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Innovations 2015(英語表記)

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ドキュメント名 Innovations 2015(英語表記)
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取り扱い企業 B&R株式会社 (この企業の取り扱いカタログ一覧)

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Page 1:Innovations 2015

Page 2:Perfection in Automation02Innovations 2015

Page 3:ContentsACOPOS P3 3-axis servo drive  04New safety functions: RSP and SLA  12Virtual motion – Realistic simulation of drives  14Virtual sensors for monitoring torque  16Autotuning without an encoder  18Simple backlash compensation  19A safe workspace for robots  20Perfect synchronization with Generic Motion Control  22Hygienic motor connectors  24More compact and dynamic servo motors  26The latest Intel Atom technology for industrial PCs  28New compact Box PC – Automation PC 2100  30Panel PC 2100 in an ultra-compact housing  32Windows 8 for industrial applications  36Stainless steel operator panel with IP69K protection  38Panel Designer – Individually design panels and PCs  42In the fast lane with reACTION technology  44Secure remote maintenance worldwide  5010 years – The X20 system  54X20 I/O modules for strain gauges  55Pneumatic solutions integrated in the B&R system  56Circuit examples for integrated safety technology  58Operator panels with an openSAFETY interface  59Safety controller with an integrated I/O interface  60Processing signals from 300 safety nodes on one controller  61PLCopen: Function block library for press applications  62Selecting the operating mode via HMI  63Develop software 67% faster with mapp technology  68Create documentation for automation products quickly and easily  72Unit testing in Automation Studio  74Quickly find source code errors  75Vendor-independent communication with OPC UA  76Process bus redundancy with bonding drivers  78Security by Design - Communicating via SSL/TLS  80Solution packages for control tasks  82Exact movement of crane loads  86Hardware-in-the-loop simulation on the real-time system  88Fast code generation for large Simulink models  89Manufacturer-independent engineering in Automation Studio  90Business intelligence for APROL  94Recording operation and process data in a central location  96More OPC UA in APROL  98Easier online parameter management with APROL  99Motion controlPC and panel systemsControl technologySafety technologySoftwareProcess automation03Innovations 201503

Page 4:The newstandard fordrive technologyACOPOS P304Innovations 2015

Page 5:05Innovations 2015

Page 6:3-axis servo driveACOPOS P3With the ACOPOS P3, B&R is setting new standardsfor motion control. This 3-axis servo drive offers apower density of 4 A per liter, making it one of themost efficient servo drives with integrated safetyfunctions on the market. It also provides previ-ously unmatched dynamics and precision, with aminimum sampling time of 50 µs for the entirecontroller cascade.The ACOPOS P3 is offered as a 1-, 2- and 3-axisdrive and covers a power range from 0.6 to 24 kWor 1.2 to 48 amps. And because the housing of the3-axis drive is as compact as a conventional sin-gle-axis drive, it is possible to reduce the amountof space required in the control cabinet by 69%.Highlights< 69% smaller footprint< 50 µs sampling time< Virtual sensors< Use anywhere in the world06Innovations 2015

Page 7:07Innovations 2015

Page 8:A new dimension in virtual sensorsThe short cycle time of 50 µs for current, speedand position control opens up new opportunitiesfor drive control using the ACOPOS P3. For highlydynamic and precise processes like those in theprinting and packaging industry, high-speed pre-cision control of movements is a must. This is nota problem with the short cycle times achieved bythe ACOPOS P3 and the bandwidth and precisionof the POWERLINK real-time Ethernet network.Reduced energy consumptionMachine manufacturers are being forced to moveto lightweight construction to meet demands forincreasing productivity while decreasing energyconsumption at the same time. To meet these de-mands, moving mass and mass moment of inertiamust be reduced. This results in reduced rigidityand increased elasticity. Virtual sensors make itpossible to control these elastic systems with ahigh level of quality and without having to use ad-ditional position measurement systems at theprocess intervention point.Lag error compensationVirtual position encoders can be used in the mo-tor, eliminating the need for a motor position en-coder, cable and evaluation unit in the servo drivewhile increasing availability. There are also furtheradditions to the standard controller cascade forACOPOS P3 servo drives. This includes repetitivecontrol, for example, which makes it possible topredict and compensate for lag errors. The result?More precise control, improved performance andincreased product quality.Maximum safetyDue to machinery directives in the EU and similarlegal regulations in other parts of the world, thesafety functions in automation components arebecoming increasingly important. The ACOPOS P3provides many safety functions that satisfySIL 3 / PL e / Cat 4 requirements. A new function,Safely Limited Torque (SLT), checks whether themaximum permitted torque has been exceeded.SafeMOTIONCombining various safety functions such as SLSand SLT makes it possible to achieve shorterchangeover times, ensuring increased machineavailability.SafeROBOTICSThe Remanent Safe Position (RSP) safety functionis also new. This safe position data allows thesafe monitoring of all serial kinematic chains forrobots with regard to velocity, orientation andworkspace. All 14 safety functions are completelynetwork-based and can be used dynamically inthe system thanks to openSAFETY.High availability –Maximum security08Innovations 2015

Page 9:0VSTOt t0Safe Torque OffT0 tT SLTSafely Limited TorqueSLT0V SLSt t0 t1Safely Limit SpeedVSLS0VSTO1t t0Safe Torque Off, single channel0V SS2SOSt t0 t1Safe Stop 20SLISafely Limited IncrementtS0SDISafe DirectiontV0SOSSafe Operating StoptVS0V SS1STOt t0 t1Safe Stop 1SSmaxSmin0SLPtSafely Limit Positiona0 taSLAaccaSLAdecSafely Limited AccelerationSLA0SMSSafe Maximum SpeedtVVSLS09Innovations 2015

Page 10:Lean automation with Scalability The compact design of the ACOPOS P3 is not theonly factor in reducing the space required for anautomation solution. Together with other com-ponents from the B&R automation product range,it is possible to implement an extremely lean au-tomation solution. A Power Panel (operator paneland controller), ACOPOS P3 and X20 I/O are allthat is needed for a complete and powerful auto-mation solution. Because this type of system iscompletely modular and scalable, it can be up-graded and expanded as needed – guaranteeingmaximum reusability of software that has alreadybeen engineered.Safety includedIt is even possible to integrate a complete safetysolution in a minimized system of this type. TheSafeLOGIC-X virtual safety controller runs on anordinary PLC and offers the reliability B&R cus-tomers have come to expect without requiring adedicated safety controller.Completely compatibleThe ACOPOS P3 can be combined with allACOPOSmulti family products. Additional spacecan be saved in the control cabinet, for exam-ple, by using the motor-mounted ACOPOSmotorservo drive or the distributed ACOPOSremotedrive system.No loss of energyWhen using an ACOPOS P3 together with anACOPOSmulti drive, it is also possible to take ad-vantage of the power regeneration capabilitiesof the ACOPOSmulti. Braking energy from theACOPOS P3 is not converted to heat using brakingresistors; instead, it is passed on to an ACOPOS-multi via the DC bus, which can feed the energyback into the power grid.Improved international capabilitiesThe flexibility of the ACOPOS P3 shines in thisregard since it supports the world's most com-mon power mains configurations, such as TN,TT, IT and corner grounded TN-S systems. Insome circumstances, only an additional line fil-ter is needed to meet the necessary regula-tions. In addition, the ACOPOS P3 satisfies themachine and system manufacturing require-ments set forth in EN 55011 CISPR 11 andEN 61800-3 (first environment, category C2).Lean,scalable,international10Innovations 2015

Page 11:2,5 A 4,4 A 8,8 A 2,5 A 4,5 A 8,8 A2,5 A 4,4 A 8,8 A 2,5 A 4,5 A 4,5 A2,5 A 4,5 A 4,5 A1 kW 2 kW 2 kW 2 kW 2 kW 2 kWSingle axis Triple axisDouble axis13 A 18 A 2,5 A 4,4 A 8,8 A 2,5 A 4,5 A 8,8 A2,5 A 4,4 A 8,8 A 2,5 A 4,5 A 4,5 A2,5 A 4,5 A 4,5 A6 kW 8 kW 2 kW 4 kW 4 kW 4 kW 4 kW 4 kWSingle axis Triple axisDouble axis2,5 A 4,4 A 8,8 A0,5 kW 1 kW 2 kWSingle axis2,5 A 4,4 A 8,8 A1 kW 2 kW 4 kWSingle axis24 A 32 A 48 A 18 A 24 A18 A 24 A11 kW 16 kW 24 kWSingle axis Double axisMain supply 1 x 110V, 1 x 230V, 3 x 208VMain supply 3 x 208 - 480V2.5 A 4.4 A 8.8 A 2.5 A 4.5 A 8.8 A2.5 A 4.4 A 8.8 A 2.5 A 4.5 A 8.8 A2.5 A 4.5 A 8.8 A1 kW 2 kW 2 kW 2 kW 2 kW 2 kWSingle axis Triple axisDouble axis13 A 18 A 2.5 A 4.4 A 8.8 A 2.5 A 4.5 A 8.8 A2.5 A 4.4 A 8.8 A 2.5 A 4.5 A 8.8 A2.5 A 4.5 A 8.8 A6 kW 8 kW 2 kW 4 kW 4 kW 4 kW 4 kW 4 kWSingle axis Triple axisDouble axis2.5 A 4.4 A 8.8 A0.5 kW 1 kW 2 kWSingle axis2.5 A 4.4 A 8.8 A1 kW 2 kW 4 kWSingle axis24 A 32 A 48 A 18 A 24 A18 A 24 A11 kW 16 kW 24 kWSingle axis Double axisMain supply 3 x 208 - 480VINaxis 1INaxis 2INaxis 3PN gesINaxis 1INaxis 2INaxis 3PN gesINaxis 1PN gesINaxis 1PN gesINaxis 1INaxis 2INaxis 3PN gesINaxis 1INaxis 2INaxis 3PNINaxis 1INaxis 2INaxis 3PNINaxis 1PNINaxis 1PNINaxis 1INaxis 2INaxis 3PN11Innovations 2015

Page 12:PositionTimeSafe position validSafe positionEncoder positionPower OFFPositionstoredSafe encoderrangeposstoredposstoredposmaxposmaxposPower ONposPower ONSafe positionset up internallyInvalid range for encoderposition at power-onPosition acknowledged byuser (homing with RSP)ΔposΔpos0ΔposSTOLSTOLOnlySOSactivatedOverflow encoderpositionSOSandSTOactivatedSOSandSTOdeactivatedPower ONUsing the Remanent Safe Position (RSP) function al-lows a safe multi-turn position to be received after arestart without having to perform a homing procedure.Homing­­­– Once is enoughWith SafeMOTION Release 1.9, B&R has updated thesafety functions for the ACOPOS servo drive family.In addition to two new functions – Remanent SafePosition (RSP) and Safely Limited Acceleration(SLA) – this update also introduces machine op-tions for SafeMOTION parameters and improvesboth system availability and user-friendliness.In order to obtain a safe absolute multi-turn po-sition, homing was previously necessary eachtime an axis was restarted. In certain situations,this can require considerable effort, especiallyfor complex multi-axis systems. The RSP functionallows SafeROBOTIC SLS, SafeROBOTIC SLP andSafeROBOTIC SLO to be used without homing afterevery power-on cycle.Remanent storage of the positionAfter a controlled functional stop of the axis, thecurrent safe position is stored in remanent(non-volatile) memory. A status bit indicates thatthe save operation is complete, and the axis canbe switched off.Data verificationWhen switched on, the stored data is checked forvalidity. The safe position can then be set to theremanent safe position after confirmation by theuser. The RSP function is available for SafeMOTIONmodules with an EnDat 2.2 interface.12Innovations 2015

Page 13:SLA control bitT (delay time tostart SLA [µs])Speed tolerance[units/s]Safe deceleration limit for SLA[units/s] in the negative directionSafe acceleration limit for SLA[units/s] in the negative directionSafe acceleration limit for SLA[units/s] in the positive directionSafe deceleration limit for SLA[units/s] in the positive directionAcceleration Deceleration Deceleration-Acceleration-SLA status bitSpeedAccelerationThe Safely Limited Acceleration(SLA) function makes it possible toconfigure the speed limits closerto the actual limit without risk.Highlights< Repeated homing procedure not necessary< Safe operation closer to the limit< Increased availabilityCloser to the limitThe Safely Limited Acceleration (SLA) functionmonitors the acceleration or deceleration of anaxis. If the limit being monitored is exceeded, theSafeMOTION module goes into an acknowledgeableerror state and power is no longer applied to theaxis. Using the SLA safety function for coupledaxes, for example, makes it possible to signifi-cantly reduce the maximum remaining distance anaxis will move in the event of an error. The speedlimit set in the SLS SafeROBOTIC function can thusbe configured closer to the point where there isreal danger. The Safely Limited Acceleration func-tion is available for SafeMOTION modules with anEnDat 2.2 and SinCos interface.Safe machine optionsWhen commissioning some machines, it is nec-essary to make machine-specific settings forcertain parameters, such as the homing offsetor the unit system as it relates to the actualgear ratio. You can now use the machine op-tions function to selectively transfer the safetyparameters from the functional application to aSafeMOTION module.Setting parameters on the panelThese safe machine options can be used to up-date parameters via the HMI application on theoperator panel, for example. Because they aresafe parameters, configuration may only be per-formed by authorized personnel, and the cor-rectness of the transferred parameters must beacknowledged. The machine options are avail-able for SafeMOTION modules with an EnDat 2.2and SinCos interface.13Innovations 2015

Page 14:multiACOPOSmultiACOPOSSimulationon the PC Simulation on the controllerSimulation on the drivePROCESSVirtual motion allows simulation on three different levels.Virtual motion –Realistic simulation of drivesCarrying out tests on real machines requires timeand money. Simulations are becoming increasing-ly important – to a large degree due to the in-creasing complexity of machines and systems.With virtual motion, B&R offers the possibility ofrealistically simulating machine behavior for cer-tain configurable environmental conditions whilestill in the development phase in order to obtainan accurate representation of how the machinewill behave when it is finished.Virtual motion allows the simulation of a singledrive system with hardware-in-the-loop (HIL)functionality as well as the simulation of complexmachine elements or even entire machines. Thereare two main areas of application for virtual mo-Highlights< Faster development< More precise configuration< Damage avoidedtion. One is realistic simulation of the behavior ofthe machine before it is even built, which allowspossible weaknesses to be detected and correct-ed early on. The second is fast and convenientconfiguration of the drive controller for alreadyexisting drive systems.Avoiding damage to the machineDuring simulation, it is easy to change systemparameters and test the behavior of the machineat its limits. Damaging the machine is not possi-ble, and the influence of external forces can beclearly depicted.Virtual motion can be used on three different lev-els: to simulate the motor and load; to simulatethe drive, motor and load; and purely soft-ware-based simulation that runs entirely on thecomputer. Complex multi-body systems and drivesystems can also be simulated in the design orprototyping phase, just like completed machineelements where all that remains is to providethem with an optimal configuration.14Innovations 2015

Page 15:multiACOPOSmultiACOPOSmultiACOPOSmultiACOPOSmultiACOPOSmultiACOPOSmultiACOPOSmultiACOPOSmultiACOPOSSimulation on the drive including load simulationSimulation on the controllerSimulation on the PCBacking rollPrint cylinderThrust bearingSimulation on the driveThe first level of virtual motion is simulating asingle axis. The behavior of the motor and theload that corresponds to the axis is simulated.This simulation mode is particularly useful in an-alyzing the behavior of the drive controller. Theresult of changing system parameters can be in-vestigated, as well as the behavior with differentloads. In addition, it is also possible to make per-formance estimates in relation to the controllerconfiguration.Simulation on the controllerSimulation on the controller offers the possibilityof replicating large processes with a high degreeof complexity or processes with coupled axes.This makes it possible to develop and test se-quential control and complex processes withoutrequiring the physical drive unit and the machine.Coupled axes can also be analyzed at the sametime, which makes it possible to assess their in-fluence on the overall performance of the ma-chine or on the performance of an individual axis.With this type of simulation, the process, the be-havior of the motors and the behavior of the drivesare simulated on the controller. The configurationof various complex process models is supportedby PLCopen model components, which are madeavailable in libraries.Simulation on the PCSimulation on the PC is the most comprehensivetype of virtual motion simulation. It provides a real-istic picture of the overall system without any actu-al machine hardware being used. Sequential con-trol systems and their impact on the machine aresimulated and analyzed directly in B&R AutomationStudio, enabling faster product development with-out any loss of quality.15Innovations 2015

Page 16:Drive systemVirtual sensorLoad torque Motor speed(measured)Shaft torque(virtual)Load torque(virtual)Motor torqueA virtual sensor can be used to precisely determine shaft and load torque in dynamic conditions.Virtual sensors formonitoring torqueMotor torque, shaft torque and load torque playan important role in condition monitoring foropen-loop control drive systems. Nevertheless,only motor torque is usually known. With virtualsensors, B&R now offers the possibility of pre-cisely determining shaft and load torque even indynamic applications. And this can be done with-out the need for additional physical sensors.Existing and easily measurable values are used asthe basis for virtual sensing, and this includesmotor speed and position. If the torque controlloop provides sufficient dynamics and accuracy, arelatively accurate motor torque value can also bedetermined. If drive dynamics can be describedmathematically and the necessary system pa-rameters such as rigidity, drive shaft damping andmoments of inertia are known, a virtual sensorcan be used to determine the difficult-to-mea-sure shaft torque and load torque.Avoiding damageOne of the ways to monitor torque is through theuse of a virtual sensor. In this way, torque andHighlights< Easier measurement< No additional hardware< Damage avoidedforce are determined virtually and used to esti-mate the mechanical stress on a drive shaft, forexample. If this is too high, mechanical damagewill occur sooner or later. This danger can be de-tected at an early stage using torque monitoring,making it possible to change parameters or switchoff the drive before damage occurs.Motor torque – Shaft torque – Load torqueShaft torque refers to the torque transferred via thedrive shaft, whereas the load torque refers to thetorque acting on the drive system. At a standstill,motor torque, shaft torque and load torque are equal.In dynamic applications, they can differ significantlydepending on the mechanical design of the system.16Innovations 2015

Page 17:-4-3-2-1-0-5234510 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8Mathematic models make it possible to replace physical en-coders with virtual encoders.If the shaft torque exceeds the defined limits, then parameterscan be changed to prevent damage.Time [s]Shafttorque[Nm]Acceleration Const. speed Deceleration StopNo loadLoad 1Load 2Max. levelTin(t)Tfr_1(t)ω1(t)J1(t) J1(t)Tshaft(t) = Cstiff· (φ1(t) - φ2(t)) ddamp· (w1(t) - w2(t))Unknown loadφ1(t)ω2(t)φ2(t)Virtual sensors can be used to prevent motor damage.17Innovations 2015

Page 18:100101102103-80-60-40-2002040100101102103-300-200-1000Standard controller cascade inservo drives with virtual encoderFrequency response of speed-controlled system for physicalencoder (blue) and virtual encoder (orange).Frequency [Hz]Phase[°]Magnitude[dB]Frequency [Hz]Current setpointSpeed setpointPosition setpointSetpoint generator Position controllerActual positionActual speedSpeed controllerTorque andcurrent controlVirtualencoderv-ctrls-ctrlρPerformance levelMotorEncoderVirtual encoderAutotuning without an encoderThe autotuning function in the standard control-ler cascade for the ACOPOS servo drive has beenupgraded to also work on axes without a dedicat-ed position encoder. This makes it possible toalso use autotuning to reliably and accurately ad-just servo axes without an encoder.Encoderless control of axes is sleek and reliablesince it doesn't require the use of an encoder, en-coder cable or evaluation unit. The size of the mo-tor can be reduced, and there are no componentsthat may require maintenance. B&R drives arebased on the principle of field-oriented control.The location of the rotor is used for commutation,speed and position control. This information isusually supplied by a position sensor mounted onthe motor shaft. If a virtual sensor is used, a phys-ical sensor is not needed.Reliable supportThe use of a virtual sensor changes the dynamicbehavior of the controlled system. The field-prov-en autotuning function takes this fact into ac-count and provides reliable support for the userwhen commissioning the machine.Highlights< Field-proven autotuning< Smaller motor< Reduced maintenance18Innovations 2015

Page 19:02040-20-8 -6 -4 -2 0 2 4 6 8Drive control for spindle drive with slope error and backlash.PositionsetpointSetpoint generatorPositioncontrollerFeed-forwardSpeed controller Current controlEncoderρlρPerformance levelMotorPBCLoadLoad position error in relation to the motor position.Without PBCMotor position in units x105LoadpositionerrorinunitsWith PBCHighlights< Increased positioning precision< Simple configuration< Fast compensation for mechanical playSimple backlashcompensationThe standard controller cascade for the B&R ACOPOSservo drive family now provides compensation forspindle pitch and backlash. The positioning preci-sion of spindle drives with and without backlashcan be increased through compensation withoutrequiring an extra encoder on the load side. Controlquality can also be significantly improved in otherapplications with mechanical play using pitch andbacklash compensation (PBC).Compared to conventional handling of mechani-cal play in the setpoint generator, spindle pitchand backlash compensation provides substantialbenefits. With condition-based closed-loop con-trol, backlash that occurs on a changing edge isovercome quickly and reliably, and the transitionto the new edge is as smooth as possible. Asmooth transition reduces the likelihood of dam-age to the mechanical components caused bycontinually changing edges.Simple configurationThe entire control loop can be configured as ifthere were no backlash. This can be achieved us-ing the new closed-loop control approach for sta-bilizing the speed controller for the motor positionwithin the range of mechanical play. A further ad-vantage of spindle pitch and backlash compensa-tion is that the currently displayed position corre-sponds to the actual position of the load. All thatis necessary is to carry out a reference measure-ment that defines the relationship between themotor position and the actual load position.19Innovations 2015

Page 20:SSFSWSB&R has updated the functions available for saferobot control. Users now have access to the mon-itoring functions SafeRC SLS, SafeRC SLP andSafeRC SLO in Safe Designer. These SafeROBOTICSfunctions are based on easy-to-configure func-tion blocks that not only provide safety applica-tions the flexibility to easily be adapted to envi-ronmental conditions, but also to be validatedas well.In addition to monitoring the speed at the toolcenter point (TCP) and at all joints of a general-ized serial robot (SLS), it is now also possible tosafely monitor the workspace (SLP) and the ori-entation of the tool mounting flange. B&R'sACOPOS servo drive provides the safe axis posi-tion using integrated safety functions to calcu-late the Cartesian positions of all joints, the toolmounting flange, the TCP and additional moni-toring points.Highlights< Improved safety< Increased flexibility< Simpler engineeringtions in the safety application round out the rangeof functions of the SafeRC SLP safety function.Calculating braking distancesThe possibility to calculate braking distances isnow available. This allows the braking distancefor each kinematic object to be determined de-pending on the current speed and position ofthe robot. If stopping the robot before reachingthe workspace limits is no longer possible ac-cording to the defined braking deceleration,this is indicated by a status output. This makesit possible to minimize the overrun distance inthe event of a workspace violation, and theworkspace limits can be more precisely matchedIn order to monitor a safe workspace (SLP), rotat-ing cuboids or planes are defined either as aworkspace (WS) or safe space (SS). Special func-tion spaces that control position-dependent ac-A safe workspace for robots20Innovations 2015