Integrating a SERVOLASER Xpert into a - LAP-News · PDF fileIntegrating a SERVOLASER Xpert into a ... an RSLogix 5000 project with the 1756-L63 ControlLogix CPU and a 1756 ... paper

SERVOLASER Xpert

Positioning system

Integrating a SERVOLASER Xpert into a ControlLogix control system

Prof. Dr.-Ing. Philipp Odensass

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Please read carefully prior to commissioning! Keep in a safe place for future reference.

Translation of the original

Whitepaper CLX Program for the SERVOLASER Xpert Positioning system

2 LAP GmbH, MAN-1343 Rev 2 en-GB, 2016-06

All brand names and product names are trademarks or registered trademarks of the respective title holder.

© LAP GmbH Laser Applikationen Lüneburg, 2015

The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without express authori-sation are prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

This document is intended to be used by the owner of the LAP prod-uct, his/her users and contractual partners of LAP. It must not be handed to other persons or made available to third parties.

This document is subject to a document content service and subject to change without prior notice.

LAP can assume no liability for the correctness, completeness or up-to-dateness of any laws, regulations or guidelines (e.g. DIN, VDE, ...) referenced directly or indirectly or quotes taken from such sources in this publication. We recommend that the complete regulation or guide-line in the latest valid version be consulted for work to be carried out, where applicable.

Subject to technical changes.

Positioning system SERVOLASER Xpert

LAP GmbH, MAN-1343 Rev 2 en-GB, 2016-06 3

Table of contents 1 Introduction ................................................................................................................................................. 4

1.1 System configuration and purpose of the white paper .................................................................... 4 2 Configuring the EtherNet/IP connection ................................................................................................... 7

2.1 Assigning IP addresses ................................................................................................................... 7 2.2 Wiring the entire EtherNet/IP network ............................................................................................. 8 2.3 Assigning an IP address to the Xpert using BOOTP ....................................................................... 8

3 Downloading the Xpert EDS file .............................................................................................................. 10 4 Creating an RSLogix 5000 project with the Xpert .................................................................................. 11 5 Controlling and monitoring the Xpert using ControlLogix ................................................................... 15 6 ControlLogix program for controlling/monitoring the Xpert................................................................. 17

6.1 I/O Configuration and structure of the CLX program ..................................................................... 17 6.2 User-defined data types (UDT) ..................................................................................................... 18 6.3 Controller tags ............................................................................................................................... 20 6.4 Detailed structure of the R00_Main routine ................................................................................... 21 6.5 Testing the R00_Main routine ....................................................................................................... 24

7 Summary ................................................................................................................................................... 30 8 References ................................................................................................................................................ 31



1 Introduction

1.1 System configuration and purpose of the white paper The purpose of this document is to present a sample application for com-missioning and programming a SERVOLASER Xpert positioning system, hereinafter referred to as "Xpert". References are made to the correspond-ing "MAN-1282-rev-4" Installation and Operation Manual [1].

The hardware of the test system for commissioning consists of the follow-ing:

• SERVOLASER Xpert SLX-S-M-2-1-2-L1-D4-IE-1-1 Firmware Rev. 309

• ControlLogix 1756-L63 CPU Firmware Rev. 20.11

• 1756-EN2TR/B EtherNet/IP card Firmware Rev. 5.028

• Dell PC with 16 GB and Windows 7 Professional Service Pack 1

The following programming software is used:

• RSLogix 5000 Rev. V20.00.00 (CPR 9 SR 5) • RSLinx Classic Lite Rev. V20.00.00 (CPR 9 SR 5) • BOOTP/DHCP Server 2.3

The components used and the system configuration are shown in Fig. 1.

Fig. 1: System configuration and EtherNet/IP cabling

ControlLogix

Ethernet

Studio 5000

SERVOLASER Xpert



Fig. 2: SERVOLASER Xpert

The Xpert used has its own controller with an EtherNet/IP port and three lasers (Fig. 2):

• One fixed red laser #3 permanently mounted in the centre. Position "0" is the middle position after the laser is switched on. The positions on the side with the EtherNet/IP port are counted as positive and the positions on the other side of red laser #3 are accordingly counted as negative.1

• Two green lasers #1 and #2 movable via stepper motors and toothed belts, with an incremental measuring system. After being switched on or upon a command from the ControlLogix, lasers #1 and #2 move to the left and right limit switches at the ends of the movement rail for referencing. Laser #1 is on the side with the EtherNet/IP port, where the positions are counted as positive. Laser #2 is on the other side, where the positions are counted as negative.

This white paper is structured according to the procedure during commis-sioning. In principle, a different sequence of steps would be possible in some places, but a modified order of steps during EtherNet/IP configura-tion and the assignment of IP addresses has frequently led to problems. Therefore, it is recommended that you adhere to the sequence of steps specified here.

After the system has been wired as shown in Fig. 1, the first step is to as-sign an IP address for the Xpert and then to check the EtherNet/IP con-nection.

The second step is to browse to the Xpert web server and download the electronic data sheet (EDS file) of the Xpert from there to the programming PC.

1 Zero point offset, scaling, etc. are described in [1].



The third step is then to create an RSLogix 5000 project with the 1756-L63 ControlLogix CPU and a 1756-EN2TR EtherNet/IP module. In order to in-tegrate the Xpert, you must register the previously downloaded EDS file in the RSLogix 5000 software using the EDS Hardware Installation Tool. When registration is complete the Xpert can be integrated as a completely normal EtherNet/IP subscriber in the usual way [4, 5]. When configuration in the RSLogix 5000 software is complete, two controller tags are automat-ically created in the ControlLogix. These tags represent an output tag comprising sixty-four 32-bit words with the configuration data and an input tag comprising sixty-four 32-bit words with the actual values and status da-ta.

By properly writing to the output data word, you can already move the la-ser axes, for example, or dim the lasers without having to write a control program. You can also read the actual values, for example, of the laser positions, laser dim values, laser status data, Xpert controller status data and error bits directly from the input tag. When the configuration data are transferred, you should adhere to a certain data transfer sequence. This means that you should not write the entire output data tag with a single COPY command, but first write the configuration data and then update the configuration (Config Update = CPU = 222 [dec]) [1, page 31].2

The last chapter of this white paper presents a sample program for con-trolling movements. It addresses the special characteristics of Control-Logix programming based on the processors working in parallel in the ControlLogix and the associated measures to ensure consistent input and output data, the use of user-defined data types (UDTs) and other special properties.

All these steps from configuring the EtherNet/IP to writing the finished pro-gram are described in detail in the following chapters.

2 An attempt to send the entire output data tag with a single COPY command may cause the Xpert controller to crash.



2 Configuring the EtherNet/IP connection

2.1 Assigning IP addresses To assign IP addresses, in this case the IP address of the Xpert, first you must appropriately set the IP address of the programming PC. This is done as shown in Fig. 3 :

Control Panel > Network and Internet > Network and Shar-ing Center > Change adapter settings > Local Area Connec-tion > Properties – Internet Protocol Version 4 (TCP/IPv4) > Properties > Use the following IP address: 192.168.1.1 > OK

Fig. 3: LAN connection and Internet protocol properties on the PC



2.2 Wiring the entire EtherNet/IP network The next step is to wire the entire EtherNet/IP network, which must be done before an IP address can be assigned to the Xpert MAC address. This is necessary because the Xpert was not detected in the network when we directly assigned an IP address using the programming PC and then rewired the network via the ControlLogix EtherNet/IP card.

2.3 Assigning an IP address to the Xpert using BOOTP Rockwell Automation provides the BOOTP program with the RSLogix 5000/ Studio 5000 programming software. When launched, BOOTP scans the MAC addresses of all connected devices (Fig. 4). The found subscrib-ers and their MAC addresses are displayed in the Request History window. Now you must highlight the Xpert MAC address and click Add to Relation List.

Fig. 4: Searching for the Xpert MAC address using BOOTP

In the next step, BOOTP prompts you to enter the IP address and the subnet mask. If entry is successful, in the Relation List window BOOTP first displays Fig. 5 and then typically after a few seconds Fig. 6 with MAC address, DHCP and IP address. If everything was successful, the message Status [Enable DHCP] Command successful ap-pears at the lower left.

Following this message, a ping can be sent from the DOS window to the Xpert to check accessibility (Fig. 7).



Fig. 5: BOOTP after assignment of an IP address to the Xpert MAC address

Fig. 6: BOOTP after Enable DHCP

Fig. 7: Sending a ping to the Xpert to check the connection



3 Downloading the Xpert EDS file To integrate the Xpert EDS file into the RSLogix 5000 programming soft-ware using the EDS Hardware Installation Tool, you must first download the EDS file from the Xpert web server. To do so, use any browser to nav-igate to the Xpert web server (Fig. 8 and Fig. 9) and select Save target as.

Fig. 8: Xpert web server

Fig. 9: Downloading the Xpert EDS file



4 Creating an RSLogix 5000 project with the Xpert After you have downloaded the Xpert EDS file from the web server, you can create an RSLogix 5000 project with CPU, EtherNet/IP card and the Xpert. After you have created the project in the usual manner with a 1756-L63 CPU in slot 0 and a 1756-EN2TR EtherNet/IP card in slot 1 [4, 5], you must install the Xpert EDS file in RSLogix 5000 in order to integrate the Xpert. To do so, select TOOLS > EDS Hardware Installation Tool (Fig. 10 and Fig. 11).

Fig. 10: EDS Hardware Installation Tool






Rockwell Automation‘s EDS Wizard steers the further steps for in-stalling the EDS file (Fig. 12 and Fig. 13). After you have successfully reg-istered the EDS file in RSLogix 5000, you must create the Xpert as a sub-scriber in the EtherNet.



Fig. 14: Creating the Xpert: I/O Configuration > New Module

Fig. 15: Creating the Xpert: I/O Configuration > ServoXpert_001 > Module Proper-ties

Highlight the 1756-EN2TR network card, right-click and select New Mod-ule and Create – as shown in Fig. 14 to Fig. 16 – to create the Xpert. It is not mandatory, but sensible that you create the Xpert input and output modules as DINT tags, since this is the standard data format of Control-Logix.



Fig. 16: Creating the Xpert: I/O Configuration > ServoXpert_001 > Module Proper-ties > Module Definition - DINT

After you have created the Xpert in the I/O Configuration, the input and output words of the Xpert are automatically created in the RSLogix5000 software controller tags (Fig. 18). The definition, configura-tion and use of these input and output words for controlling and monitoring the Xpert are explained in the following chapters. This ends the hardware configuration. Using RSLinx Classic under RSWho, the ControlLogix chas-sis with the 1756-L63 CPU and the 1756-EN2TR/B EtherNet card with the IP address 192.168.1.20 now recognises the Xpert with IP address 192.168.1.21 (Fig. 17).

Fig. 17: Checking for correct creation and communication of the Xpert in RSLinx



5 Controlling and monitoring the Xpert using ControlLogix Input and output tags are used for the communication for controlling and monitoring the Xpert (Tab. 1 and Tab. 2). Data words #1 to #9 are default data words which are always evaluated by Xpert. However, data words #13, #14 and #15 represent configuration data words which are read by Xpert only if decimal 222 is written in data word #10 bits 23 ... 16.

Xpert input tag in ControlLogix [1]3

Dw

ord

# Dword

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

0 Connection Faulted Bit #0

1 Target Position L1

2 Target Position L2

3 Reserved

4 Speed L1

5 Speed L2

6 Reserved

7 Laser Dim L1

8 Laser Dim L2

9 Laser Dim L3

10 System flags

11 Reserved

12 Reserved

13 Laser Projection Distance

14 Zero Point Offset

15 Resolutions

16 … 64

Reserved

Tab. 1: Structure of the input data packet (Dword stands for data word)

The new configuration data words #13, #14 and #15 are applied edge-triggered when the CUP value is changed from some other value to deci-mal 222.

3 In [1] data word 0 is the Target Position L1; however, data word 0 in ControlLogix is actually the Connection Faulted Bit. For this reason, the data word numbers of this Table 1 differ from the corresponding table in [1].



Xpert output tag in ControlLogix [1]

Dw

ord

# Dword

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

0 Current Position L1



3 Reserved Status L1



6 Reserved Status System

7 Reserved

8 Reserved

9 Reserved

10 Reserved

11 Reserved

12 Laser Projection Distance

13 Zero Point Offset

14 Resolutions

15 Laser Focus Distance

16 Max Move Range

17 Firmware Revision SVN

18 … 63

Reserved

Tab. 2: Structure of the output data packet (Dword stands for data word)

The structure of the input and output data packets is the same for all SERVOLASER Xpert versions. Depending on the version, certain data words do not contain a return value.



6 ControlLogix program for controlling/monitoring the Xpert

6.1 I/O Configuration and structure of the CLX program After you have created the Xpert under I/O Configuration in the Controller Organizer, the LAP_Xpert:I and LAP_Xpert:O con-troller tags are automatically created (Fig. 18). It is now already possible – without using a CLX control program – to manually control the Xpert simp-ly by writing the LAP_Xpert:O output data and reading the returned LAP_Xpert:I input data.

Fig. 18: Controller Tags LAP_Xpert:I and LAP_Xpert:O after creating the ServoX-pert_001 in the I/O Configuration

A sample CLX program is shown in the overview on pages 22 and 23 in Fig. 24 and Fig. 25. In principle, a routine with just a few rungs is sufficient. In our example, it is the R00_Main routine in the LAP_Xpert program in the continuous task MainTask; see Controller Organizer in Fig. 18 on page 17.



The flow of communication with the Xpert is reflected in the basic structure of the R00_Main routine. After internal variables are initialised, first the configuration data are transferred, that is, data words #13, #14 and #15, according to Tab. 1 on page 15 and data words #12, #13 and #14 accord-ing to [1] on page 29ff. Then the Xpert gives the command to transfer the configuration data (data word #10 bit 23 ... = decimal 222), and after that the standard data (data words #1 to #9) are transferred. The R00_Main routine can be divided into the following sections:

• Initialisation of internal CLX routine flags in rung #0, • Transfer of the configuration data in rungs #1 to #3, and • Transfer of the standard data in rung #44 and reading of the feedback

data in rungs #5 and #6.

6.2 User-defined data types (UDT) The following data structures have been defined for controlling the Xpert and for evaluating the data returned from the Xpert:

• UDT_Xpert_CUP for controlling the data transfer by the Xpert

• UDT_Xpert_I_Feedback for the data returned from the Xpert

• UDT_Xpert_O_Config for configuration data sent to the Xpert

• UDT_Xpert_O_Standard for standard data sent to the Xpert

Fig. 19: Data type UDT_Xpert_CUP for updating the configuration data



Fig. 20: Data type UDT_Xpert_I_Feedback for data returned from the Xpert

Fig. 21: Data type UDT_Xpert_O_Config for configuration data to the Xpert



Fig. 22: Data type UDT_Xpert_O_Standard for standard data to the Xpert

6.3 Controller tags The following controller tags have been created using the user-defined da-ta types described above (Fig. 23). It is irrelevant whether these tags have been defined as global variables – as in this example – or as local pro-gram variables in the respective application program. Both definition methods have advantages and disadvantages [2].

Fig. 23: Controller tags of the LAP_17092015.ACD project



6.4 Detailed structure of the R00_Main routine In the first rung #0 of the R00_Main routine, the two variables Xpert_CUP.Request and Xpert_CUP.Lock are reset during the first scan. Afterwards, you can set the Xpert_CPU.Request bit in rung #1 or toggle it to "1" and thus initiate writing of the configuration data to the Xpert. In the process, by setting the Xpert_CUP.Lock bit, the writing of the standard data and the reading of data returned from the Xpert are simultaneously blocked. The data are transferred to the Xpert byte by byte. By using the Immediate Output (IOT) command [3 page 210ff], you immediately send the configuration data without delay to the Xpert. To give the Xpert the time to read the configuration data, the Xpert_CUP.Timer[0] delay timer is now started. When this Xpert_CUP.Timer[0] timer expires, CUP data word 9 (bits 23 … 16) with the value decimal 222 is output to the Xpert in the next rung #3. This process is also delayed with Xpert_CUP.Timer[1]. In the sample pro-gram, the selected delay times of 3 s are very generous so that you can observe the process. In practice, around 100 ms should be sufficient.



Fig. 24: Rungs for transferring the configuration data and for reading the data re-turned from the Xpert as well as for writing the standard data to the Xpert



Fig. 25: Rungs for transferring the configuration data and for reading the data re-turned by the Xpert as well as for writing the standard data to the Xpert

After the Xpert has been configured by transferring the configuration data, the Xpert data such as the current laser positions can be read and the new standard data such as the target laser positions can be written to the Xpert in normal operation. Standard MOVE or COPY commands should not be used for these operations if controllers of the 1756-L60 or the new 1756-L70 family are being used.

Fig. 26: 1756-L6x ControlLogix controllers dual-ported RAM [2 page 13]



These controllers have two CPUs which communicate with each other via dual-ported RAM (Fig. 26) [2 page 13]. You should access the input and output data with the Synchronous Copy File CPS command, since it locks data access so that the transferred data are consistent [3 page 365ff].

6.5 Testing the R00_Main routine To test the R00_Main routine, we first set the preset values of Timer[0] and Timer[1] to 3000, that is, to 3 s, (Fig. 27) so that the transfer of the configuration data could be tracked on the programming device. Then we checked the transfer and feedback of the standard data and configuration data: Target Position L1 and L1, Speed L1 and L2, Laser Dim L1, L2 and L3 and the REOR Resolution of Range. This was done by reading the val-ues of the controller tags (Fig. 27). No discrepancies were found.

In particular, the length resolutions were tested and logged in centimetres, millimetres, tenths of millimetres, hundredths of millimetres, micrometers and inches as examples for the user. The corresponding screens are shown on the following pages in Fig. 27 to Fig. 31.



Fig. 27: Controller tags in micrometres [µm] Target Position L1/L2 = +100 mm/-100 mm



Fig. 28: Controller tags in 1/100 mm Target Position L1/L2 = +100 mm/-100 mm



Fig. 29: Controller tags in 1/10 mm Target Position L1/L2 = +100 mm/-100 mm



Fig. 30: Controller tags in mm Target Position L1/L2 = +100 mm/-100 mm



Fig. 31: Controller tags in inches Target Position L1/L2 = +10 inch/-10 inch



7 Summary This white paper provides a sample application for commissioning and programming a SERVOLASER Xpert positioning system in connection with a Rockwell Automation ControlLogix control system.

After the hardware and software used were listed in the first chapter, the EtherNet/IP connection to the PC, the wiring of the EtherNet/IP network and the assignment of IP addresses using BOOTP were described in the second chapter.

The third chapter described the download of the Xpert EDS file from the Xpert web server to the programming PC, and the fourth chapter ex-plained how after this EDS file is integrated into the RSLogix 5000 pro-gramming software, a project can be created with the Xpert, controlled by a 1756-L63 CPU. Then correct communication of the CPU, Xpert and pro-gramming PC is checked using RSLinx Classic.

After a brief presentation of the basic communication structure between the CPU and Xpert via input and output data words – refer to the Xpert Operation Manual [1] for a detailed description – the sixth chapter covered a ControlLogix program for controlling and monitoring the Xpert with the following subitems:

• Creating the Xpert in the I/O-Configuration, • Defining the user-defined data types (UDT) for the project, • Creating controller tags based on the defined UDTs, • Writing a routine for controlling and monitoring the Xpert.

The developed ControlLogix program, the defined UDTs and the created controller tags are documented according to the Rockwell Automation standard.

In the last chapter, the overall system was tested for correct functioning of communication and then for various target positions, speeds, laser intensi-ties and especially for various position resolutions, for example, in μm, mm or inch. These tests are documented by means of screenshots of the input and output variables during operation. Basically, the Xpert and Control-Logix have always worked together without problems and errors, provided that the points described in the operation manual [1] and in this white pa-per are observed.



8 References [1] SERVOLASER Xpert Installation and Operation Manual,

MAN-1282 Rev. 4, LAP GmbH, Lüneburg, 2015

[2] Logix5000 Controller Design Considerations

Rockwell Automation, Milwaukee, WI, USA, November 2012

[3] Logix5000 Controllers General Instructions Reference Manual

Rockwell Automation, Milwaukee, WI, USA, December 2014

[4] Logix5000 Controllers Common Procedures

Rockwell Automation, Milwaukee, WI, USA, October 2014

[5] Logix5000 Controllers I/O and Tag Data

Rockwell Automation, Milwaukee, WI, USA, October 2009

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Integrating a SERVOLASER Xpert into a - LAP-News · PDF fileIntegrating a SERVOLASER Xpert into a ... an RSLogix 5000 project with the 1756-L63 ControlLogix CPU and a 1756 ... paper