Hello! I am working on a project involving the packaging of candy bars using a collator mechanism to gather the bars before placing them into boxes. The collator mechanism is equipped with a Mitsubishi MELSEC iQ-R R04CPU and a Simple Motion Module RD77GF. The racetrack features two belt-driven mechanisms, with each belt serving as an independent axis controlled by 1 indexer per belt. You can see a similar setup in the video at 0:18s. I have experience with motion control on a box conveyor with a similar structure - 2 belts independently driven in a linear CAM motion controlled by a virtual master. However, I believe a different motion control approach may be needed for the racetrack. I am looking for guidance on the general application of master-slave axis relationships, main shaft clutch utilization, CAM modes, and overall procedures for making the racetrack function effectively. Any advice, even if not specific to the Mitsubishi equipment mentioned, would be greatly appreciated. Thank you for your assistance in helping me understand and optimize the operation of the racetrack mechanism. Best Regards, Konstantin Kolev
Has anyone on this forum been involved in the creation of a similar application? It's hard to believe that no one here has experience with something like this.
It is currently late at night here, but I can still discuss the various components of your machine with you. The initial part may appear jerky due to its frequent short movements, as opposed to a continuous motion until it slows down for the pushing mechanism. It seems that a linear cam is not in use, as the stops are smooth when the boxes come to a halt, indicating the presence of ramp-down and ramp-up features. Achieving synchronization is key, and it is essential to have a timing diagram detailing the positioning of all elements throughout the cycle to prevent any collisions. The cam likely includes ramp-up and ramp-down phases. If there is indeed a cam involved, the first step would be to locate the virtual master or index, followed by identifying the cams that the index interacts with. It is probable that the cams include both ramp-up and ramp-down sections for optimal functionality.
Peter Nachtwey mentioned that it was late at night for him, but he still took the time to analyze the different parts of the machine. He noticed that the jerky movement of the first part was due to very short moves instead of one continuous motion until the pushing device needed to slow down. While he couldn't spot a linear cam, he observed smooth stops indicating ramp down and ramp up mechanisms. Nachtwey emphasized the importance of having a timing diagram to prevent collisions and ensure everything is synchronized. He suggested looking for a virtual master or index linked to cams for ramp up and ramp down phases. Nachtwey expressed surprise at not finding a standard packaging example in manuals from a renowned PLC manufacturer. He further explained the use of a linear CAM on the conveyor moving boxes, specifically on the conveyor behind the pusher device. The linear CAM advances the boxes to the pusher and holds them in place for candy bar insertion. The racetrack does not utilize a linear CAM. For a clearer understanding, Nachtwey provided a visual representation of the cell along with an explanation of the racetrack's temporal positioning. He raised a query on creating a CAM and connecting a virtual axis to real axes, sharing his attempt at developing a coordinate CAM (x, y). Although it functioned partially for one real axis and the virtual master, he sought advice on optimizing the setup. Regards, Konstantin Kolev
Hi Konstantin, It sounds like you're really deep into an interesting project! When considering master-slave axis relationships, it's often best to determine which axis will have the most impact on the overall operation and assign it as the master. This ensures smoother coordination and control. In terms of clutch utilization, the main shaft clutch can help to compensate for any variations in load and speed; the important thing is to fine-tune the settings to match the specific dynamics of your setup. For CAM modes, consider that the motions of the slave devices are directly related to the master axis position - this might require adaptations to your current approach. Essentially, optimizing your racetrack will likely involve carefully tuning based on the specific response characteristics of your two belts and the movements they require to work together. I hope this provides some useful points to consider!
Hi Konstantin! It sounds like an exciting project you've got going on. Since you’re already familiar with linear CAM motions, consider exploring how to adjust the phase relationship between the two belts for optimal candy bar alignment and packing. Using a master-slave setup could really streamline your process by allowing one belt to pull the second into alignment at just the right moment. Don’t forget to experiment with the timing and clutch engagement on the main shaft to ensure smooth transitions, especially during acceleration and deceleration phases. It may also help to prototype your CAM profiles before full implementation to find the sweet spot for your application. Good luck, and I can't wait to hear how it turns out!
Hi Konstantin, it sounds like you have an interesting project on your hands! For a racetrack setup, you might want to consider implementing a synchronized motion strategy where one belt acts as a master while the other (slave) follows its movements closely, compensating for speed or positional variations. Utilizing a main shaft clutch could be beneficial in decoupling the belts when needed, which allows for flexibility during operations like maintenance or adjustments. I also recommend exploring CAM profiles tailored to your candy bar dimensions; these can help optimize spacing and timing when the bars are gathered for packing. Keep experimenting with different motion profiles, and don’t hesitate to leverage simulation tools to visualize how adjustments will impact your setup before implementation. Good luck with your project!
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Answer: - The project involves a collator mechanism equipped with a Mitsubishi MELSEC iQ-R R04CPU and a Simple Motion Module RD77GF. The racetrack features two belt-driven mechanisms, with each belt controlled by an indexer.
Answer: - The racetrack mechanism consists of two belt-driven mechanisms, each serving as an independent axis controlled by an indexer. This setup helps gather the candy bars before placing them into boxes.
Answer: - The project utilizes master-slave axis relationships, main shaft clutch utilization, and CAM modes to control the racetrack mechanism effectively. These features help optimize the operation of the collator mechanism.
Answer: - Advice on the general application of master-slave axis relationships, main shaft clutch utilization, CAM modes, and overall procedures for making the racetrack function effectively would be helpful. The goal is to optimize the operation of the racetrack mechanism for efficient candy bar packaging.
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