D

; .

2-J.

SPINDLE ORIENTATiON
by ENCODER
TYPE

DL-AE

MAINTENANCE MANUAL
h

MITSUBISHI
ELECTRIC
c

----a-.-w

CONTENTS

~~~~~~~

1.

INTRODUCTI(-jN

2.

SpECIFICATI(-jN ________-_---_--_-____________________________

3.

COMPOSITION

4.

PRINCIPLE

~-~~~~_____----_-_--____________________~~~_~~~~--

5.

INTERFACE

________---_--______--------_------_-_----_____---

6.

APPEARANCE

______-_--_-_____-_----_____-_____-~~~~~~~~----

____-________-____------------------------------

AND

DIMENTEIONS

6.1 Card arrangement ---------------------------~-------------

6.2 gncorder outline dimensions -----~~--~~~~~-~~~------------

7.

INSTALLATION AND ADJUSTFNT

7.1 Instaration _-________--_--_--------~----~~~~~~~--~~-~~-~~

7.2

Wiring __________-__----___-_-------_---------_~__-------_

9
9

7.3 Setting befor making the circuit ------------------------- .+

7.4 Test run ---_________________--~-----------~--~-----~-~~~~

11

7.5 Adjustment --__________________~~~-~~~-~-~-~----------~~~-

11

a.

CHECK TERMINALS/LEDs

LIST ---_______________________________

14

9.

REPLACEMENT

OF PARTS ------_---__-_--_----_------~---_~~~~--

17

9.1 Removal of card

9.2 Adjustment at replacement of orient card
9.3 Replacement of encorder

10.

TROUBLE-SHOOTING

~~---~~~~--~~_~~~~_____-_-__-------------_~

19

11.

ELEMENTARY DIAGRAM ___________________________-_____________

22

1. INTRODUCTION

This Instruction Manual describes optional card "DGAE" used for control of encoder type spindle orientation device.
.

2 SPECIFICATION
(1) Mechanical

Specification

(a) Spindle speed:

Max. 6000rpm

(b) Gear ranges:

3 speeds (HIGH, MID, LOW)

(c) Speed llH/Llf gear ratio:

3/l- 10/l

(d) Load GD"

Shall be equivalent to or less

than the load to the motor.

(e) Backlash
(Between PLG and mzr)

Max. 1.0' (converted into PLG shaft)

It is desirous that backlash
is small enough to prevent occurrence of gear sound.

(2) Photoelectric rotary encoder

(a) Model:

RFH-1024-22-l-68 (NIPPON KOGAKU

(b) Ambient temperature:

o-5o"c

(c) Permissible thrust load:

lkg

(d) Permissible radial load:

l-kg

(e) Input shaft torque:

Max. lkg-cm

(f) Inertia:

1.6 x lo-'kg cm.sec"

(g) Permissible speed:

6,OOOrpm

(h) Power source:

Y&5%, Max. 250mA

(i) Coupling:

Max. runout: O.O2mm, 0.03'

(3) Performance and accuracy

(a) In-position signal:

iO.088' x (2 - 128)

(b) Positioning accuracy:

+O.l" (depends on the lost motion

(Target value)

of the machine)

(c) Position&g time:

Max. 3 sec. (depends on load GD2

and motor)

(d) Orientation speed:

(preset Low speed)

50*30Orpm (At spindle)

3. C O M P O S I T I O N

r----I

Controller

' Sequence

I+

i____1

Orient
(Option)
D L-AE

r-

Ml9
v106

,Orient
!--command ]

Orient position command

((l&bit binary))
I

i_-_
Spindle

-2-

4. PRINCIPLE
The following Time Chart shows the pattern of operation.
Speed depending on positioning
amlifier gain
Motor speed

Orient command
(ORCl-COM)

'
tip-to orient speed,
Reference
In-position output
(ORA1+XlA2)
-l-l-2OOmb

Time Chart

(1)

When orient command is given, the motor speed changes to "orient

speed".

(2)

When the motor speed reaches orient speed, the detection speed
level at which speed is detected by comparator steps up.

(3)

When a mark pulse is given after the up-to orient speed steps
UP,

the desired orient position signal delivered from external

source in 12-bit binary is read and at the same time counting

starts.

The speed at this step of operation remains at the

orient speed.
(41

When the spindle reaches at approximately 90" before the resired

orient position, the control loop changes from "speed loop" to
"positioning loop" and the motor speed changes from the orient

-3-

speed to the speed that depends on the gain of the positioning

amplifier.
(5)

The linear zone of positioning loop starts at about 11 before

the orient position.
After that, the motor speed goes down and the motor stops at the
orient position.
i.

(6)

k,f6regoing by setting
"IN POSITION" signal occurs at a positio
value of CSl from the orient position and "fN

POSITION" signal

output contacts close in 200mS after the occurrence of the signal.

(7)

When the orient command is canceled, the motor speed returns to

the speed specified by S command".

(8)

When the orient command is given again while the spindle is

under orient position, the orientation is realized in one turn of
the spindle.

However, depending on the desired orient position signal and the

setting of CS2, CS3 and CS4 for the position shift, the spindle
may rotate over one turn.

NTERFACE
: TB4 in the diagram indicates the

Controller

Specification for the c&troller.

re4(Note)

Orient command
'7
TB4
CTL

"L" gear select

(Closes at low gear)

T04
C$lE#$ORLK)

"M" gear select

(Closes at medium gear)

30V DC
0.2A

In-poisition,signal
(String for customer use.)

ORA

CON4

<181

I
<<c

PA

(191

<<R

xP5l-l
OH
OG

LO1-03)

1(20)

y_________________Y

kK

(Cable connector
MR-20LF not furnished)

c
CON5 (Same as CON 4)

I
WTo NC

R-20L F

(For application to
synchronous feed)

MR-20RhlA

-5-

Controller

kient position data

CON6

(151

_\2048

(16)

_\1024

(171

_\

12Ha
11Ha
foH-_cn

_B,

09H -_EII

15V DC
5.6~~

,(19>

q,

07H--c71

,GJO>
..

06H_r=a

,d (2)

u,

08H-_c=D

05Ha04Ha
03Ha
02H-_I=o
OlH-_cID

MSB

I.
. ,

-u,
-u,

,(6)
a ,(7)

-ULSB

r Y __-___--_-____
(14)

OL

'Cable connector
MR-20LM
(Not furnished)

CON4,5
Pill arrangement

CON6

Pin sr&ngement

-6-

..

6. A P P E A R A N C E A N D D I M E N S I O N S
6.1

In-position range
setting switch
I

Card Arrangement
Orient direction
setting pin
/

In-position range
setting jumper
I

Orient position
shift switch
/

DL-AE
Orient speed
setting

Counter
contents
display
LED

Gain setting

Offset .
adjustment

I-

Test
pushbutton,

Operation
status
display
LED

Test mode
,display LEC
f

Test mode settingpin

.

f--

5V

I
supply jumper

ficoder/m\otor running
direction setting

-7-

Size: 180 x 280 x 25

Weight: About 3OOg

6.2

Encoder outline dimensions

Key way dimension

CANNON connector

MS3102A20-29P
MS3106A20-29s

Output terminal arrangement

MS3057-12A
(Cable connc>ctor is not
furnished)
'[Reversktg signal

7. INSTALLATION AND ADJUSTMENT

7.1

Installation
Install the encoder to the machine using care not to exert large
force to the shaft.

7.2

Wiring
Since the encoder outputs faint signal that is liable to catch external noises, use twisted and shielded wires for wiring of the enThe wires should be laid down remotely from the high

coder.

voltage circuits, and not extend over 20m.

The orient position signal is also faint signal.

Be sure to use

a bound, shielded cable not extending over 5m for wiring of the signal,,

7.3

Setting before making the circuit

Item

Orient
direction

Symbol of Selecdevice
tion
PIN 1

LCK
PRI

PIN 2

Direction of PIN 4
rotation of
encoder

Description
Orientation is always in the direction
preset by PIN 2.
Orientation is in the direction in which
motor ran before orientation is commanded

ccw

Orientation starts in counter-clockwise

direction of the motor.

cw

Orientation starts in clockwise direction

of the motor.

FWD

The motor runs in the same direction as does

the encoder.

REV

The motor runs in reverse direction to the

rotation of the encoder.
"If the rotation of the encoder is reversed,
spindle rattles largely and cannot stop.

Range of
IN-POSITION CS 1

IN-POSITION within 2 pulses

IN-POSITION within 4 pulses

IN-POSITION within 6 pulses

IN-POSITION within 8 pulses

-9-

Item
Range of
IN-POSITION

SelecSymbol
of device tion
cs 1

cf.
0.088"fpulse

Jumper
Encoder
power supply S-S

5
6
7
8
9
A
B
C
D
E
F

Description
IN-POSITION within 10
12
14
16
18
\
20
22
24

26
28
30
32

64 pulses

128 pulses

Disconnect

pulses
pulses
pulses
pulses
pulses
pulses
pulses
pulses
pulses
pulses
pulses
pulses

However, jumper is disconnected between G and G.

However, jumper is disconnected between H and H
Jumper G-G may be connected,
or disconnected.

Since the standard model has no incorporated

5V DC source, use the power supply from the
N/C.
For special model equipped with 5V DC supply,
a jumper is provided.
When power supply from the NC is used, disconnect the jumper.

- 10 -

Test Run

7.4

I
Step

Note:

B e f o r e s t a r t i n g t h e a d j u s t m e n t , m a k e sure all settings are in

compliance with the instruction ADJUSTMENT DATA.

Item

Symbol of Setting
device

escription
9
Remove PIN 3 from DRIVE and then
set into TEST before the line
power supply is given.

R EADY (PRQARATION)

PIN 3

POWER ON

LED 16

Red LED denoting "TEST" mode will

light.

';

ORIENT

PB 1

When PBl is depressed after the

machine sequence is set up for
operation, orientation (operation
at orient speed) starts.

TEST

,-

When PBl is released, orient positioning takes place.

RESET

PIN 3

VERIFICATION

LED 16

DRIVE

Turn off the power source end

return PIN3 to DRIVE position.
Turn on the line power supply and
make sure that red LED "TEST" not
does not light.

7.5 Adjustment

S tep

Item
"HIGH" range
Orient speed

Symbol of
device
VRl

Description
Start the orientation and adjust VRl so
that the spindle stops smoothly and rapidly
as shown by the graph below.
If VRl is turned in

--*

excessively,

the spindle will stop with overrun.

NSA

If VRl is turned in ' .L

excessively,

time taken for positioning (orient position) delays.

Orient---speed
I

-t

2'
Overrun

- 11 -

tep
2

Symbol of
device

Item
"H" range.
Gain adjustment

JR4

Description

+t This variable resistor will have been set

by manufacturer.
3: After VR4 is turned, be sure to perform
the following of set adjustment:
'\
Hunting occurs making impossible orient
direction
stop if VR4 is turned in fl
excessively.

If VR4 is turned in n

direction excessivly, servo lock torque

decreases and stopping accuracy will worsen
Set VR4 at a position about one grade
turned in n direction where overrun or
hunting is about to occur.
3

"H" range.

VR7

Ml9 in MD1 repeatedly, adjust VR7 so that

Offset
adjustment

LEDs 1 - 8 all light and go out.

Orient positioning display

LED1
LED2
LED3
LED4
LED5
LED6
LED7

LED8

0
0
0
0
0
0
0

By depressing 'TEST pushbutton or entering

Position error corresponding to 1 pulse occur:

from lighting to going out of the LEDs.

0
0
.
or .
.

LED1
LED2
LED3
LED4
LED5
. LED6
0 LED7
. LED8

Therefore, the offset adjustment with MO3

command is not correspondingly applicable
to M04.

0
. . . Lights.
z **-Does not light.

"Medium" range
Orient speed

VR2

Gain

VR5
VR8

Offset
5

Shift the spindle gears to "Medium" position

"Low" range

and se-b the potes in the same manner as for

"H" range. This range is not provided in
two gear range ("H"/"L") machine.

Shift the spindle gears to 'lLOW't position

Orient speed

VR3

G&l

VR6

Offset

VR9

ad set the potes in the same manner as for

"H" range.

- 12 -

Step
6

Item

Symbol of
device

Description
Orientation occurs at 'IL" range speed.

Orient position
shift

Error from comm ded (specified) position should be Ta justed by CS2, 3 and
4.
cs 2
cs 3
cs 4

. . . . 256 pulses/notch (22.5'/notch)

. . . . 16 pulses/notch ( l.A'/notch)
....
1 pulse/notch (O.OSS'/notch)
When CS 2, 3 or 4 is turned under orient
control, the spindle turns correspondingly,

_-

8. C H E C K TERMINACS/LEDs LIST
Symbol

Check terminal No.

ORAl

CHl

ORA

CH2

LNZ

CH3

Function

Standard value or wave form

Remskrs

In-position Closes at corn letion

contact
r*ac\ 1
'L_*CH2
Linear zone tl5V within ill0 from the orient
position
OV at other position

.I

POS

CH4

Positioning At stop of orientation

amplifier
0~ i2OmV
output

DRP

CH.5

D/A conver- (1) During usual continuous operation, the

ter output
output varies +30% at +sV.
q-+_:q
(2) At stop of orientation
0 - +25OmV
(3) Position loop gain can be obtained from,
Voltage
Gp=510* CH4
CH5 Voltage *KG
o

(SW

-1 )

Read voltages at CH4 and CH5 when

voltage at CH5 is within a range from
0.3 to 0.7V.

o KG is gear ratio (Spindle gear/Motor

gear)
RI

CH6

Speed COII+
mand voltage

(1) At usual operation

+lOV/Max. speed
(2) The voltage is same as at CH4 when the
spindle stops (orient stop).

CH7

count
pulse

Jygi-3
2.5 rus

- 14 -

l-

Symbol

U/D

Check terminal No.

CH8

Standard value or wave form

Function
Pulse of addition

Remarks

OV at subtraction
At addition wlT[
about

.
r-

5/(s
READ

CH9

Data reading

(1) Pulse generates at

reading
n
(2) Short-circuit across the following
terminals to make possible data reading for checking of D/A converter
characteristics.
CH3 - CHll
I CH9 - CHll

cs3
When CS3, CS4
sre changed
with CON 6
disconnected,
the indication
changes as
listed to the
right.
l : LED does
not light.

cs4

LED

112 13 I 4 1 5 1 6 17 18

lololololo~o~~ Oc)

1 F

6
I

D/AUUtput

cCH5)<v

o: LED lights .

CP

CHlO

Clock pulse

P15

CHll

t15v DC supply

N15
COM

CH12

-15V DC

P5

CH14

suPPly

OV Common line

CH13
t5V DC supply
for encorder

4-5~0.5V

- 15 -

To make encoder
compatible with
the NC, disconnect jumper JP3
(S-S) andobtain 5V source
from the NC.

LEDs

8.2

Symbol LED No.

LED 1

.I

Function

Description

Counter contents

Conunecontents are displayed in

8 bits.
ZED 8 is a sign bit.
For details, refer to the previous

LED 8

-.

page.
*

IN-POS LED 9

In-position

The LED lights at the same time when

orientation ansel-back signal is output.

SERV.IN LED 10

Servo In

The LED lights while the position servo

loop is formed.
The LED starts lighting at 90' before
crient position.

Orient command

ORIENT LED 11

The LED lights when orient command is

input.

M. GEAR LED 12

"M" gear selection

The LED lights when M range is selected

for spindle speed and its signal is given.

L. GEAR LED'13

"L" gear selection

The LED lights when L range is selected

for spindle speed and its signal is given.

PULSLA LED 14

Encoder "A"-phase
pulse

The LED lights when A phase pulse signal

is output from the encoder.

PULSE-B LED 15

Encoder "B"-phase

The LED lights when B phase pulse signal

is output from the encoder.

pulse
TEST

LED 16

Orientation test

The LED lights when the short pin is

/
set to "TEST".
? 4
For usual operation, set the short pin:
,,
in "DRIVE" position.

;:
,.I I,
c
4

.I

I 4,

,!C

- 16 -

.,

9. REPLACEMENT OF PARTS

Removal of Card

9.1

\
The orient card is installed to card spacer

Card

as shown to the left.

Press down the lugs at the top of the spacer
by pliers and remove the card

9.2 Adjustment at replacement of orient card

(a) There are two types of card, namely, DL-AE (without 5V power sup
ply) and DGAEl (with 5V power supply).
Identify the type before replacement.
(b) Set the VRs, short pin, jumper wire and select svitches as they
are set on the previous card.
(c) Perform orientation at each gear range and make offset adjust-

ment.

(See para. 7.4.)

(d) Repeat orientation with command MO3 and MO.4 and adjust the orient
speed, gain and offset so that smooth orientation is assured. .
(See para. 7.4.)

i\

9.3 I Replacement of encoder

For encoder, use that of balance (Deferential signal) type, 1024P/rev.
ep1ac.e the encoder using care not to exert excess force to the
coder, shaft and body .

c'

' I (c) Perform orientation and adjust the position by CS2, 3 and 4.
8
*
, *

c
,

i,
i

(In the case of machining center)

Remove the drive key from the spindle, perform tool
change (Mob) and set Cs2 - 4 so that the key slot is

- 17 _

~_~_ .-

properly positioned.
Since backlash in gearing mechanism, runout of tool change
arm and structural deflection affect positioning accuracy,
repeat orientation in CW and CCW directions(M03, M04) and
repeatedly change tools to properly position the key
slot.
(In the case of lathe)
Perform orientation and adjust CS2 - 4 to establish the
orient position.
Since backlash in gearing mechanism affect positioning accuracy, perform orientation in CW and CCW directions to
set CS2 - 4

SO

that the orient position comes to the

center CT the range of backlash.

10. T R O U B L E S H O O T I N G

Appearance

10.1

Visually check:
- Appearance
- Parts for damage
_ If forein matter is found
- Connectors for looseness
DC supply

10.2

voltage

Measure the following voltages using a DC voltmeter:

.-

- CH14

. . . . . +5v+10%

- CHll

. . . . . +14.5@3.5v

- CH12

. . . . . -14.5QO.5V

For common terminal, CH13 is used in this measurement.

Troubleshooting

10.3

(1) Motor operation does not change although orient command (M19,
M06, etc.) is given (orientation is impossible).

c
Cause
Orient command signal is not
given to the card.

Remedy
If LEDlldoes not light, signal is not
Remedy so that command
received.
signal is produced.

(2) When orient command signal is given, the motor continuously runs
at a-orient speed of about 200rpm.
Cause
1.

Pulse signal from the encoder is not output.

Remedy
When pulse is input, all LEDs 14 and
15 on the card light during rotation
of the spindle.

- 19 -

Note:

When speed amplifier gain control VRL+, VR5 or VR6 (VRll, VR12
for DL-SDZ) turns, be sure to make offset adjustment.

Orientation occurs in correct position, but IN-POSITION signsl

(5)

is not output...

,-

Remedy

Cause
Offset is out of adjust-

Perform offset adjustment.

ment.

(6)

When ATC arm clamps tool, In-position signal goes out causing
stop to the ATC action.

Cause

c
1.

Remedy

Because offset is out of

- Perform offset adjustment.

adjustment, position moves

when tool is clamped,
canceling IN-POSITION sig-

- Check if the ATC arm is displaced.

nal.
2.

Because orient position is

- Perform orient position adjustment.

out of adjustment, position

I-

moves when tool is clamped,

canceling IN-POSITION sig-

- Check if the spindle is distorted

by collet chuck at unclamping.

nal.

- 21 -

r,

DP
Eli

CONS-2

I_

- 24 -

f
P

D L - A E 3/4

_-