Newbie project description

[Guest rastring]

I am trying to design and build a material handling machine as described below. I know all of the rules of control needed to make it work properly, just don't know about the hardware needed to actually control and monitor the movements. I have bought the PC-Based motion control development and HMI software from GE Fanuc (Proficy Motion Developer and Proficy View). This is as far as I have gotten. The motion developer software will program GE Fanuc S2K controllers. My question is could anyone please guide me in the direction of how all of this software and hardware works together, and what type of motors (stepper, servo, or?), switches, power supply, ECT... I can only seem to find very specific details and how to's regarding programming and interface and control, but I think I still do not understand the big picture. My understanding includes: I will have a program that outputs the material cut lists into a spreadsheet or database. The PC based control software will be programmed to figure out the most efficient way to cut the material list out of the stock in the machine, and the series of motions needed. Then it will tell the S2K controllers where and how to move the motors. Is this possible? Practical? Any help is much appreciated. This machine will have three basic structural/mechanical parts; material rack table, carriage #1, and cut table/carriage #2: Carriage #1.) Description: A steel material carriage 50' long (x-axis) and +-6" wide (y-axis) guided on tracks in the ground 26' long (y-axis). Carriage #1 will have 26 chain driven rollers evenly spaced along the 50' carriage, attached to a drive motor. This drive motor will move material along the carriages 50' (x-axis). This carriage will have a material rack above it with 48' long stock positioned parallel with the x-axis. There will be up to 66 pieces of stock separated into 66 bays evenly spaced along the 26' y-axis. When positioned correctly under a piece of stock along the y-axis, this carriage (or chain driven rollers) will lift up about 3" (z-axis) to lift vertically the stock off of the material rack. The stock will then be resting on top of the chain driven rollers. The chain driven rollers will then drive the material along the 50' x-axis to transfer it onto the cut table/carriage #2. After material has been transferred to the cut table it will then drop back down (z-axis) and reposition under the next piece of stock to transfer. Motions of carriage #1: 1 motor driving a sprocket and chain that moves this entire carriage on rollers on the floor track along its 26' y-axis. This motion will need to have position feedback and control. 1 motor that will lift (z-axis vertical) the carriage or chain driven rollers (and piece of stock) up about 3", then back down. No positioning required, limit switch will stop motion. 1 motor that will drive the chain driven sprockets (moving the stock above) about the x-axis. Forward and reverse needed. This motion will be stopped by a proximity or limit switch when stock reaches its desired location on the cut table/carriage #2. No positioning required. Cut table/Carriage #2.) Description: A steel material carriage 50' long (x-axis) and +-6" wide (y-axis) guided on tracks in the ground 26' long (y-axis). Cut Table/Carriage #2 will have 26 chain driven rollers evenly spaced along the 50' carriage, attached to a drive motor. This drive motor will move material along the carriages 50' (x-axis) to stop at the adjustable material stops position. (There will be a limit switch on the stop so when material hits it will stop the rollers. Exactly like carriage #1 except: No z-axis motion of rollers. Chain driven stock rollers will be fixed at the uppermost height of the carriage #1 z-axis motion. No stock table above carriage. (This will be a cutting table and to facilitate material transfers and organization material in the stock table.) There will be a chain driven adjustable material stop able to stop at any point along the 50' length x-axis. There will be a cut saw at the head of the carriage (the end closest to the material rack table. This saw will have y-axis motion in order to cut stock. Motions of carriage #2: 1 motor driving a sprocket and chain that moves this entire carriage on rollers on the floor track along its 26' y-axis. This motion will need to have position feedback and control. 1 motor that will drive the chain driven sprockets (moving the stock above) about the x-axis. Forward and reverse needed. This motion will be stopped by a proximity or limit switch when stock reaches its desired location on the cut table/carriage #2. No positioning required. 1 motor moving the adjustable material stop along the 50' x-axis. This motion will need to have position feedback and control. 1 motor operating the cut saw z-axis (vertical) motion (travel approx. 24") Material Rack Table.) Description: Fixed and no moving parts, stock (48' long material) sits parallel to the x-axis in 66 bays evenly spaced across the 26' y-axis.

[Wordman]

S2k is a standalone motion controller. You can get it in different configurations: servo amplifier, servo controller/amplifier, and stepper controller/amplifier versions. need to know more about what hardware you DO HAVE now to know what else you will need. Who spec'ed all of this out? was it just done by guessing?

[Guest rastring]

Yes, up to this point it has been done by guessing. All I have now is an abundance of PC's running all types of windows, the GE Proficy view and runtime development software as well as the Proficy motion developer, and cash for whatever else I need. I also have this machine drawn in autocad with everything but the motors, controllers ect... I know it will work, just need to find out where to go with the types of motors, controllers, and a general idea of how to hook it up. I am not searching for anyone to do this work for me, just trying to get a feel of how all these electronic components interact. A general overview of this would be a godsend. IE: This PC will have your programming software and runtime programs on it and relay via ???(what kind of wire) to the ???(is there hardware needed here) before hooking into the ???(S2K controller or something cheaper). The controller has 120AC power coming to it and then it outputs to a ???(amplifier) via a ???(what kind of wire) to the ???(stepper motor, or AC motor) to move the carriage.

[GerryM]

Based on your questions, I recommend you call your distributor of GE automation equipment. They may have applications people that you can hire to help you out. If not, I would consider hiring someone with experience in motion control to give you some help.

[Wordman]

I'm more of a PLC-based control kind of guy, espeically for machines that require synchronization and path control. I like having a master feedback source, and usually projects demand future scalability. I don't have much experience with stand alone or PC based motion systems. I believe the S2ks will use profibus or devicenet to talk to each other. You will have to read the manuals, or talk to a App Engineer. If you bought this stuff from someone, they ought to help you out or at least get you started in the right direction for free. Not all off the shelf components suit all applications. You have to recognize the demands of the system.If it gets overwhelming, I recommend a call to a systems integrator who is knowledgable in motion control.

[gravitar]

"Yes, up to this point it has been done by guessing." Dude.. this doesn't sound like a good INTRODUCTORY motion job. If I'm reading you correct, you're pretty new to motion control. There's nothing wrong with that, everyone started somewhere! But you describe what sounds to me like a pretty BIG, possibly complex application. I'm not a motion guy myself, but I've done some work with simple servo-ballscrew shuttles and stepper-based pick-n-place units. There's a lot more than first meets the eye with something like you're talking about. "I am not searching for anyone to do this work for me, just trying to get a feel of how all these electronic components interact. A general overview of this would be a godsend" If I were you, I WOULD be searching for someone to do the work for you, and watch very closely how they do it! Well, maybe that's too harsh of a statement. You should find out from GE who is a competent integrator of their controls in your area, and work closely with them to complete this project. You will invariably look better in the eyes of your management if you do it this way, as opposed to possibly having purchased the wrong equipment (and not being able to return it), breaking stuff, not meeting your deadlines, and worst of all, possibly causing harm to man or machine. I'm not trying to come off as a know-it-all, far from it. I have next to nothing in the way of motion control experience.. other than knowing that you don't just "wing it" if you hope to succeed!

[Guest <>]

phew - if you manage to design & code this yourself on your first motion project then I take my hat of to you