exceeding +40 °C are expected, it is essential to contactthe Beckhoff applications department.

Transport and storage temperature -25 °C - +85 °CPermissible relative humidity 15 % - +95 %, no condensationContamination level EN 60204 / EN 50178 Level 2Corrosion protection Normally not required. Under extreme operating conditions, special measures

may be imposed by the production.Installation altitude Between 1000 m and 2500 m, the performance reduces by 1.5% per 100 m.Installation position Vertical installation position of the starter kit and housing

Other installation positions are possible for further individual XTS componentsVentilation XTS via convectionProtection class IP65

Note

Ventilation of the machine bed!To improve system utilization, it is strongly recommend to actively or passively cool the ma-chine bed of the XTS. For further information on cooling please contact the Beckhoff appli-cations department!

System properties XTSMax. force 100 N at standstillPayload 80 N at 2 m/sContinuous force 30 N (at approx. 30 °C temperature increase between motor / mounting frame)Velocity 4 m/s at 48 VDC supplyAcceleration > 100 m/s² (without payload)Synchronization accuracy < ± 0.151*) mm at 1.5 m/s within a straight moduleAbsolute accuracy < ± 0.252*) mm within a straight moduleRepeatability (unidirectional) < ± 10 µm (standstill)Mover length 50 mm in direction of movement (AT9011)Mover weight Approx. 350 g (complete mover without attachments)Maximum system length > 10 m (dependent on computing power, no system limit)Occurring temperature during operation /storage temperature

0…< +105 °C3*) / -25 °C…+85 °C

Protection class IP 65Approvals CEVibration/shock resistance Conforms to EN 60068-2-6/EN 60068-2-27EMC immunity/emission Conforms to EN 61000-6-2/EN 61000-6-4

1*) The synchronization accuracy is primarily dependent on the mechanical stiffness and the load on themover. The controller setting and the mechanical offset between the modules must also be taken intoaccount.2*) Typically achievable absolute accuracy; this may be exceeded in case of significant thermal warming ofthe module (∆ϑ ≥ 30°C) or lack of parallelism or orthogonality of the encoder flag to the motor module.3*) Please note the special safety instructions for the XTS on page 8 of this manual!



Electrical data XTSSupply voltage Control voltage 24 VDC, power supply 50 VDC

Current consumption Power supply: 16 A rated currentPower consumption control voltage (24 V) Motor modules: 30 W/m (communication, electronics,

displacement measurement)Length per infeed Typically 1 m – max. 3 m (depending on computing power)Power consumption per mover approx. 30 W at 2 m/s constant speed

approx. 60 W at 4 m/s constant speedapprox. 60 W at a peak acceleration of 10 m/s² and a massof 1 kgapprox. 300 W at a peak acceleration of 50 m/s² and amass of 1 kg

Note

Length per infeed!The length per infeed is application-dependent. For precise dimensioning of the power sup-ply please contact the Beckhoff applications department.

Note

Energy recovery from the XTSThe XTS is capable of energy recovery. If kinetic energy is fed back during an emergencystop, measures should be taken to avoid voltage overshoot, and associated prematureauto-shutdown of the motor modules. For further information please contact the Beckhoffapplications department.

6.1.1 DimensionsModule Width at the ma-

chine bedWidth at thetrack connection

Height Depth

Straight motor moduleAT2001-0250

39.1 mm 22.1 mm 96 mm 250 mm

Straight line motor module with powersupplyAT2001-0250

39.1 mm 22.1 mm 96 mm 250 mm

Curved motor module 180° (clothoid)AT2050-0500

39.1 mm 22.1 mm 306.5 mm 204.2 mm

Distance between movers and modules

The air gap between the magnet and the motor should by 0.85 mm on each side. Important: The magnetsmust not touch the motor modules of the XTS!

The air gap between the encoder flag and the sensor should be 0.9 mm. A tolerance range of 0.4 mm – 1.4mm applies (as of December 2015). Important: Under no circumstances must the encoder flag touch the sensors of the motor modules!



6.1.2 Connection diagram XTS-Infeed

24V

Pow

er s

uppl

y

48VGND24V

PE connection port of the module body

EtherCATline

48V

Pow

er s

uppl

y

Con

trol c

abin

et e

arth

Circuit diagram 48 V negative not grounded:

Do not ground the negative side of the 48V DC BusPower Supply! The adjacent diagram describes thecurrent distribution in the individual conductors. Insidethe module the negative 24V and negative 48Vcables are connected together. If the 48V minus isnot grounded the current for each circuit remains onits conductors. The current for the 24V control powerremains on the 0.75mm wires to and from themodule. The current for the 48V power remains onthe 2.5mm 48V wires to and from the module. Thegrounding of the DC Bus circuit is not necessary. TheEN60204-1 Standard chapter 9.4.3.1 (ground faults)describes that the control circuits must be groundedto ensure a machine cannot start with a broken cable.Load circuits are not affected.

Circuit diagram 48 V minus grounded:

If the negative side of the 48V power supply isgrounded, the following situation occurs as describedby the adjacent diagram. Again, the -48V and -24Vlines are connected internally in the modules. If thenegative side of the 48V power supply is alsogrounded, -24V wire (0.75mm) and the -48V wire(2.5mm) act in parallel for the return path. This willoverload the -24V (0.75mm) wire. The +48V wire(2.5mm) will carry the 48V load circuit current to themodule, the +24V wire (0.75mm) will carry the 24VControl circuit current to the module. On the returnside, the -24V (0.75mm) wire will carry half of thesum of the 48V load circuit current and the 24Vcontrol circuit current. The -48V (2.5mm) wire willcarry the other half of the sum of the currents. The0.75mm wire does have a slightly higher resistance(0.042Ohm/m) than the 2.5mm (0.013Ohm/m) wirebut the difference is so small it can be omitted.



6.1.3 Connection overview

Slot assignment of the power voltage

For produce a power supply, connect the Harting plug of the starter kit with the Harting slots on the controlcabinet.

Line identification Slot Signal Wire cross sectionPhase 1 Pin 1 +48 V 2.5 mm²Phase 2 Pin 2 GND (48 V) 2.5 mm²Phase 3 Pin 3 +24 V 0.75 mm²Phase 4 Pin 4 GND (24 V) 0.75 mm²green and yellow phase screwed to the side Functional earth 2.5 mm²

Note

Design of the wire cross-sectionsThe cable length (supply voltage + EtherCAT) of the supply modules is 5 m. The cable endof the supply voltage is pre-assembled with ferrules. The EtherCAT cable end is pre-as-sembled with an RJ45 connector.

Slot assignment of the EtherCAT lines

For produce an EtherCAT connection, connect the EtherCAT cables with the corresponding labeled slots onthe control cabinet. If the cables are reversed, agree the teaching data of the respective modules will nolonger match.

• Pos. 1 shows the two places of assignment forthe Harting connector of the XTS.

• Pos. 2 shows the input and output slot for theEtherCAT connection



6.2 ConfigurationThe linear XTS combines all drive technology functions in a single mechatronic system. Motor movement,power electronics and displacement measurement form a technical unit, which can be used to implement awide range of complex movements. A user-friendly program interface enables different movements to berealized simultaneously directly from TwinCAT with little effort. The modular XTS enables fast adaptation of atransport concept to different geometries and applications. The XTS contains a fully integrated linear motorwith power electronics and position sensing in a single unit, a mover as moving part and a mechanical guiderail. The desired geometries, lengths and radii are formed by the number and choice of the components.

6.2.1 Basic functionsThe XTS enables a new class of functions that can be used at the same time in several places. Completelynew, particularly flexible: transport and positioning tasks are economically solvable with little effort.

6.2.1.1 Function of the linear motor with NC and further degrees of freedom

Free movement of the mover

The individual mover can be moved like a linear motor along the entire path, since it makes do withoutcables. It can arbitrarily start, stop, brake, accelerate and drive to positions. Like a linear motor with NCcontrol, an individual mover can be synchronized to external motion profiles, thereby achieving maximumflexibility.

Production speed

An individual mover can be addressed sensitively – without jerking and with maximum positioning accuracy.The production speed may be up to 4 m/s over the entire track. The jerk-free acceleration profiles even allowthe transport of liquids.

Wear resistance

The use of XTS leads to less mechanical wear, since only the mover needs mechanical bearings. Gears,belts, guide rollers and clamps are no necessary. Due to the high positioning accuracy, the compensation ofinaccuracies as required in common transport solutions is unnecessary: there is no stretching of chains dueto load and wear, re-tensioning of toothed belts or mechanical backlash during load changes. Apart from thepayload, only the small mass of the mover is moved.

6.2.1.2 Synchronous movement in the group

Movements with constant force

One mover follows another with a defined force. It can apply a clamping force and at the same time follow amovement. For other applications the force can be limited so as not to place an unnecessary load on aproduct under any conditions.

Synchronization in the group

Groups can be formed at any point on the track “on the fly” (during motion). The groups stop together ormove along processing stations with a specified velocity profile. The size of the group (number and spacing)can be changed dynamically.

Free mobility of several movers

The movers can all be moved independently of one another. They can take up absolute positions along theentire travel distance. In addition, they can be moved relatively to each other and always avoid a collisionwith their neighbor.



6.2.2 Use of the basic functions

Interruption-free production flow

From the combination of the basic functions, product flows can be kept constantly in motion with the XTS.Since the movers in the XTS operate independently of each other, it is possible to stop and processindividual objects without having to interrupt the entire process; viewed from the outside the production flowis maintained.

Pushing products, adjusting the product gap and product velocity

The movers of the XTS can always run with the flow of product. No return travel or return stroke against theproduct flow is required. The transported material can be accumulated and grouped during the movement viathe dynamic buffering.

Clamp and move product

Through the combination of the synchronous movement of a group and the application of a near constantforce, a product can be clamped and moved in a clamped condition. Movement is controlled at all times andat all places on the transport path.

6.2.3 System length and curve functionDue to the mechatronic concept, XTS combines functions and characteristics that are required for thedynamic transport of goods of all kinds. Apart from the basic functions of the movers, the complex functionsof the XTS enable the gentle control of an endless product flow.

System length

There are no restrictions on the total length of the path, so that 10 m and much more are technicallypossible. The system consists of individual modules, which when combined with one another create bothsmall, compact solutions and meter-long transport sections. Straight sections are made up of 250 mmmodules, which can be infinitely extended through curved sections. Motor cables must be provided atmaximum intervals of 3 meters. The electrical connection between the modules is automatically made whenassembling. The guide rail system offers individual lengths up to 2.5 m.

Curve function

The entire travel path becomes the utilizable path, since the outward and return path and also the curvesegments are available for the transport and processing of materials. Maximum possible utilization of thetransport movements results in very compact application solutions that enable completely new machineconcepts.

Movers

There are no system limits for the number of movers. The system can therefore be optimized to suit therespective application. In practice the number is limited only by the available computing power of the PC.



6.3 Overview

Note

Composition of the starter kitThis section exclusively deals with the XTS components of the starter kit.

Basic components• Stand and holder for all mechanical parts• Industrial PC with all necessary interfaces and sufficient system performance• TwinCAT NC PTP and XTS function package• 24 V DC and 48 V DC power supply units• CU2508 Real-time Ethernet port multiplier

XTS starter kit small AT2000-0500, 500 mm, straight length

Pos. Number Product description Item number1 1 XTS straight module with connecting cable and EtherCAT

interfaceAT2001-0250

2 3 XTS straight module AT2000-02503 2 XTS curved module 180° (clothoid) AT2050-05004 5 Movers including rollers, magnetic plates and encoder flag AT9011-0050-05505 1 Software license TwinCAT TC3 XTS Extension TF5850-00806 1 TwinCAT 3 PLC/ NC PTP 10 TC1250-00807 1 TwinCAT 3 Scope View Professional* TC1300-00808 1 TwinCAT 3 Scope Server* TF3300-00809 1 TwinCAT 3 CAM Design Tool* TE151010 1 TwinCAT 3 NC Camming* TF5050-008011 2 Guide rail, 180° (clothoid) AT9050-050012 1 Guide rail straight with lock AT9100-050013 1 Guide rail straight without lock AT9000-0500

XTS starter kit medium AT2000-1000, 1000 mm, straight length






XTS starter kit large AT2000-1500, 1500 mm, straight length




*Subject to modification



6.4 Overview of the componentsMover 6 rollers Straight motor module

Position number Description1 Mover body2 Rollers3 Rubber bumper4 Magnet plates5 Encoder flag for position measurement6 Track mounting surface7 Encoder flag detection surface8 Motor coils9 Dowel pin hole for alignment10 Module to module connection card. Transmits control power (24 V) DC bus (50 V)

power and EtherCAT between modules.11 Machine bed mounting surface

Note

Alignment Dowel PinsExact locations and dimensions of the dowel pins are given in the 3D drawings (.stp files) ofthe motor modules. For further information please contact the Beckhoff applications depart-ment.



Curved motor module 180° (clothoid) Guide rails with and without lock cover

Position number Description12 Slot for Module to Module connection card (10)13 Motor Coils14 Slot for Module to Module connection card (10)15 Track Mounting Surface16 Encoder Flag detection surface17 Straight track without gate18 Gate which can be removed to allow movers to be added/removed from the track.19 Motor Module mounting surface


Installation

7 Installation

7.1 Mechanical installation

DANGER

Acute risk of injury or death by electric shock!Before assembly or disassembly of the XTS, make sure all electrical components are in ade-energized idle state! Failure to observe this instruction may result in serious bodily injuryor death!

Danger from magnetic fields!In particular, the magnetic field poses a danger to:

• Persons with cardiac pacemakers (the magnetic field may cause the pacemaker toswitch to test mode and thus cause a cardiac arrest!)

• Persons with magnetically conductive implants• Magnetic data storage devices• Chip cards with magnetic strips, and• Electronic devices• Also keep in mind that the magnetic fields can influence implanted defibrillators and

make external defibrillators inoperable.• Ensure a safety distance of 500 mm to all magnetic parts. Also, make sure that there is

no direct contact with magnetic components near parts that are susceptible to interfer-ence. The national regulations and guidelines applicable in other countries must be followed!Also note the requirements of BGV B 11 in connection with magnetic fields (BGV B 11Section 14).

Danger from magnetic attraction forces!The Beckhoff XTS is equipped with permanent magnets at the guide rails and movers. Dur-ing the installation and commissioning of components, magnetic attraction forces may re-sult in bruising or injuries of body parts. Therefore, please observe the following safety in-formation:

• Move the magnetic components together slowly. Never leave magnetic components un-secured next to each other. Wear protective gloves.

• Avoid shocks or jerky contact between magnets. This could lead to splintering and eyeinjuries. Wear safety goggles.

• Make sure that your working environment is free from ferrous tools or materials. Thesecould be attracted by the magnetic field and cause injuries to body parts. Do not wearmagnetisable objects such as watches, necklaces, earrings, etc.

• Always work in pairs• Always wear personal protective equipment (PPE)!

Attention

Changes to system componentsMachining (milling, drilling, etc.) of individual components of the XTS and associated modi-fication of the overall configuration can lead to deformation of system components.Please note: Any unauthorized modifications of the XTS would void any warranty claimsagainst Beckhoff Automation GmbH & Co. KG.


Installation

7.2 Overview of the tightening torques

Screw sizes and tightening torques

Motor modules

Straight motor module Curve motor module 180° (Clothoide)

Position number Description1 Screw: M5 x 20 DIN EN ISO 4762-A2 tightening torque 6Nm2 Screw: M6 x 12 ISO 7380-A2 Tightening Torque 8Nm3 Screw: M5x30 DIN EN ISO 4762-A2 Tightening Torque 6Nm

Note

Screw Tightening TorquePlease note the tightening torque values given are those recommended by Beckhoff Auto-mation GmbH & Co. KG. Use of other tightening torques can result in damage to the com-ponents.


Installation

Guide rail with mover 6 rollers

Guide rail with lock Mover 6 rollers

Position number Description4 Screw: M4 x 10 DIN EN ISO 4762-A2 Tightening Torque 3Nm5 Screw: M3 x 30 DIN EN ISO 4762-A2 Nut: M3 DIN 985 Tightening Torque 2Nm6 Screw M4 x 40 DIN EN ISO 4762-A2 Tightening Torque 4Nm.7 Screw: M3 x 6 DIN EN ISO 4026 Tightening Torque 0.5Nm8 M6 (see full description below)9 Screw: M3 x 12 DIN EN ISO 4762-A2 , Nut: M3 Tightening Torque 1.5Nm10 Screw: M3 x 6 DIN EN ISO 4762-A2 Tightening Torque 1.5Nm11 Screw M3 x 4 ISO 7380-A2 Tightening Torque 0.8Nm

Note

Maximum Screw Depth for the threaded through holeThe M6 threaded through holes (Pos 8) are located directly behind the upper rollers of themover. When mounting equipment using these M6 threaded holes a screw depth of 6.5mmmust not be exceeded. Exceeding this depth will drive the screw into the roller damaging it.


Installation

7.3 Mounting the movers on the guide railInstallation instructions

1.) First release both socket head screws at the motor modulelock with an Allen key (size 3) by turning them clockwise.

2.) Remove the lock cover by lifting it. Avoid contaminating ordamaging the released screws or the lock cover. Work in aclean and largely dust-free environment. Attention: Please note that the edges that are nowaccessible are very sharp and not chamfered. Risk of cuts!

3.) The three alignment pins on the lock module can beremoved and put to one side if necessary. Next, place the redfeed aid on the guide rail. Fasten it with the two socket headscrews (size 3) and an Allen key.

4.) Now place the mover on the guide rail. Hold the moverstraight over the motor module and insert it slowly onto theguide rail, without forcing it. If the permanent magnets of themovers and the motor modules have a magnetic field, bothcomponents will automatically attract each other.Attention: Risk of injury by crushing


Installation

5.) The mover is now mounted on the guide rail. Slowly pushthe mover out of the work area by hand.Attention: Please take care when rerailing the mover toavoid damaging the plastic rollers on the sharp edges.

6.) Remove the red feed aid, once all movers were replacedor rerailed. To this end release the two socket head screws(size 3) with an Allen key and lift off the feed aid.

7.) Now place the lock cover onto the alignment pins fromabove. Check the exact position and ensure that the lockcover sits tightly on the alignment pins.Attention: If the lock cover does not sit properly on thealignment pins, the guide rails and movers may becomedamaged!

8.) Finally, fasten the lock cover with the two socket headscrews and an Allen key (size 3). The screw-in direction isanti-clockwise.


Installation

7.4 The positioning systemBefore the movers are set in motion at the new XTS, the offset levels of the encoder sensors have to becalibrated. In ready-made starter kits the system sensors are already calibrated, and the sensor values arestored in a file. New systems or systems, in which motor modules were replaced or regrouped, have to berecalibrated. The calibration is straightforward and can be performed without damage to the system.

7.4.1 Zero point of the encoder systemThe zero point of the encoder system is at themodule edge (at the side of the cable joint) of the firstfeed module.The arrow in the image (item 1) figure shows thepositive count direction of the system.


Installation

7.4.2 Teaching the encoder systemBefore January 2014 it was still necessary to carry out a measurement at standstill (to determine the zerooffset) and a measurement in operation (to determine peak values). With the new CTcolXstDrv, only still themeasurement at standstill is required. Measurements should generally be carried out when the motormodules are assembled. XTS starter kits come with a ready-made calibration file, which can be found under\TwinCAT3.1\Boot folder.

1.

Once the configuration and the TwinCAT system have been activated, the Run mode can be started.The TwinCAT toolbar should now be green. The standstill measurement can now commence. Theparameters to be adjusted as part of the calibration can be found in the CTcloXTSDriver underTcCom Objects.

2.

The idea behind the standstill measurement is to capture all values without interference. To this end,in a first step all movers are moved to motor modules 1, 2 and 3, in order to exclude them from theteaching process. Only the remaining motor modules are set to zero in this step.


Installation

3.

In this example image, up to 10 motor modules can be selected. Modules 1, 2 and 3 are not part of theteaching procedure, since there are still movers on these motor modules. The other motor modulesare part of the teaching process. The zero point is now set for the motor modules.

4.

Use the command “Online Write” to start the teaching process. The lower output window with thesetting TwinCAT opens and displays the teaching history.

5.

This window shows that the motor modules 1, 2 and 3 were excluded from the teaching, and that theprocess was started.


Installation

6.

The teaching process can now be stopped by repeating the command “Online Write”.7.

The process is now stopped. This display window also shows that the technical data of modules 1, 2and 3 are invalid, because they were excluded from the teaching process.

8.

Now, all movers are manually pushed to motor modules 7, 8 and 9. The previously excluded motormodules 1, 2 and 3 can now take part in the teaching process. Since the movers are now on modules7, 8 and 9, these modules are now also excluded from teaching.


Installation

9.

The teaching process is identical to the already completed process for motor modules 1, 2 and 3. Themodules that are blocked/excluded from the teaching process are 7, 8 and 9.

10.

Repeat the command “Online Write” to start a new teaching process.11.

The output window with the setting TwinCAT now shows the values again, which were set in theprevious steps. 7, 8 and 9 are now excluded from the teaching process.


Installation

12.

Repeat the command “Online Write” to end the teaching process.13.

The final output window with the setting TwinCAT now indicates that the teaching process wasstopped and that all movers were found and can be started.

14. When the XTS is started for the first time, the system returns the error “Initial Axis Fault”. This is a steperror, which occurs only once. Restart the system to rectify the error. No further errors should occur.


Installation

15.

Now that all motor modules have completed the teaching process, you can use this operation screento move the movers on the XTS. Please note that all three fields should be ticked under “Enabling”.The value in the field “Override” should be set to a value greater than zero. You can now use thefunction keys F1 – F9 to move the movers on the system.Important: Collision avoidance has not yet been set. Collisions between movers can thereforenot be ruled out! Activate collision avoidance before commissioning and moving the movers.This is described in the next section.

WARNING

Risk of injury from moving movers!When the XTS is started up, the movers start moving on the guide rails. There is a risk ofinjury to body parts. Keep an appropriate safety distance, and stay clear of the operatingspace.


Installation

7.4.3 Application simulation1.

The XTS system also enables simulation of the mover movements. It is therefore not imperative toinvolve real movers on the XTS system. The simulation process is started in the Solution Explorer viaSoftDriveEncoder_Obj2. The tab is called Parameter (Init), where the PositionsFeedbackMode canbe set to simulation.

2.

Once this is done, all the movers have to be declared with a starting position for the simulation. Tosimulate a precise practical application, we recommend setting the distance between movers to 100mm. This parameter must be set for each simulated mover. The value for the starting positionindicates at which position the movers start in the simulation.

3.

To ensure the simulation runs smoothly, the trees Device 1 (EtherCAT) and Object1 (CTcIoXtsDrv)should be expanded in the Solution Explorer.

4. Restart the system, once all parameters have been set. The simulation can then be started.


Installation

7.5 Collision avoidance

7.5.1 Operating principle of collision avoidanceIn collision avoidance mode, the parameters “InTarget”, “InPosition” and “HasJob” are disabled, even if theywere configured. Collision avoidance is intended to assign all movers concrete travel paths, velocities andgaps. These settings prevent collisions of the movers during motion.

1a.

All movers are positioned at the zero point (feed-in motor module). Various settings are nowimplemented via the PLC blocks of the movers, which prevent collisions between the movers.

1b.

This window shows the PLC block for mover no. 9. We now instruct this mover to move to position2000 with a velocity of 1000. The gap of mover in traversing direction is set to 100.


Installation

1c.

The diagram now indicates that the mover is active and has assumed the specified velocity over thetravel path. At target position (2000) the velocity has reduced, and the activity of the mover hasceased.

1d.

The mover no. 9 has now arrived at the previously set position.2a.

A further mover is now parameterized. Mover 8 is also instructed to move to position 2000, with avelocity of 1000. The distance of 100 remains the same. Since mover 9 is already at this position, atypical collision scenario would arise. However, both movers are declared with a gap of 100. Thismeans that mover 8 moves to position 1800 and keeps a distance of 100 to mover 9.


Installation

2b.

Since mover 8 has not yet reached its final position 2000, but remains at 1800, the mover remainsactive. The diagram shows that the busy and active straight section remains active when theposition 1800 is reached.

2c.

The diagram also illustrates the positioning of the two movers on the XTS system. Mover 8 stopsbehind mover 9.

3a.

We now instruct mover 9 to move to position 2500. The velocity and the gap remain the same.


Installation

3b.

Changing the commands for mover 9 also changes the diagram. It shows that mover 9 is againactive and has assumed a velocity, which decreases to zero at position 2500. Mover 8 has alsoassumed a velocity, which falls to zero at position 2000. The active and busy straight sections alsofinish at this position.

4.

Mover 9 has now moved to position 2500 and mover 8 to position 2000 without colliding. Once thepositions have been reached, the activity of the movers is completed until new values or cycles areentered.


Technical data

8 Technical data

8.1 AT9011-0050-0550Technical data Symbol [Unit] AT9011-0050-0550Length mm 50.00Width mm 62.00Height mm 78.50Weight g 410.00Center of gravity mm from above appr. 42.5Roll 6 x D19 cylindrical

8.2 Technical drawing AT9011-0050-0550


Support and Service

9 Support and ServiceBeckhoff and their partners around the world offer comprehensive support and service, making available fastand competent assistance with all questions related to Beckhoff products and system solutions.

Beckhoff's branch offices and representatives

Please contact your Beckhoff branch office or representative for local support and service on Beckhoffproducts!

The addresses of Beckhoff's branch offices and representatives round the world can be found on her internetpages:http://www.beckhoff.com

You will also find further documentation for Beckhoff components there.

Beckhoff Headquarters

Beckhoff Automation GmbH & Co. KG

Huelshorstweg 2033415 VerlGermany

Phone: +49(0)5246/963-0Fax: +49(0)5246/963-198e-mail: [email protected]

Beckhoff Support

Support offers you comprehensive technical assistance, helping you not only with the application ofindividual Beckhoff products, but also with other, wide-ranging services:

• support• design, programming and commissioning of complex automation systems• and extensive training program for Beckhoff system components

Hotline: +49(0)5246/963-157Fax: +49(0)5246/963-9157e-mail: [email protected]

Beckhoff Service

The Beckhoff Service Center supports you in all matters of after-sales service:

• on-site service• repair service• spare parts service• hotline service

Hotline: +49(0)5246/963-460Fax: +49(0)5246/963-479e-mail: [email protected]


http://www.beckhoff.de/english/support/default.htm

http://www.beckhoff.com

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Documentation eXtended Transport System Start-Up · installation of the XTS in a machine or system,...

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