VRP 500

Rotary Knife Profiler

Application Specification

2121 South Bridge Street

1000 New Ulm, MN 56073
455233-95G Telephone: 507-354-1616
©MTS Systems Corporation 2000 Fax: 507-354-1611
VRP 500 ROTARY KNIFE PROFILER
APPLICATION SPECIFICATION

Overview
The custom machine (Figure 1) consists of a web feed rotary knife
controlled by an MTS Automation control system. The web is transported
by pull rollers driven by a variable speed motor. The pull rollers act as the
reference axis for the control system. The rotary knife accelerates and
decelerates as the reference accelerates and decelerates.

The control system consists of a VRP 500 digital servo controller with
custom firmware to provide for the control of a single axis.

The servo axis operates the rotary knife in ratio mode to the web. The
knife makes a cut at relative speed (overspeed) to the web. After the knife
has cleared the web it rotates around in time for the next cut. After an
operator-selected number of cuts (COUNT) have been made Output 1 will
come on and stay on for 250 ms. During operation the operator can make
incremental changes to the part length (trim) and COUNT.

The machine designer specifies machine parameters and enters them

into the VRP 500 via a custom SETUP [MACHINE] screen. The operator
enters product parameters via a new PRODUCT mode. After all the
parameters are entered, profile 0 of the VRP 500 can be calculated for
controlling the knife by pressing the CALC function key.

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Hardware Description
The control unit consists of a VRP 500 with custom firmware for
calculation of profiles and a COUNT output. Programmable limit switch 1
is designated as the COUNT output.

The machine reference is provided by an encoder (absolute or

incremental) driven by the pull rollers. It is necessary that this signal
provides an accurate and constant representation of material speed.

Count VRP 500

Output Follower

Command

Reference
Enable

E
M
Master
Encoder Rotary
Knife
E

Web

Pull
Rollers

Elevator

Figure 1

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Description of Operation
Profile Calculation

The machine designer enters the following machine parameters into the
VRP 500, while the RUN line is off, through the custom SETUP
[MACHINE] screen:

• maximum knife speed in scaled units per second

• maximum knife acceleration in scaled units per second per second
• knife radius in scaled units
• maximum part length in scaled units
• minimum part length in scaled units
• maximum cycle rate in parts per minute
• maximum web speed in scaled units per second
• percent of knife cycle at overspeed
• maximum trim in scaled units
• trim step size in scaled units
• knife offset in scaled units
• reference acceleration increment in milliseconds
• number of knives per revolution of cutter head

The operator enters the following product parameters into the VRP 500,
while the RUN line is off, through the custom PRODUCT mode:

• part length in scaled units

• overspeed as a percent of web speed
• cycle rate in parts per minute
• COUNT in units.

After all the parameters (product and machine) have been entered, the
operator presses the CALC function key; profile 0 is calculated, the home
position is calculated, and the COUNT register is reset to zero. The CALC
function is active from both the PRODUCT screen and the SETUP
[MACHINE] screen. If there is no solution for the parameters that have
been entered, an error message is displayed; DATA ERROR n. Appendix
A describes the error messages.

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Motion Profiles

The motion profile has the following profile segments: a cutting segment,
a non-cutting constant velocity (relative to the reference) segment, and
the transitional segments between the cutting and non-cutting segments.
The knife always travels one cycle per part. (This means that the number
of knives per revolution is identical to the number of cycles per revolution.)
The reference travels the part length ± trim units per part. The cutting
segment is defined by the product parameter, overspeed (cutting speed),
machine parameter, and percent of knife cycle at overspeed. The non-
cutting constant velocity portion is the segment that is altered by the trim
adjustment. The transitional segments are constant acceleration
segments (relative to the reference). The acceleration used to make these
transitions is the maximum acceleration of the machine when the web is
running at maximum web speed. See Figure 2 below.

Cutting Period

Time

1 Rev

Reference Position

Figure 2

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Home Position
The home position of the follower is automatically calculated and
displayed in the SETUP [FOLLOWER] menu. This position is defined as
the point in the follower cycle where the knife is in the cut position. Once
calculated, this parameter should not be changed (if it is changed, the cut
will not be positioned correctly in the cycle).

The knife offset position must be entered to compensate for the distance
between the knife cut position and the follower home sensor position. If
the home sensor is before the cut, this offset should be a negative value.
If the home sensor is after the cut, this offset should be a positive value.
Once set correctly, any changes in product or profile will automatically be
calculated to ensure that the knife cuts at the correct point in the profile.

On Power-Up

The accumulated COUNT register is set to zero. The new custom mode
PRODUCT will be the first screen visible on power-up. All other operations
of the VRP 500 at power-up are the same as the standard VRP 100.

Removal of Run Controller Input

If the knife axis is moving, it decelerates to a stop using the rate defined
by ALIGN ACC. The accumulated COUNT register is not reset. All other
operations of the VRP 500 at power-up are the same as the standard
VRP 100.

After an Emergency Stop (any controller fault)

The accumulated COUNT register is reset to zero. All other actions are
the same as the standard VRP 100.

Select Profile 1 to 3

The accumulated COUNT register is reset to zero (whether or not the

selected profile is run). All other actions are the same as the standard
VRP 100.

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Operator Interface
Parameter Entry

Machine and product parameters are entered into the VRP 500 via the
numeric keypad. For example, to enter machine setup parameters, press
the mode key until the SETUP mode is on the screen. Then press the
arrow keys until the SETUP [MACHINE] screen is present and press the
EDIT key. Press the function keys NEXT and PREV until the desired
machine parameter is displayed. Key in a new value and press ENTER.
This saves the new value.

If you attempt to enter a parameter value that is outside the specified

range, the controller will enter the nearest maximum or minimum value
instead. The precision of any custom parameter is limited to six
significant digits.

In new controllers, custom parameters are initialized to zero, except for

the following parameters:

• percent overspeed, which is initialized to 100%

• reference acceleration increment, which is initialized
to 2 milliseconds
• number of knives per revolution, which is initialized
to 1

After these values are entered, they are saved in non-volatile-memory and
remain even if power is removed. If there is a version or parameter
checksum fault, the custom parameters will be reset to zero, except for:

• percent overspeed, reset to 100%

• reference acceleration increment, reset to 2 milliseconds
• number of knives per revolution, reset to 1

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Machine Parameters

MACHINE MACHINE MACHINE

MAX KNIFE VEL MIN PART LENGTH MAXIMUM TRIM
(xxx.xxx)rev/sec (xxx.xxx)in (xxx.xxx)in
CALC PREV NEXT CALC PREV NEXT CALC PREV NEXT

MACHINE MACHINE MACHINE

MAX KNIFE ACC MAX CYCLE RATE TRIM STEP SIZE
(xxx.xxx)rev/s^2 (xxx.xxx)prt/min (xxx.xxx)in
CALC PREV NEXT CALC PREV NEXT CALC PREV NEXT

MACHINE MACHINE MACHINE

KNIFE RADIUS MAX WEB SPEED CUT % OF CYCLE
(xxx.xxx)in (xxx.xxx)in/sec (xxx.xxx)%
CALC PREV NEXT CALC PREV NEXT CALC PREV NEXT

MACHINE MACHINE MACHINE

MAX PART LENGTH KNIFE OFFSET # OF KNIVES
(xxx.xxx)in (xxx.xxx)rev (x)/rev
CALC PREV NEXT CALC PREV NEXT CALC PREV NEXT

MACHINE
REF ACEL INCR
(xxx)msec
CALC PREV NEXT

The machine parameters are entered into a sub-screen of SETUP called

MACHINE. These parameters (maximum knife speed, maximum knife
acceleration, maximum cycle rate, percent of knife cycle at overspeed,
maximum trim, trim step size, knife radius, maximum part length,
minimum part length, maximum web speed, knife offset, reference
acceleration increment, and number of knives) are located in the setup
mode so that access can be limited using the access input. During
operation, with the RUN line active, access to the MACHINE screen will
be denied regardless of the state of the access input. The RUN line must
be off and the profile must be recalculated before new values will be
incorporated into the profiles.

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Product Parameters

PRODUCT PRODUCT
PART LENGTH CYCLE RATE
(xxxx.xx)in (xxx.xxx)prt/min
SAVE CALC NEXT SAVE CALC NEXT

PRODUCT PRODUCT
OVERSPEED COUNT
(xxx.xxx)% [xxxxx]
SAVE CALC NEXT SAVE CALC NEXT

The product parameters are entered into the custom mode called
PRODUCT. These parameters are overspeed, part length, cycle rate, and
COUNT. During operation, the part length can be incrementally adjusted
using the arrow keys on the controller keypad. The size of the increment
is defined in the SETUP [MACHINE] screen. If the length is incremented
to the maximum trim limit, further attempts to increment the trim will be
ignored.

Changes in length beyond the trim limit must be made by stopping the
machine and entering a new product length through the PRODUCT
screen. The profile must then be calculated using the CALC function
before the change has an effect on the product length. This is the same
procedure that must be followed to make changes to the overspeed and
cycle rate limit.

If the operator runs the machine at a cycle rate higher than the value that
was entered into the PRODUCT mode CYCLE RATE, the controller will
attempt to accelerate the knife motor at rate higher than the maximum
knife acceleration that was entered as a machine parameter. The
maximum velocity of the knife may also be exceeded in this case. MTS
Automation cannot guarantee what will result in this case. The effect will
depend on what happens to the specific machine and motor when the
motor is commanded to accelerate faster than the machine/motor
specification. Possible results include: the parts will not be of the proper
length, the knife motor will overheat, or the knife motor will shut down. If
the knife is actually capable of the resulting acceleration and velocity,
there will be no effect.

The COUNT can be changed while running. The new value will take effect
before 2 complete cycles. A cycle is defined as making COUNT cuts. The
maximum count is 32,767.

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Documentation
The following sources are available:

• Motion Plus™ VRP 100 Digital Controller User’s Manual

(Part Number 117649-00)
• This Application Specification (Part Number 455233-95)

Miscellaneous
Unless otherwise specified, the operation/performance of the custom VRP
500 controller is limited to the performance of the standard VRP 100.

How to Order
Part Number 462576-05

Includes VRP Controller, custom firmware, VRP 500 label, and User’s
Manual.

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APPENDIX A. DATA ERROR
MESSAGES

The recommendations for clearing data errors are based on the

mathematical relationships used to calculate profiles. Some of the
recommended methods may not be practical in every case. For example,
recommendation 4 of DATA ERROR 4 suggests increasing the radius of
the knife. If the actual knife radius cannot be increased, this is not a
possible resolution for that DATA ERROR. The recommendations for
clearing the data errors involve changing parameters that appear in the
PRODUCT mode or the SETUP [MACHINE] mode. Since access can be
denied to the SETUP mode, some potential solutions are reserved for the
machine designer. In all cases a combination of the recommendations
can be used. There is no significance to the order of the
recommendations. Those implemented through the PRODUCT mode are
marked with an asterisk (*).

DATA ERROR 1

Trim size error.

1. Maximum trim size is larger than the minimum part length. Increase
the minimum part length or decrease the maximum trim adjustment.
2. Maximum trim size is less than the trim step size. Either increase the
maximum trim size or decrease the trim step size.

DATA ERROR 2

Part length is outside of part length limits.

1. Change the part length.*

2. Change the part length minimum limit or maximum limits.

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DATA ERROR 3

One or more machine or product parameters are set to zero.

1. Length = 0 [scaled units]*

2. Percent overspeed = 0*
3. Cycle rate = 0 [parts / minute]*
4. Knife radius = 0 [scaled units]
5. Maximum cycle rate = 0 [part/unit time]
6. Maximum web speed = 0 [scaled units/ unit time]
7. Maximum knife velocity = 0 [scaled units/unit time]
8. Maximum knife acceleration = 0 [scaled units/unit time^2]

DATA ERROR 4

The requested setup would require the velocity during the cut portion of
the cycle to exceed the maximum velocity of the knife.

1. Decrease the percent overspeed.*

2. Decrease the speed of the web. The speed of the web is limited to the
maximum speed of the web or the product of cycle rate and product
length whichever is lower.*
3. Increase the maximum velocity of the knife.
4. Increase the radius of the knife.

DATA ERROR 5

Solution not valid (decelerating to make cut).

1. Decrease the speed of the web. The speed of the web is limited to; the
maximum speed of the web, or the product of the cycle rate and
product length, whichever is lower.*
2. Increase the percent overspeed.*
3. Increase the length of the part.*
4. Decrease the maximum trim length.
5. Decrease the percent of cycle at matched speed.

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DATA ERROR 6

Solution not valid (accelerating to make cut).

1. Decrease the speed of the web. The speed of the web is limited to; the
maximum speed of the web, or the product of the cycle rate and
product length, whichever is lower.*
2. Decrease the percent overspeed.*
3. Increase the length of the part.*
4. Decrease the maximum trim length.
5. Decrease the percent of cycle at matched speed.

DATA ERROR 7

Velocity of knife during the non-cutting portion of the cycle is greater than
the maximum knife velocity.

1. Increase the percent overspeed. *

2. Increase the length of the part.*
3. Decrease the speed of the web. The speed of the web is limited to; the
maximum speed of the web, or the product of the cycle rate and
product length, whichever is lower.*
4. Decrease the percent of cycle at overspeed.
5. Increase the velocity of the knife.
6. Increase the acceleration of the knife.
7. Decrease the maximum part trim length.

DATA ERROR 8

Out of profile memory space.

1. Delete one or more profiles other than profile 0.

2. Delete one or more points for any profiles.
3. Increase maximum acceleration of the knife.
4. Increase reference acceleration increment time.

* Changed in PRODUCT mode.

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