M600 Operator Guide

8/10/2019 M600 Operator Guide

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Motionbase

Maxcue 600 series operator's manualSerial numbers MB 00001429 onward : Document 00058604.doc


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Maxcue 600 series operator's manual

Copyright Motionbase (Holdings) Ltd 1999.All rights reserved

This document is copyrighted and all rights are reserved. This document may not, in whole or in part,be copied or reproduced in any form without the prior written consent of Motionbase (Holdings) Ltd.

Motionbase (Holdings) Ltd makes no representations or warranties with respect to the contents hereofand specifically disclaims any implied warranties of fitness for any particular purpose. The informationin this document is subject to change without notice. Motionbase (Holdings) Ltd assumes noresponsibility for any errors that may appear in this document.

Motionbase (Holdings) Ltd

52 Ashton Vale RoadBristolBS3 2HQEngland

Telephone: +44 117 907 7690Facsimile: +44 117 987 3112Technical Support [email protected]


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Table of contents

Table of contents ............................................................................. 3

1 Glossary of terms ....................................................................... 5

2 Essential information.................................................................. 6

2.1 Electrical testing.................................................................................................................. 6

3 Overview..................................................................................... 73.1 Motion base ........................................................................................................................7

3.2 MDU .................................................................................................................................. 7

3.3 MCC................................................................................................................................... 8

3.4 ICB..................................................................................................................................... 8

3.5 Software ............................................................................................................................. 8

4 System Installation ..................................................................... 94.1 Unpacking / Shipping..........................................................................................................9

4.1.1 Equipment / tools required. ..........................................................................................9

4.1.2 MCC, ICB and cables.................................................................................................. 9

4.1.3 Lifting the motion base ................................................................................................9

4.1.4 Packing ..................................................................................................................... 10

4 2 Installation 10


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6 Health and Safety..................................................................... 21

6.1 Avoidance of moving parts................................................................................................ 216.2 Start button ....................................................................................................................... 21

6.3 Interlock circuit and emergency-stop action ....................................................................... 21

6.4 Action in the event of failure of the mains power supply .................................................... 22


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1 Glossary of terms

Operator

Person or body who owns and/or operates a Maxcue 600 series motion base.

Attendant

Person who is given responsibility by the operator for ensuring the safe use of a Maxcue 600 seriesmotion base on a day-to-day basis.

ICB

Interlock control box.

MCC

Motion control card.

MCP

Motion control program.

MDU

Motor drive unit.


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3 Overview

The key elements of a Maxcue 600 series motion platform are:

A high efficiency six degree of freedom electric motion base.

A motor drive unit (MDU).

A PC ISA bus motion control card (MCC).

An interlock control box (ICB).

Operating software.

3.1 Motion base

The motion base is a six-degree of freedom motion platform based upon the Stewart platform principle.It consists of a bottom frame and top frame (flying frame) that are connected by six electromechanicalactuators.

The bottom frame has 5 mounting holes at each of its three corners. All 15 mounting holes must beused to secure the motion base for operation.

The flying frame has 6 holes that must all be used to mount the payload.

The actuators comprise a precision ballscrew directly driven by an in-line brushless servomotor. Eachactuator has sub-micron position resolution. The motion base is factory wired to the motor drive unit(MDU).

WARNING The motion base presents a crushing hazard. No person must be allowed toapproach the motion base when the MOTION BASE ENERGISEDwarning is active. The motion base


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3.3 MCC

The MCC is an intelligent ISA based servo control card. It occupies two full-length, full height ISAslots and backplates within a host PC. It has 1k words of dual port RAM (DPR) that allows rapid andeasy transfer of data to and from a host PC.

The MCC is connected to the MDU via two 2m cables.

The MCC executes a motion control program (MCP) that allows the motion base to be operated andassists in fault diagnosis. Motionbase provide an API and support software that allows high levelcommunication with this program via DPR.

The MCP is a program that is downloaded to the MCC by the host PC. The program runs on the MCC

and is responsible for:

Servo loop closure.

Profile generation.

Kinematic transformations.

Actuator state limiting.

Washout filtering.

Implementation of a state machine.

Safety system checks.

3.4 ICB

The interlock control box (ICB) is a small enclosure that is connected to the MDU via a 3m cable. Theenclosure contains:

St t b tt t hb tt it h t t t th ti b Thi i bi d ith


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4 System Installation

4.1 Unpacking / Shipping

4.1.1 Equipment / tools required.

Power screwdriver.

Number 2 Pozi-drive bit.

2 x 19mm A/F spanners.

3 x 25mm U-clevis rated at 500kg SWL. 3 x 1m sling rated at 500kg SWL.

1 x U-clevis rated at 1000kg SWL.

Crane or fork-lift truck with lifting hook having 1000kg SWL at a reach of 1.2m and a minimumheight of 3.5m.

A custom 3-piece sling (part number 000144) is available from Motionbase.

4.1.2 MCC, ICB and cables

The MCC, ICB, cables and other lightweight items are contained within a single package secured to themotion base pallet. This should be removed before the motion base is lifted from its pallet.

4.1.3 Lifting the motion base

The motion base (approx. 550kg) must be lifted from its pallet and moved to its operating position.

Three 30 lifting points are provided as shown in Figure 1.


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4.1.4 Packing

The motion base and associated components should be packed and secured as received should theyneed to be shipped to another location.

4.2 Installation

This section describes the equipment required and procedures that must be followed to safely install themotion base and its ancillary equipment.

4.2.1 Floor structural requirements

The floor requirements are as follows:

Each of the three groups of five floor fixings must be able to withstand 50kN tensile force. Thisequates to 10kN for each fixing. A suitable factor of safety should be applied to this figure.

The floor must be able to withstand a downward force of 50kN spread over an area of 20,000mm2.

This equates to a downward pressure of 2.5N/mm2.

4.2.2 Equipment Required

Installation equipment required Lifting gear as described in section 4.1.1.

Fixings to suit the floor material. The motion base has fifteen holes in the base frame which mustall be used. Refer to Figure 2 for the hole layout.

To secure the motion base to a steel or similar surface, M16 high-tensile bolts must be used(minimum grade 8.8).

To secure to a concrete surface, epoxy acrylate resin anchors are recommended. The size offixing depends on the strength of the concrete. Where the concrete has a strength greater than28N/mm2bolting should be M16 with 125mm insertion; where the concrete has a strength less

h 28N/ 2 b l i h ld b M20 i h 170 i i Ti b ll d f h


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4.2.3 Orientation of the motion base

The top frame has three axes of symmetry so there are six principle orientations in which the motionbase can be positioned. Figure 3 shows the control system X-axis related to the actuator joints on thebottom frame. The X-axis is normally aligned with the payload forward / backward direction.


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For other surfaces.

Prepare holes for the fifteen bolts.

Position the motion base over the mounting holes. Check for correct orientation. Fit the spreader plates, washers, nuts and bolts as described above.

Torque the fixings to 40Nm.

Use paint or similar substance such as varnish to mark the position of the fully-tightened nutsrelative to the exposed thread of the screws for future maintenance and safety checking.

Figure 4 - Spreader plate details

4 2 5 R i d i i h MDU


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4.2.6.1 Selection Of MCC Address

The MCC uses four consecutive I/O address locations that allow access to its Dual Port RAM. The baseaddress of the card may be set using a combination of DIP switches and jumper links. The card isfactory configured to reside at a base I/O address of hexadecimal 300. If the card is likely to conflictwith other hardware within the PC the address may be changed using the table below.

S1.1 S1.2 S1.3 S1.4 MCC Address (hex)

On On On On 300

On On On Off 304On On Off On 308

On On Off Off 30C

On Off On On 310

On Off On Off 314

On Off Off On 318

On Off Off Off 31C

Off On On On 320

Off On On Off 324

Off On Off On 328

Off On Off Off 32C

Off Off On On 330


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4.3 Connecting the MDU

Figure 5 shows the front panel layout of the MDU and identifies its connectors (should information berequired for an MDU of an earlier serial number, please contact Motionbase plc for the appropriatemanual). Figure 8 (towards the end of the document) shows the wiring of MDU connectors P9, P10 andP11.

Figure 5 - Motor drive unit front panel serial numbers MB 00001429 onward

4.3.1 Motor power and signal cables

The MDU is factory wired to the motion base. Motor power cables are terminated within the MDU andpass through glands G0 to G5. Motor signal cables are connected via MDU connectors P0 to P5.


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The MDU is protected by a type C MCB rated at 40A. It is the customers responsibility to provideover-current protection for the wiring to connector S15/P15.

The motion base draws a current of between 3A and 32A rms, depending on the payload and themotion being performed. The mains supply and wiring must be rated accordingly. Consult Motionbaseplc if in doubt about the appropriate rating of the supply.

It should be noted that the MDU current demand is very variable, depending on operating conditions,with brief (a few milli-seconds) demands of greater than 100A. For this reason, the wiring of the supplyfor the MDU needs to be of low impedance and of greater copper cross-section than might be installedon the basis of the nominal rating. Normally an electrician may install either 2.5mm2or 4mm2wiring toa 32A outlet. However, it is strongly recommended that the wiring to the 32A outlet for the motionplatform is of 6mm2minimum conductors for runs up to 35m in length from the distribution board, and10mm2for runs from 35m to 60m. Although the rms current drawn by the MDU will be below 32A,the current waveform is such that unacceptable voltage drops may develop if smaller conductors areused. Such voltage drops will have a direct effect on the maximum available speed of the actuators.

Of course, if statutory regulations require larger conductors than those recommended above (a localqualified electrician will advise) then those larger sizes should be used.

WARNING - On no account should a three-phase supply be connected to the MDU, unless theinternal wiring changes detailed in section 4.3.4.3 have been carried out. Note that thesemodifications make the MDU suitable for use with three-phase supplies up to 240 volts phase-to-phase. Higher voltages such as the 415 or 380 volt three-phase supplies commonly availablein Europe must not be connected directly to the MDU as severe damage will be caused, possibly

causing violent ejection of particulate material.

4.3.4.1 Single-phase operation of the MDU (European voltages)

Figure 9 shows a partial schematic wiring diagram for the MDU, including the external wiringconnections, for operation without a UPS whilst Figure 10 shows the corresponding diagram with an


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For USA operation with a UPS (see section 4.3.5), it is recommended that all three phases are used,since the neutral has to be connected anyway. This requires a few changes to the internal wiring of theMDU, detailed below, as it is normally supplied for single or two-phase operation. Consult Motionbaseplc if in any doubt regarding the wiring changes needed.

WARNING The wiring changes below should only be carried out by a qualified electrician.

Figure 6 gives a layout of the DIN connector assembly in the MDU and should be used in conjunctionwith Figure 12 to carry out the wiring modifications listed below for conversion to three-phase,120/208 volt operation: -

remove the IEC 320 link cable between P12 and P13 and discard

remove and discard the wire connecting DT9b to CN1A/1 on the main contactor connect a 6 mm2 red wire between DT6b and CN1A/3

connect a 6 mm2 red wire between DT8b and CN1A/1

check that the original connections to SUPP1 and SUPP2 are still secure after these changes.


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WARNING The wiring changes below should only be carried out by a qualified electrician.

Figure 6 gives a layout of the DIN connector assembly in the MDU and should be used in conjunctionwith Figure 13 or Figure 14 to carry out the wiring modifications listed below to operate the MDU withthree-phase AC (up to 240 volts between phases): -

remove the IEC 320 link cable between P12 and P13 if a UPS is not in use; otherwise remove theIEC 320 connector from P13 and provide a separate supply direct to the UPS

extract the wire ends from DT4b and DT10b and insulate the ferrules (thus isolating P13)

remove and discard the wire connecting DT9b to CN1A/1 on the main contactor



check that the original connections to SUPP1 and SUPP2 are still secure after these changes.

4.3.4.4 Three-phase operation of the MDU (Norwegian IT system)

The MDU can be supplied wired for this system with 240 volts between phases. The correspondingpartial schematics are Figure 15 without UPS or Figure 16 with UPS.

4.3.5 Operation with an uninterruptible power supply (UPS)

If desired, the user can provide an uninterruptible power supply (UPS). A UPS allows the motion baseto return automatically to its parked position if the mains power supply should fail (see section 4.3.4).

The UPS will itself require a mains power supply. It is the customers responsibility to ensure that anappropriately rated fuse protects the output of the UPS. The external connections to the MDU whenused in conjunction with a UPS are given in Figure 10 for single-phase operation and Figure 12 orFigure 14 for three-phase operation. Note that the IEC-320 cable supplied with the MDU to linkconnectors P12 and P13 when a UPS is not used should be removed and discarded in either case.

In the single-phase application, a supply is routed from P15 to connector P13, which may be used to


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P11 Pin # Function

4 Output 65 24VDC

7 Input 21

8 Input 17

10 Input 18

11 Input 16

15 Input 19

16 Input return

18 Input 22

19 Input return

21 Input 23

22 Input return

24 Input 20

25 Input return

4.3.7 Customer analogue I/O

User analogue inputs may be connected via the 25-way D-type socket, P10.

The +/-12VDC supplies available from P10.1 and P10.2 may be used to power potentiometers. The


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5.1.1.2 Weekly maintenance

Visual inspection of the following:

Inspect the paint markings on the fifteen base-frame mounting bolts. If these markings indicate thatloosening has occurred, check the tightening torque. Refer to the motion base installation details insection 4.2.4 for the tightening torque for these bolts. If frequent loosening occurs, contactMotionbase for advice.

5.1.1.3 Monthly maintenance

Visual inspection of the following:

Check all welds and framework for signs of fatigue, deformation and damage. None is acceptable.Contact Motionbase immediately if any failure or damage is suspected.

5.2 MDU

There are no operator-serviceable parts inside the MDU case. The cover should not be removed.

5.2.1 Maintenance

5.2.1.1 Monthly maintenance

The only parts that need maintenance are the filters for the two air-circulation fans on the front panel.The two filters are mounted in housings on the outside surface of the MDU. They may be replacedwithout removing the MDU cover.

Remove the plastic filter cover by pulling first one edge, then the complete cover, away from itshousing.

Remove the foam filter element and inspect for damage. If it is in an unserviceable condition,replace it with the correct part (Motionbase part number 000155).

If the element is serviceable, clean it by washing in warm, soapy water then dry.


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6 Health and Safety

The following sections describe health and safety matters pertaining to the Maxcue. It should be notedthat the cables connecting the MDU to the actuators of the motion base have integral electrical screens.The integrity of these screens is important to the correct operation of the motion base and adequateprecautions should be taken to avoid mechanical damage to the cables.

WARNING The cables connecting the MDU to the actuators provide electrical safetyearthing. If the cables are likely to suffer mechanical damage e.g. from footwear or heavierequipment they must be provided with adequate protection. Should mechanical damage besuspected, earth bonding to each actuator must be tested before further operation.

6.1 Avoidance of moving parts

Barriers that conform to the local regulations governing the guarding of machinery must guard themoving parts of the motion base. It is the responsibility of the operator to provide such barriers. Thebarriers must be sited so that there is no risk of injury to persons reaching over or through the barriers,taking account of the full range of motion of the motion base. The barriers must be positioned so thatbody parts cannot be crushed between the barriers and any parts of the motion base.

A gate or similar device must control access to the motion base. This device must control an approvedinterlock switch that is connected to the interlock circuit of the Maxcue.

Wherever steps or elevated walkways are used to gain access to the motion base, these should conformto local safety regulations. For example, suitable handrails, barriers and non-slip surfaces should beprovided.

The interlock control box is equipped with a red warning light, called the MOTION BASE ENERGISED

light. When illuminated, this light indicates that the motion base is energised. The motion base must


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6.4 Action in the event of failure of the mains power supply

If the mains power is removed without warning, the motion base will settle in an attitude determined bythe motion being performed at the time and the payload mounted to the top frame. During this settlingthe MDU provides regenerative (or dynamic) braking, where energy is dissipated as heat in a powerresistor. This braking retards the actuators as they move under the weight of the payload.

The motion base may settle in an attitude where one or more actuators are extended.

WARNING Any subsequent changes in the distribution of the payload may result in further

settling motion. There is therefore a potential hazard to anyone in the vicinity of the motion baseuntil power is restored and the base can be returned to its normal parked position. For thisreason it is strongly recommended that an uninterruptible power supply (UPS) be used, so thatthe motion base can be automatically returned to its parked position.

When a UPS is used, the motion control program will wait for the motion base to settle, and willthen use the UPS to bring the motion base to its parked position. This action may take 30-40s.The MOTION BASE ENERGISEDlight will briefly go out when the mains fails, and will then comeon again when UPS power is being used to park the motion base. The attendant must be made

aware that backup power will be applied after failure of the mains power supply.

M 600 i t ' l


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Document 00058604.doc Page 23 of 31

Figure 8 Pin designations for MDU con ectors P9, P10, P11 and wiring of Interlock control box (ICB)



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Maxcue 600 series operator s manual


Figure 9 Partial schematic wiring diagram for the MDU showing external power connections: Singlephase without UPS, European supply (220/240 volts)



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Maxcue 600 series operator s manual


Figure 10 - Partial schematic wiring diagram for the MDU showing external power connections: Singlephase supply with UPS, European voltage (220/240 volts)



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Figure 11 Partial schematic wiring diagram for the MDU showing external power connections: Twophase supply without UPS, USA voltage (120/208 volts)



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Figure 12 Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply with UPS, USA voltage (120/208 volts)



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Figure 13 - Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply without UPS, European voltages



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Figure 14 - Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply with UPS, European voltages



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Figure 15 - Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply without UPS, Norwegian IT supply



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Figure 16 - Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply with UPS, Norwegian IT supply

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M600 Operator Guide