Setting up the HSI card is easy. Here we have a new project and we are online with the controller.
STEP1: Auto-discover the Hardware – click on Hardware Configuration, then read the configuration. Remember, you have to be in STOP mode to read the configuration. The software is now going to tell us all the new modules it found- we know that so we’ll just say YES to all. We now have a fully populated system with a local base and a remote base with our HSI and HSO cards.
STEP2: Configure the HSI module. Double click on the HSI Module, Give it a name – how about “HSI Demo.” We have out tooth counting prox sensor connected to channel 2A – let’s make a note of that. And our Index Proximity sensor is connected to 2Z - Index Prox. Note that you can’t use 2B for counting pulses. It is strictly used for direction like when we use encoders, for example. We’re not going to use direction in this example so it is ok to just leave it blank and unconnected.
We also want to use Output2 to drive our strobe light, so let’s call it “Prox Strobe.”
We’re not using Channel 1 yet, the encoder is connected to that one, so let’s go straight to Channel 2. The software is telling me I defined some new tags and is asking me if I want to create them. Sure. I really like that it does that for me so I don’t have to fool with it later.
Let’s name this channel “Tooth Counter.” And since we want to count teeth – let’s change our units to “Teeth” and we’ll get one pulse per tooth, so we don’t need to change that Even though that didn’t change anything, the cool part is now all of our units going forward will be in “teeth!” I love that feature – it makes things so much easier. Plus it is really going to help us in our second example when we use the encoder.
Our current position is really a count of the teeth, so we’ll call that “Tooth Count”-note the units are all setup for us - and our velocity will be “Tooth Velocity” again the units are all setup. Finally “Tooth Status” is our status.
We are counting pulses (this isn’t an encoder), so we want to make sure pulse and direction are selected.
And we are done! So all we did was name the channel, change our units, define some tags, and make sure we are counting some pulses.
Hit OK. Let the Productivity 3000 create the TAGs for us. And close the hardware dialog.
Well, that’s all there is to setting up the HSI.
Step 3: It’s time to use it! Let’s bring up a registration instruction from our high speed instruction palette here. Right there – I’m going to drop him on rung 1. And fill in the blanks.
We want our tooth counter channel. We’ll use trigger group 1. We want to trigger everything on that index proximity sensor. Rising Edge is fine.
Since each index hit is one rotation of the sprocket, we’ll create a sprocket count TAG that will keep track of the number of rotations of that sprocket. When we see that index hole, we are going to delay that registration by the number in this TAG. Note that our custom units are in place already.
Then after that delay, we want to pulse our strobe light, let’s say for 1 millisecond.
Let’s do one more thing – let’s create a tooth progress – that will tell us whether the process is enabled or not. And let’s go ahead and create a tooth status – so if we get any errors we’ll know immediately. That’s all we need for now.
We chose the correct channel, we’re triggering on the proximity index sensor, we’re keeping track of how many hits we get, we’re going to delay the registration action by the number in this TAG, and after we do the delay, we are going to pulse our LED strobe.
We’ll say OK. We’ll add the new TAGs to our database. And all we have to do now is enable our instruction.
I’ve already added a normally open contact here which is connected to switch 16 on my input simulator. That way I reach over to the P3 and enable this instruction manually.
Let’s transfer that to the controller. And we are ready to go.
Before we get started, let’s do one more thing. I’m going to go back into this instruction, and say monitor. That’s going to create a Dataview for me that is going to monitor all of those TAGs we created.
Let’s bring up the Dataview so we can see all of those TAGs. Now we know we can’t have a delay of zero, I’m going to put in a delay of 30 teeth. Write that out.
I’m going to reach down and flip switch 16 on my input simulator. And now I see my instruction is running because my In Progress flag went to a 1.
I’m going to reach over with my hand and move the sprocket. And sure enough, I can see the registration input toggle and my sprocket count is increasing as I rotate the sprocket.
Let’s go ahead and fire up the VFD. And I’ll bring our strobe light up, and sure enough we can see the little smiley face frozen in time.
If I change the tooth delay, to let’s say, 24 and I write that out. Then Boom, instantly the smiley face moves and we are now monitoring a different tooth in the process.
So remember what’s happening here. The index hole was detected by this prox sensor. But then the registration activity was delayed by in his case – 24 teeth. And we are now seeing that index hole rotated all the way around over here with this green strobe light. And note that this is completely independent of motor speed. If I reach down and change the speed, we can see that smiley face stays right there.
The best part is, even though all of this is going on, the Productivity3000 CPU doesn’t have to worry about keeping up with all of this registration and counting and velocity stuff – the values are just sitting there ready for it to use however it wants just like any other TAG in the system. Even if it is happening on a remote base like we have here. That’s really cool because you don’t have to go fetch the data or manipulate it or anything. It’s just sitting there ready to use.
Could we have done the same thing using the encoder instead of the prox sensor? Sure! Check out Part 3 to see the exact same example but using an encoder instead of the Prox sensors to do the sensing.
Be sure to check out the other videos in this series for more ways to get up and running quickly with this controller. And as always, please send us any comments you may have, we appreciate the feedback.
Performance plus Value … That's Productivity.