Bimba PCS Bedienungsanleitung

We make

things MOVE

Please read this manual carefully before implementing your

Pneumatic Control System.

Model PCS

Pneumatic Motion

Control System

User Manual

Model PCS

Pneumatic Motion Control System

GENERAL WARNINGS AND SAFETY GUIDELINES

Start by Reading These Important Safety Rules

This safety alert symbol means caution ― personal safety, property/ﬁxturing damage, or danger

from Electrical shock. Read instructions with this symbol Carefully.

Read all instructions carefully before installation.

Save this manual for future reference.

If actuator becomes jammed, disconnect all compressed air connections to the actuator before

attempting to release or remove jammed item.

This symbol represents boxes that contain helpful hints and recommendations.

This symbol represents boxes that contain important notes, reminders, and items that may need

special attention.

If full system pressure is applied with a large error signal present, the actuator will attempt to

instantaneously move to the command signal position. This could potentially cause physical harm or

damage to application tooling. Once system is installed, always ensure that the command signal and

feedback signal are equal at start up, or start system up at low pressure.

User Manual

Model PCS

Pneumatic Motion Control System

General Overview 4

Typical Applications 5

Glossary of Terms and Formulas 5

Installation Instructions 9

1. Install the Bimba Actuator 9

2. Mount the PCS 9

3. Make the Pneumatic Connections 9

4. Connect the Power Cable 11

5. Connect the Feedback Cable 12

6. Connect the Command Signal Cable 13

7. Perform the Following Step For Option N Only 14

8. Check All Electrical and Pneumatic Connections 14

9. Apply 24 VDC Power 14

10. Apply Pneumatic Pressure 15

11. Set the “Deadband” 15

12. Command the Bimba Actuator to its Zero Position 16

13. Preliminary “Zero” Adjustment 16

14. Preliminary “Span” Adjustment 18

15. Final “Zero” and “Span” Adjustment 19

16. “Decel” Range Adjustment 19

Application Example 21

Speciﬁcations 22

Application Sizing and Rules of Thumb 22

Troubleshooting 24

Frequently Asked Questions 32

Appendix A

PFC System Block Diagram 30

PFCN System Block Diagram 31

PTF System Block Diagram 32

Appendix B - PFC probe replacement instructions 33

Appendix C - PFCN Probe adjustment and replacement instructions 35

TABLE OF CONTENT

User Manual

Model PCS

Pneumatic Motion Control System

GENERAL OVERVIEW

The Bimba Pneumatic Control System (PCS) is a closed loop electronic controller with pneumatic valves that

can move the rod or shaft of a pneumatic position feedback actuator and hold it in any desired position with

accuracy and force. The PCS system is designed for series PFCN, PFCNL, PFC, and PFCL cylinders for linear

motion and the Position Feedback Pneu-Turn (PTF) for rotary motion. The PFC should be ordered with the -L

option, low friction seals, for the best positioning accuracy and smoothest operation. The standard PTF includes

low friction seals.

The standard PCS accepts a 0 to 10 VDC or 4 to 20mA analog command signal, jumper selectable (refer to the

illustration on page 11). The command signal defines the position the rod must move to. The rod stops when

the feedback voltage from the probe is equal to the command signal.

For example, if the application has a stroke of 10 inches and zero and span adjustments are set for zero to ten

inches as well, then a 1 volt change in the command voltage is equal to a 1 inch movement. Similarly, a change

in command signal of 0.005 of a volt equals a position change of 0.005 of an inch for the same 10 inch stroke

application. If the application has a stroke of 5 inches, a change of 1 volt in the command signal represents a

half inch movement. For rotary applications, the convention is similar. If the application has a rotation of 180

degrees, then a 1 volt change in the command signal is equal to 18 degrees of rotation.

The system utilizes the feedback from the actuator to close the control loop. The control loop compares the

0-10 VDC or 4-20mA input command signal to the feedback signal from the actuator. The difference between

the command and feedback is referred to as the error term. When the error term is zero, all valves close,

trapping air on both sides of the actuator piston. (The error term is considered to be zero when it is within

the deadband range. The deadband is defined in the Glossary of Terms section.) This holds the rod at its

commanded position. If a force attempts to move the rod or shaft out of the commanded position, the system

will react by increasing the restoring force to maintain position. Likewise, if the command signal changes, the

system will respond to make the feedback equal the command signal.

The actual accuracy/repeatability of the movements will depend on many factors, including

signal noise, load, velocity, supply pressure, supply voltage, and application friction. Refer to

the Application Sizing charts for detailed information regarding sizing and suggestions for your

application.

User Manual

Model PCS

Pneumatic Motion Control System

TYPICAL APPLICATIONS

The PCS system is ideal whenever increased flexibility and adaptability is needed in a process; for example, in

order to accommodate various size parts and assemblies, or to add control for improved consistency, quality,

and productivity. Typical applications are listed below.

Flow Gate

The PCS system can control the position of a flow gate, controlling the rate of product that flows to downstream

processes. The position of the gate can be changed to allow more or less product flow depending on the

requirements of the process. Sometimes this is controlled manually, resulting in wasted manpower and less

control.

Robotic End Effector

The PCS system can control the open position of an end effector for a robotic arm. If the robotic arm is picking

and placing differently sized products, the cycle rate can be increased if the open position is automatically

adjusted to be only slightly larger than the product itself, reducing the time it takes to grasp the product.

Exhaust Control

The PCS system can control the position of exhaust dampers used in process control systems for increased

control in plant emissions, smoke houses, and similar applications.

Labeling

The PCS system can position differently sized parts under a label applicator, allowing the labeling process to

continue without any down time for a setup change to adjust for product size.

Animatronics

The PCS system can produce lifelike movements of puppets and figures, such as those used in amusement

and entertainment industries. Using an industrial computer or PC, movements can be changed without a

hardware change, simplifying new shows and edits.

GLOSSARY OF TERMS AND FORMULAS

For clarity, please review the definitions below. Descriptions for linear motion actuators (PFCN, PFC, PFCNL,

PFCL) are often different from descriptions for rotary actuators (PTF).

ZERO (ZERO Position)

When the PFC rod is fully retracted or the PTF shaft is rotated fully counterclockwise (CCW), it will reach a

mechanical stop, due to either a mechanical limit in the application or the actuator’s end of stroke or rotation.

The PCS’ Zero adjustment allows you to adjust the position of the cylinder at 0 VDC control voltage input.

Adjustment range is from the fully retracted mechanical limit to approximately 50% of the full actuator stroke or

rotation. Refer to the installation section for a description of the adjustment procedure.

User Manual

Model PCS

Pneumatic Motion Control System

SPAN (Full Scale Position)

When the PFC rod is fully extended or the PTF shaft is rotated fully clockwise (CW), it will reach a mechanical

stop, due to either a mechanical limit in the application or the actuator’s end of stroke or rotation. The PCS’

Span adjustment allows you to adjust the position of the cylinder at 10 VDC control voltage input. Adjustment

range is from the fully extended mechanical limit to approximately 50% of the full actuator stroke or rotation.

Refer to the installation section for a description of the adjustment procedure.

MAIN CONTROL (Command or Input Signal)

The Main Control command signal is a variable analog signal, either 0-10 VDC or 4-20 mA depending on the

position of jumper JO2 (see the illustration on page 11 for instructions on setting jumpers). The command signal,

proportional to the displacement of the actuator, can be supplied by a PLC analog output card or any other low

noise signal source. The low end of the range affects the zero position of the actuator and the high end of the

range affects the full scale position of the actuator.

The command signal can be translated into actuator displacement with the following formula:

CS = (d * R / t ) + Z

where:

CS = the command signal required to achieve a desired position

d = the disdplacement the desired position is from the zero position

R= the full range of the command signal

t= full scale travel of the actuator (Note: for PTF rotary actuators with total rotation less than 180º,

always make t = 180)

Z= the command signal for the zero position

Example 1: A system uses a 0-10 volt command signal, “R” is 10 and “z” is 0. If a position of 2 inches is

desired from a 7 inch stroke cylinder, the required Command signal (CS) is ( 2 * 10 / 7 ) + 0 or 2.857 volts.

Example 2: A system uses a 4-20 mA command signal, “R” is 16 and “z” is 4. If a 30º position is desired from a

90º rotary actuator, the required Command signal (CS) is (30 * 16 / 180) + 4 or 6.67 mA.

The Zero and Span adjustments can be combined for a total adjustment window of only 50% of total

actuator travel, i.e., if the Zero Adjustment is adjusted out to 50% of actuator travel, then the Span

Adjustment cannot be adjusted lower than 100%. The eective travel of the actuator in this case

would be between 50 and 100%.

Special Note for PTF’s with less than 180 degrees of Travel:

Due to the 50% window limitation, the minimum eective electrical rotation for PTF’s is 180 degrees

of rotation. This is explained further in the PTF application example on Page 21.

User Manual

Model PCS

Pneumatic Motion Control System

FEEDBACK SIGNAL

The feedback signal is a voltage signal from the actuator that corresponds to the displacement or rotation of the

actuator. The feedback signal range is approximately 0 - 10 VDC.

DEADBAND

The Deadband is a bi-directional band, centered on the commanded position. Once the actuator is within this

zone, the error term will be considered zero and all valves will be closed. This deadband is measured in volts

and can be adjusted between 0.005 and 0.500 volts. This voltage can be translated to a deadband width with

the following formula:

w = 1/10V * t

where:

w= deadband width

V = voltage reading from the PC

t= full scale travel of the actuator (Note: for PTF rotary actuators with total rotation less than 180º,

always make t = 180)

The full deadband zone is the deadband width above and below the target position.

Example 1: If the deadband is set for 20mV (0.02 of a volt) for a 6 inch stroke cylinder, the width of the dead-

band zone will be 1/10 * 0.02 * 6 or ±0.012 of an inch.

Example 2: If the deadband is set for 20mV (0.02 of a volt) for a 180º actuator, the width of the deadband zone

will be 1/10 * 0.02 * 180 or ± 0.72º.

PTF Note:

The PTF has a ﬁxed electrical rotation span of 340 degrees. This will aect some of the following

adjustments and signals for PTF’s with full scale rotations of less than 180 degrees.

DECEL RANGE

Once the PCS receives a command signal to move the actuator rod or shaft to a new position, two of the

pneumatic valves are opened causing the actuator to move toward the desired position. The Decel Range is an

adjustable zone outside the Deadband in which the PCS control begins to slow (decelerate) the actuator rod.

The Decel Range enables the PCS system to accurately position the actuator inside the Deadband. The Decel

Range is measured in volts and can be adjusted between 0.5 and 13.5 volts. Optimal decel settings vary with

the load and application. However, 1.5 volts is a good default setting for PCS models 1, 2, and 3, and 9 to 11

volts usually works well for PCS models 5, 7, and 8.

User Manual

Model PCS

Pneumatic Motion Control System

The following formula will translate the voltage reading into the Decel Range.

DR = 0.01485 * V * t

where:

DR = decel range

V = voltage reading from the PCS

t= full scale travel of the actuator (Note: for PTF rotary actuators with total rotation less than 180º,

always make t = 180)

Example 1: If the Decel Range is set to 5 volts for an 8 inch stroke cylinder, then deceleration will occur for 0.60

inches (0.0149 * 5 * 8).

Example 2: If the Decel Range is set to 5 volts for a 180º rotary actuator, then deceleration will occur for 13.4º

(0.0149 * 5 * 180).

CURRENT POSITION

Current Position is a 0 to 10 volt output signal that mirrors the feedback signal from the actuator, fully scalable

with the Zero and Span adjustments. In other words, its output will always be 0 to 10 volts no matter how Zero

and Span are adjusted. It can be used to monitor the motion of the actuator and the output may be sent to a

calibrated display.

AT POSITION (@ POS)

At Position is a digital output signal that is normally open and switches to ground when the actuator is within the

Deadband zone. This signal is useful for utilizing a PLC I/O card to receive a signal indicating that the actuator is

within the Deadband zone, potentially eliminating the need for an analog input card.

REPEATABILITY AND STABILITY

It is important to understand the difference between repeatability and stability. A system is considered

repeatable if it comes to a stop inside the deadband zone. A system is considered stable if it comes to a stop

in the deadband zone time after time with no overshoot. There are different degrees of instability. The first is a

system that approaches the commanded position and overshoots it just a little and has to reverse itself before

settling to a stop in the deadband zone. This level of instability may be acceptable in many applications. The

worst type of instability is oscillation around the deadband zone, never settling to a stop. This level of instability

must always be resolved.

MOVEMENT DIRECTIONS

Movements of the actuator may be described as “Increasing” or “Decreasing.” An “Increasing” move is one that

moves toward the Full Scale Position. A

“Decreasing” move is one that moves toward the Zero position.

Be cautious when utilizing the @ POS signal. If there is overshoot in the application, the actuator may

momentarily go through the Deadband Zone, causing the @ POS signal to momentarily transition

back open, before ﬁnally stopping in the Deadband Zone.

User Manual

Model PCS

Pneumatic Motion Control System

INSTALLATION INSTRUCTIONS

Before installing your system, refer to the Application Sizing and Rules of Thumb section to ensure your system

is sized properly for your application. Use the following steps to successfully install and operate your PCS

system. There are a couple of application examples that follow this section which are helpful in gaining a full

understanding of the adjustments that will be made.

1. INSTALL THE BIMBA ACTUATOR

Install the actuator as you would any other actuator, ensuring that the feedback cable routes away in a careful

and protected manner.

2. MOUNT THE PCS

Select a mounting location for the PCS not more that 18 inches from the actuator if possible. Positioning

accuracy and efficiency improves when the PCS is mounted close to the actuator. Be sure to allow sufficient

room for both the pneumatic connections and the electrical connections on opposite sides of the PCS

enclosure. Drill four mounting holes (for up to 5/16 diameter mounting bolts) and secure the PCS in position by

the enclosure’s mounting flanges.

Option-N (No Enclosure)

If Option-N is specified, the PCS system will be shipped with the PCS printed circuit board, a snap track, a

valve manifold, and four 25 foot valve cables. The snap track allows for easy mounting inside a larger enclosure

box. Mount the snap track in the enclosure and snap the PC Board in place. Mount the valve manifold near the

actuator. Be careful to mount the manifold in a place where the valves will not be vulnerable to physical damage

3. MAKE THE PNEUMATIC CONNECTION

The supply air must be 70 to 80 psi. Air supply pressure affects system performance, not just force. Air must be

filtered to 5 microns and regulated, and the connections must be leak free. Leaks of any kind in the plumbing wil

cause the PCS to adjust to make up for this air loss, creating unnecessary wear on the valves and generating

chattering that might be interpreted as a malfunction. All of the pneumatic fittings, tubes, etc., must seal

perfectly. For a perfect seal, push-in fittings with O-rings inside perform well. If Teflon tape is employed, care

must be taken to ensure that loose pieces don’t get into the system. Liquid thread sealants must not be used;

they can attack the materials of the transducer. It is also important that tubing used between the PCS valve

manifold and the actuator does not expand with pressure. Volume changes, even though slight, will cause the

system to work harder. Metal tubing is the best, but nylon is also satisfactory. Do not use very soft, easy to

expand tubing like Tygon®.

!Pressures above 100 psi may damage the PCS control’s valves.

Pressures below 70 psi may result in erratic operaion.

User Manual

Model PCS

Pneumatic Motion Control System

The following table shows recommended tubing sizes. Oversized tubing will degrade positioning repeatability.

Air line connections are described in the illustrations below. Instructions follow. Also consult the Appendix for air

and electrical connections to PFCN, PFC, and PT.

BORE SIZE

PFC PTF TUBING SIZE

1-1/16” (09) 5/64" 5/32” OD

1-1/2” (17) 1-1/2” (098/196) 5/32” OD

2” (31) 2” (247/494) 1/4” OD

Air hose connections for enclosed controls PCS models 1, 2, 3

Air hose connections for enclosed controls PCS models 5, 7, 8

Air hose connections for option N PCS

controls (without enclosures)

>Connect the 70 -80 psi supply air to the center port of the valve manifold.

>Connect the valve manifold retract port (the port directly to the left of the center port when the manifold is

facing you) to the rod end of the cylinder.

>For PTF rotary actuators, connect this to the port on Body “A” for single rack models (left side when the

PTF shaft is facing toward you), or connect to bodies “A” and “D” for double rack models (lower left and

upper right when the PTF shaft is facing toward you).

>Connect the extend port (the port directly to the right of the center port when the manifold is facing you) to

the cap end of the PFC cylinder.

>For PTF rotary actuators, connect this to the port on Body “B” for single rack models (right side when the

shaft is facing toward you), or connect to bodies “B” and “C” for double rack models (upper left and lower

right when the shaft is facing toward you).

Do not turn the air supply on at this time.

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