4d ship simulator user guide rev1.0(20130225)
TRANSCRIPT
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4D SHIP SIMULATOR
4D SHIP SIMULATORMaintenance Manual
Document No. : CJI-201302-001-4DSSSRevision : 1.0
Date : Feburary 25, 2013
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Table of Contents
Shooting Simulator................................................................................................................................................................................. 3
I. Configuration ................................................................................................................................................................................ 3
II. Connection with the remote computer via UDP ....................................................................................................... 7
III. Library Installation .................................................................................................................................................................. 9
Edge Blending for Projectors .........................................................................................................................................................11
I. Connect to device ....................................................................................................................................................................11
II. Timing and blend-width setting.......................................................................................................................................12
III. Edge-blend parameters setting ......................................................................................................................................13
IV. Keystone settings..................................................................................................................................................................15
V. Curved screen settings ........................................................................................................................................................17
VI. Color correction and pure white correction ...........................................................................................................17
VII. Black level setting ...............................................................................................................................................................19
VIII. Warp table load ....................................................................................................................................................................20
6-axis Driving Device ...........................................................................................................................................................................21
I. Outline ............................................................................................................................................................................................21
II. Product Configuration Details .........................................................................................................................................23
III. Equipment Inspection and Maintenance ..................................................................................................................46
1. Servo Motor........................................................................................................................................................................46
2. Servo Driver........................................................................................................................................................................48
3. Cylinder Assembly ( Servo Motor, etc ) ...................................................................................................................49
4. Other Inspection and Measures .................................................................................................................................51
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Shooting Simulator
I. Configuration
1. Camera Tab
1) Basic UI
- Screen Calibration : Calibration button for the screen
- Laser Threshold
Reference value of the laser detection.Change the value when the laser detection is not good.
Click Apply button to save the reference value.
- 1 Gun Range : Display X and Y coordicate of the Gun number 1 on triggering.
- 2 Gun Range : Display X and Y coordicate of the Gun number 2 on triggering.
- 1 Gun Track : The trace of Gun number 1
- 2 Gun Track : The trace of Gun number 2
- Capture FPS : Capture frame cycle of the cameras. (Standard : 20)
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2) Screen Calibration Mode
- Screen Calibration
Click the Camera 1 or Camera 2 then it split the screen as the picture.
Check the 4 corners of the screen and click the screen for making the corner point.
Click Save Calibration for saving the calibrated corners.
Caution
Before finishing the calibration, dont change the camera bay click the camera tab.
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2. Controller Tab
Controller Tab is for setting the communication with digital gun controller and the camera
- Connect Status
Display the status of the connection
Input : The status of the input control signal(Open, Close)
Camera : The status of the camera control signal(Open, Close)
Boat : Information from the boat, wheel, remote controller(speed and direction control
lever. Open, Close)
Effect : Special effectors for making the environment(wind, light, etc. Open, Close)
- Connect Port : Setting the connection ports
Input : Com 4
Camera : Com 3
Boat : Com 7
Effect : Com 6
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3. UDP Tab
- Address : Setting the address of the server.
When it is used in one computer, use localhost or 127.0.0.1
- Port : Setting the port of the connected server, 27015 default
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II. Connection with the remote computer via UDP
1. Connect two computers via Hub(residential gateway)
1) Connect the host computer and the client computer to the hub using UDP cable
2) Host computer : the computer who runs the main program
Client computer : the computer who runs the Camera3x.exe program
2. Check the IP address of the host computer
1) Check the IP address in the control page of the hub(open 192.168.0.1)
2) If the IP address of the host computer is 192.168.0.6(Kong-PC of the picture), change
the IP address of the UDP tab and click Apply.
3) After changing the Address of the UDP tab, restart the Camera3x.exe again.
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III. Library Installation
Caution
DO NOT DELETE any file on the main computer.
Some programs need to get the license code again after re-installation.
1. Install the Matrox Mil Lite 9.0.
2. Select the Solios driver on installation.
3. Reboot after the installation.
4. Run Windows Start Button(Start) -> All Program -> Matrox Imaging ->Tools ->
MilConfig.
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5. Select General -> Default Values.
6. Digitizer for current default system
A. Format(DCF) : Select the DCF file(hr50c.dcf).
7. Image
B. Select Band Monochrome(1 Band).
C. Fill the image size 640, 495.
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Edge Blending for Projectors
I. Connect to device
Connect Mviewer device to PC with DVI cable and Serial cable, insert CD, run the
software and a dialogue appears.
Click "OK" to enter the main interface:
If the main interface doesnt appear, right click my PC to open the hardware
manager of PC, select the correct COM port, and click Detect device for PC to detect
Mviewer device and connect to it. After around 10 to 20 seconds, a dialog-box pops up
notifies the device is detected as connected to 3 projectors and connection to PC through
COM port. Also the internal modules for Mviewer MPG203 and projectors is listed.
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MP103 at com1, connected to projector 1, 2 and 3 through 3 units of MG210 If the 30
seconds reading fails to find the device, another notice pops to say no Mviewer device
detected In this case, check the connection between PC and MPG20X and check if
MPG20X is powered on already.
II. Timing and blend-width setting
Afterconnection, click Input Timing to unfold the resolution list, choose one according to
your projectors native resolution. Then enter the screen width and height. Normally, you
can enter the width and height in millimeter, or if you know the ratio, enter the pixels for
width and lines for height. For 3 projectors edge-blending, there are 2 edge-blending
zones, so please also enter the width for BlendWidth0 and BlendWidth1 accordingly. Click
set Timing, the following diagram shows a resolution of 2560x768 , 3x1024x768 edge-
blending with two overlap region all at 256 pixels.
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After setting the total result resolution and blend width, restart your PC and invoke the
NVIDIA/ATI control panel to choose the newly added resolution from list.
III. Edge-blend parameters setting
There are two tabs in the software available for blending effect settings. The first is the
blend set tab and the second is the MG200 blend set tab. The Blend set tab sets the
edge-blending in the MP103 module. The MG200 blend set sets the edge-blending in the
MG200 modules that are connected to MP103s outputs. It is recommended to set the
MP103s edge-blending parameters to bypass mode, and set the MG200s parameters
which is more flexible and fast.
1. Edge-blend parameters setting in MP103
Click blend set tab to set alpha, P, gamma parameters of each blend zone. Select blend1
and blend2 for setting, the blend1 means the overlap zone between left projector and the
center projector, the blend2 means the overlap zone between center projector and right
projector.
Fill the parameters of Alpha/P/Gamma to adjust the effect. Normally, alpha is 0.5, P is 2
and Gamma is 2 to 2.4. The larger the alpha, the brighter the center of blending zone.
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Click test to check the effect; repeat testing until the effect is the best and Click update
to store the parameters. To bypass the MP103s edge -blending feature, set the alpha to 1
and P/Gamma to 0.
2. Edge-blend parameters setting in MG210
Click the MG200 Blend set tab to enter into the edge-blending setting using MG210
modules as Figure 3 on page 9 shows.
In Figure, following operations can be done for each MG210 (Each Projector):
- Enable / disable the MG210 blend, by check / uncheck theMG200 Blend Enable
check box.
- Set the edge-blending parameters for 3 projectors separately by adjusting the
alpha/P/Gamma parameters.
- Set the blend parameters for white level and non-white level. White level can be
defined by user. It is the R/G/B threshold value that defines white. Set to 255 means not
use white level. Set to, say 240, means that all R/G/B value larger than 240 will be treated
as white level, and MG210 will choose the white level blend curve for those pixels in doingblending.
- Set the four corners blending of projector. For horizontal blending, the right blend of
first projector, the left and right for second projector and the left blend of third
projector should be enabled. The blend width can be set in the edit-box.
- Test the edge-blending effect, and fix the parameters into MG210 by click update
button.
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Figure. Edge-blending setting with MG210
IV. Keystone settings
Click "keystone set" Tab to enter into Keystone adjustment for geometry distortion. Click
the "Read device Para" button to get the output resolution and four vertices coordinates of
the projected image appear to be seen.
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The gray part is the projected shape onto a flat screen. We can adjust the quadrilateral
coordinates of the vertices, as in Figure below:
Generally speaking, projectors cant be accurately positioned right opposite the screen, so
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the gray part must be treated with deviation in consideration. When the left of the projected
image is too big and goes outside the screen, adjust the
left upper and left lower coordinates to pull in the gray part. Click Test to apply the
keystone adjustment. If the current resolution is not correct, click reset to get the right
resolution.
V. Curved screen settings
For curved, spherical or cylinder screen, pincushion correction is needed. Click pincusion
tab to enter Pincushion Setting interface as below.
You can set or drag the coordinates of 9-point grid show in the figure to change the
projected image shape, by click the test button. After the settings, click update button to
fix the parameters into MG210.
VI. Color correction and pure white correction
The color correction and pure white correction cannot be used together. If select to do
color correction first, then do white correction, this may overwrite the color correction result,
and vice versa.
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1. Color correction
9 segments of color region, for each R/G/B component, are adjustable. Use one projector
as reference, and adjust another projectors color for each segment / components, click
Test button to show that color to the screen and compare to adjust and match them.
2. Pure white correction
Pure white correction:
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Use one projectors white level as reference, select another projector for adjustment.
When doing adjustment, select one segment for both projector, for example the seg8,
which is the most brighter white level, and fill the values for separated R\G\B value, click
Test button, the MG210 will output a white level according to the parameters set,
compare the level with the reference projectors and adjust accordingly.
VII. Black level setting
In dark scene, although digitally the R/G/B values send to projector are 0, the projector will
still generate a certain brightness to the screen, this is so-called light-leakage due to the
light-path of the projector is not 100% shut-off. The effect to the edge-blending is that the
overlap region will be brighter than the non-overlap region. To overcome this issue, the
edge-blender provides a mechanism of boosting the brightness level of non-blending zone
and blending zone in black scene. This is by defining the black level of non-blending area
and blend-area. If the source brightness level less than the defined level, the blender will
boost the level to the defined level, thus the non-blend zone could be brighter and possibly
compensates the light leak effect. However, due to the non-linearity of projectors light
leakage effect, this could never been perfectly solved. The best solution is to use
projectors with less light leakage.
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Blackness level: enter a number from 0-255 for the level defined as black; normally it
should be less than 100. Light leak width: 0 is invalid here.
VIII. Warp table load
This is advanced functions for geometry correction that is more flexible than pincushion.
Image processing and form load are to be adjusted by a professional mechanic or done
with their help. Dont try adjusting without professional guide at hand.
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6-axis Driving Device
I. Outline
1. Purpose
This User Manual is for the 6-axis Driving Device for the 4D Ship Simulator, and describes the system
construction, specification for main parts, operation and main maintenance procedure.
2. Concept of Composition
This system is composed of hardware such as cylinder assembly, control assembly and software for
operating hardware. Driving computer in the control assembly is linked with user host computer via Ethernet
based network, it get the control command from the host computer and drives 6 electric cylinder assembly
and generates 6 DOF(Degree of Freedom) motion. This 6 DOF motion makes the user(passenger) to feel
the movement.
A. System
1) Hardware
Name Description Unit Qty Remark
6-axis Driving
Device
Cylinder Assembly, Operating, Linear SET 6
Hinge Block Assembly, Upper part SET 3
Hinge Block Assembly, Lower part SET 3Controller Assembly, Driving SET 1
Cable Assembly LOT 1
2) Software
Name Description Unit Qty Remark
Driving Program SmartCue6015.exe LOT 1 Operation Program
B. Main Part List
No. Part Number Description Manufacturer Unit Qty Rem.1 KL1224GEA Pilot Lamp KACON EA 6
2 KF-15A1(include 5A fuse) Fuse Socket KACON EA 1
3 K22-27G-RFON Switch(lighting type,
green)KACON EA 1
4 K22-27G-RFOFF Switch(lighting type,
red)KACON EA 1
5 UF12AM23-H Fan Fulltech EA 2
6 PRW12-2DN2Proximity Switch (B
contact)Autonics EA 12
7 AHN22324 Relay SamwonACT EA 10
8 VG3102 24-22P(3102 VG Connector Daehyun EA 1
http://endic.naver.com/enkrEntry.nhn?entryId=7e5c2c411f154d90962bf86601fea1e1&query=%EA%B7%BC%EC%A0%91%EC%8A%A4%EC%9C%84%EC%B9%98http://endic.naver.com/enkrEntry.nhn?entryId=7e5c2c411f154d90962bf86601fea1e1&query=%EA%B7%BC%EC%A0%91%EC%8A%A4%EC%9C%84%EC%B9%98 -
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Type) Corporation
9VG3102 20-3P(3102
Type)VG Connector
Daehyun
CorporationEA 1
10 AMP 206430-1 AMP Connector AMP EA 1
11AX60551WB, PEAK-
872VL2Bare bone Case Yoi System SET 1
12 CSDP-20BX2 Servo Driver 2KW Rockwell Samsung SET 6
13 RSMH-20BA1ATK3 Servo Motor 2kW 220V Rockwell Samsung SET 6
14 MMC-BDPV81PNA MMC Board Rockwell Samsung EA 1
15 MMC-LM11 LIMIT Board Rockwell Samsung EA 1
16 MMC-IN11 INPUT Board Rockwell Samsung EA 1
17 MMC-OU11 OUTPUT Board Rockwell Samsung EA 1
18 MMC-CA20LIMIT,I/O Internal
Connection BoardRockwell Samsung EA 1
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II. Product Configuration Details
1. System Composition
A. Hardware/Software Link Structure
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B. 6-axis Driving Device Configuration and Specification
6-axis Driving Device Configuration
6-axis Driving Device Specification
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Driving Device Specification of Motion Platform
Name Dimension Description
Minimum Height 1,056mm Minimum height of Driving Device
Moving Reference Height 1,300mm Neutral height of Driving DeviceMaximum Height 1,544mm Maximum height of Driving Device
Upper Plate Radius 700mmFrom the center of the upper plate to the center of
the upper joint
Lower Plate Radius 1,100mmFrom the center of the lower part of motion platform
to the center of the lower joint
Upper Joint Angle 20 degAngle between two joints near the center of the
upper plate
Lower Joint Angle 14 degAngle between two joints near the center of the
lower part
Performance and other specification of Motion Platform
Displacement Speed Acceleration
Surge -356/362 mm 600 mm/s > 0.6 g
Sway -324/324 mm 540 mm/s > 0.6 g
Heave -244/244 mm 400 mm/s > 0.6 g
Roll -20/20 deg 33 deg/s >200 deg /s2
Pitch -20/20 deg 33 deg/s >200 deg /s2
Yaw -26/26 deg 43 deg/s >200 deg /s2
Payload
Operation Payload 1,500 kgf
Momentary Maximum Payload 3,500 kgf
Power Consumption
Power Requirement 3 phase 220VAC, 50/60Hz
Consumption Average 6kW, Peak 15kW
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2. Hardware
Configuration and Functions of the Hardware
Part Description RemarkCylinder Assembly, Operating,
Linear
Composed of 6 Cylinders. Each cylinder has electric
servo motor for realizing the 6 DOF motion
Hinge Block Assembly, Upper part Supporting the upper 6 cylinder assembly
Hinge Block Assembly, Lower part Supporting the lower 6 cylinder assembly
Controller Assembly, Driving Control the 6 cylinder assembly
Cable Assembly Interface the electric signals between cylinder assembly
and the controller assembly
A. Cylinder Assembly
This cylinder assembly uses ball screw type brush-less AC servo motor with good performance and highmaintainability. And the design is for high safety and reliability, it is simple to install and easy to maintain in
comparison with the hydraulic or pneumatic type.
Specification of the Cylinder Assembly
Name Description Remark
Length 1.144mm(the shortest distance between the upper hinge joint and the
lower hinge joint
Stroke 400mm(the maximum length of piston operation
Maximum Speed 333 mm/s
Rated (Max.) Thrust 600(1,700) kgf (maximum thrust 0.2 sec)
Ball screw Lead 10 mm
Weight 60 kg(for each cylinder assembly, including servo motor)
Driving Motor
Coupling Housing
Cylinder/Piston
Upper Hinge JointUp/down Limit Sensor &
Air Outlet
Lower Hinge Joint
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Servo Motor Configuration and Torque
Specification of the Servo Motor
Name Description Remark
Model Name RSMH-20BA1ATK3
Rated Power 2 kW
Rated Torque 9.55 Nm
Max. Torque 28.5 Nm
Rated Rotation Speed 2,000 RPM
Max. Rotation Speed 3,000 RPM
Rated/Max. Current 12.3/51.9 Amp
Rated Voltage 220VAC 3 PHASE
Brake O
Brake Control DC 24 V
Brake Pull Time 160 ms
Brake Release Time 75 ms
Brake Rated Current 1.287 A
Weight 19.5 Kg
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B. Cylinder Assembly Connection Part (Hinge Blocks)
This connection part attached the upper/lower part of the cylinder assembly, realize the smoothing
movement and proper angle, and provide the stability of the system.
Cylinder Assembly Connection Part (Lower) Cylinder Assembly Connection Part (Upper)
C. Cable Assembly
Cable Assembly is composed of the interface cable between the driving controller and cylinder assembly,
main/sub power supply, LAN, KVM(keyboard, Video, Mouse), and emergency stop cable.
Cable Connection Diagram
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D. Controller Assembly
Controller assembly makes the 6 DOF movements using 6 electric actuators, it receives the control
commands from the host computer linked with Ethernet based network.
Controller Assembly
Power control and status indicator assembly : check the power control status
Circuit breaker : break the main power and the motor power Driving control computer : control the servo driver using embedded motion control board
External interface assembly : interface between external servo motors and controller
Servo driver assembly : control servo motors using the signal from the driving control computer
Top
FrontRight
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1) Power Control and Status Display Assembly
Motor Power : Using the push switch with signal light, check the ON/OFF status of the motor power
Operation : Check the 1~6 axis motion operating status
Power Control and Status Display Assembly
2) Circuit Breaker
Circuit breaker : break the main power and the motor power
Circuit breaker
Motor Power ON(220VAC 3 Phase)
Motor Power OFF
(220VAC 3 Phase)
1~6 axis operating status(When operation, green
light on)
Control Power Breaker(Computer & Servo Control
Power,220VAC Single Phase)
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3) External Interface Assembly
A. Emergency Stop Input : the emergency stop signal input
B. KVM : KVM signal output
C. LAN : Ethernet communication port
D. Upper Limit Sensor : Upper limit sensor input of 1~6 axis actuator
E. Lower Limit Sensor : Lower limit sensor input of 1~6 axis actuator
F. Control Power Input : Computer & Controller power input (220VAC Single Phase)
G. Motor Encoder : Motor encoder signal input
H. Motor Power Input : Motor power input(220VAC 3 Phase)
I. Motor Power : Motor power output
External Interface Assembly
A
B
C
D E
F
G
H
I
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4) Controller Assembly Internals
Controller Assembly Internals
A. Servo Driver, 6 sets
Servo Driver
RegenerativeBrake Resistor
Brake RelayServo Driver Fuse
Input Module
Output ModuleElectric Outlet
Fan
Interface TerminalBlock
DC Power Supply
Limit module Driving ControlComputer
KVM Extender
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Specification of the Servo Driver(CSDP-20BX2)
Name Description Remark
Main Supply Voltage 3-phase 200 to 230V, 5%, 50/60 Hz
Control Voltage Single Phase 200 to 230V, 5%, 50/60 HzEncoder Type 2500 P/R, 9-wire type Inc.
Output Signal Type Differential Line Driver Output
Control Method PWM Control by IPM
Speed Control Range Internal Speed command 5,000
Output Voltage 200Vrms
Rated Output Current 13Arms
Peak Output Current 39Arms
Rated Input Current 10.3Arms
Speed Response Frequency 400Hz
Speed/Torque Command Input Signal 0~10 V DC, Can be controlled by parameter
Ambient Temperature in Operation 0 to 55C/
Ambient Humidity in Operation 90% RH or less
Ambient Temperature in Storage -25 to 80C
Ambient Humidity in Storage 90% RH or less
Weight 4.6kg
(1) Regenerative Brake Resistor 6 sets : consume the regenerative power when brake the motor
(2) Brake Relay 9 sets : brake for prevent the vertical falling
(3) Fan 2 sets : internal circulation
(4) Interface Terminal Block 15 sets
(5) Fuse 1 set : protect the sequence circuit
(6) Input Module 1 set : input data gathering device(emergency switch, main power status)
(7) Output Module 1 set : control signals for the device from the computer(motor brake, main power
on/off)
(8) Limit Module 1 set : actuator(1~6 axis), upper/lower sensor input
(9) Electric Outlet 1 set : external power output(computer, KVM extender)
(10) Driving Control Computer 1 set
Driving Control Computer
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Specification of the Driving Control Computer
(11) KVM Extender 1 set : external monitor, keyboard, mouse connection
(12) DC Power Supply 1 set : power supply for the motor brake
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3. Software
A. User Interface(GUI)
Motion Control Software Main Window
Composition of the control button
Number Description Remark
1 Title
2 Lamp of the system status
3 Operation mode selection radio button
4 System time information
5 Sub menu window activation push button
6 System monitoring sub menu window7 System operation information
8 System control button
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4. Motion Platform Start-up Process
Caution!
Before operating the motion platform, please keep people away from the motion platform.
For the abnormal operation of the motion platform, keep the emergency stop switch at hand when
operation the motion platform.
Check Power On status of the motion driving control computer, control box and servo driver again.
Double-click the SmartCUE6015" icon to run the motion control software.
After running the software, check the followings,- System Status : check the limit is ON
- System Operation Information : Check the message as the picture
Before the operation of the motion platform, test the communication between the motion computer and
the other controllers.
At first, click the NEUTRAL button.
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If the communication is normal, the CL(mm) value of the each 6 actuator increases together in
actuator status and,
In the system status, MOV light on.
After reaching to the neutral position, the following messages come out.
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5. Motion Platform Operation Process
Caution!
Before operating the motion platform, please keep people away from the motion platform.
For the abnormal operation of the motion platform, keep the emergency stop switch at hand when
operation the motion platform.
In the Sinusoid Motion mode, the motion platform plays the damping motion with the programmed
motion data.
A. Replay Motion
Replay operation mode is drive the motion platform using preset motion data file.
Follow the procedure,
Run the motion system and move to the NEUTRAL position.
Click the Replay button in the Operation mode selection radio button.
In the pop-up file selection window, select the file to load and click the Open(O) button.
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If the loading file is normal, the following message will pop-up, then click the Check button.
Click RUN button to start the motion.
When operation, the system status and replay information can be check the following GUI window,
- System Status Lamp
MOV. lamp flicker on and off.
- System Monitoring Information
The file name in operation, progress and frame information can be checked
File name Progress bar for checking Frame/Total Frame
After playing, the system moves to the NEUTRAL position. To stop when playing, press STOP
button of the system control button, then the system stop the playing and move to the NEUTRAL
position.
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B. Sinusoid Motion
Sinusoid motion waveform
Sinusoid operation mode is driving the motion platform according to the sinusoidal parameter
input(amplitude, frequency) by the user.
Follow the procedure,
Run the motion system and move to the NEUTRAL position.
Click the Sinusoid button in the Operation mode selection radio button.
In the pop-up parameter input window, fill up the amplitude, frequency value and the running time.
Click APPLY button to set the sinusoid mode data.
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If the input data exceed the normal range, the following error message comes out, on click Check
button, the input data will be reset.
Enter the digit from 0 to 320.
If the input data in the normal range by the step 4 , click the EXIT button to return to the main
window.
Click RUN button to start the motion.
When operation, the system status and replay information can be check the following GUI window,
- System Status Lamp
MOV. lamp flicker on and off.
- Actuator Status
Actuator Status window displays the length, error, motor speed and otherstatus information.
Select the display item Activate the motion data recording Display pause and resume
- Motion Command/Feedback
Motion Command/Feedback window displays the position or the angle of each DOF.
Graph Display
Status of
Servo Amp.
Status of
Limit Sensor
Control Len th
Feedback Length
Length Control Error
Total Deviation
Motor Speed
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After playing, the system moves to the NEUTRAL position. To stop when playing, press STOP
button of the system control button, then the system stop the playing and move to the NEUTRAL
position.
Control commandInfo.
Feedback info.
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6. Motion Platform Shutdown Process
Caution!
Before operating the motion platform, please keep people away from the motion platform.
For the abnormal operation of the motion platform, keep the emergency stop switch at hand when
operation the motion platform.
Motion should be in the NEUTRAL position.
Click the Bottom button in the System control button.
On click the Bottom button, the actuators start to fall down. The actuators reach the lower limit, the
motion platform turned to bottom status and stop. At that time, tick sound occurs and it is the brake
operation sound of the motors.
On the normal bottom status, check the following status,
- System Status Lamp
Check the Limit : ON status.
- System Operation Information
Check the messages as the picture.
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Click the Exit button in the System control button or Click the right click at MCM Tray of the system
tray and click the Exit button to end the software.
Push the Motor power OFF button to disconnect the servo driver power.
Push the motion driving control computer power button to shut down the computer.
Motor Power ON(220VAC 3 Phase)
Motor Power OFF(220VAC 3 Phase)
1~6 axis operating status(When operation, green
light on)
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7. Shape
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III. Equipment Inspection and Maintenance
Caution!
Servo driver is very dangerous because it has the high-voltage terminal. DO NOT TOUCH the terminal
of the servo driver.(Electric Shock)
For a while after power off, the internal circuits is kept charged at higher voltage. Inspections should be
done a while (about 10 minutes)
Only the trained engineer can do the maintenance, inspection and parts replacement. In addition,
before working, remove all the metallic items (watch, rings, etc.).
Do not disassemble, repair, or alter the device arbitrarily. It can cause fire, electric shock or injury.
1. Servo Motor
Inspection and maintenance should be done according to the following table. However, do not
disassemble the motor.
Never contact the servo motor with water directly.
Servo motors can be operated normally less than 90% of relative humidity. High humidity can affect the
performance of servo motors.
Servo motors can be operated normally less than 40 of temperature. Do not apply shock to servo motors. Especially, the encoder on the servo motor is very sensitive to the
vibration and the shock and can be damaged by the shock.
Servo Motor Check
Inspection Item Cycle Description Remark
Vibration and Noise Everyday Adjust it to not be bigger than usual occasions. Abnormal
Foreign BodiesInstantly
when foundVacuum clean.
Insulation resistance1 Year Checking with the insulation resistance
measuring instrument. It should be higher than
500V 10M.
Contact thecompany if it is
lower than 10M
Oil Seal 5,000 Hours Replace with a new oil seal.
Overall Inspection 2,000 Hours Check with the manufacturer.
Disassembly and
worn-out part
replacement
In the event of disassemble the servo motor for repair or inspection, a care shall be taken for A/S not
available.
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Servo Motor Error Cause and Inspection/Action
Error Cause Inspection Action
The motor
does not run
Motor error
Measure the resistance
between U - V, U - W, V W.
Replace the motor if they are
unbalanced.
Overload No load test.
Reduce the load or replace the
motor with the higher capacity
motor.
Loosened connections
Check if the U/V/W connector
pins are firmly secured with
screws.
Loosened pins should be fixed
firmly. Replace the damaged
parts.
Wiring errorCheck the wirings are made
correctly.
Refer the System Configuration
and Wiring
Motor is
overheated
The ambient
temperature is high.
Lower the ambient
temperature(under 40C)Keep the proper temperature.
Overload No load test.Reduce the load or replace themotor with the higher capacity
motor.
Foreign BodiesCheck foreign bodies on the
motor surface.Clean the surface.
Abnormal
sound and/or
vibration.
Loosened connections
Check if the U/V/W connector
pins are firmly secured with
screws.
Loosened pins should be fixed
firmly. Replace the damaged
parts.
Mechanical installation
condition is bad.
Loosened for mismatched
coupling.
Confirm the installation
condition (coupling, nut
tightening) and adjust.
Motor bearingOperate the motor without loadin order to check the sound and
vibration near the bearing.
Replace the motor and operate
it to do the same checks.
Mechanical noise and
vibration of the load
Check the mechanical part of
the load if it has been damaged.
Contact the manufacturer of the
mechanical part of the load.
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2. Servo Driver
The servo drive has an embedded electronic circuit. Dust and other foreign bodies may cause malfunction.
Please keep the system cleaned and serviced periodically.(1 Year)
Never disassemble the servo driver.
Never contact the servo motor with water directly.
Servo motors can be operated normally less than 90% of relative humidity. High humidity can affect the
performance of servo motors.
Servo motors can be operated normally less than 55 of temperature. Do not apply shock to servo motors.
Refer the attached CSDP Plus Servo Drive User Manual for the further inspection and maintenance.
Servo Driver Check
Inspection Item Cycle Description Remark
Main Body 1 YearRemove the dust and grease with compressed
air and cloth.
Socket, Connector,
Screw1 Year Tighten.
Circuit Board 1 YearContact the company in the case of
discoloration, breakage or a broken wire.
Servo Driver Part Replacement Cycle(20 hours running a day)Item Cycle Remark
Capacitor 3 Year
Cable 3 Year(Traveling Cable)
Power Element 3 Year
Regenerative Brake Resistor 2 Year
Dynamic Brake Resistor 2 Year
Fan 2 Year
Cooling Fan 4~5 Year
Fuse 10 Year
In the event of disassemble the servo driver for repair or inspection, a care shall be taken for A/S not
available.
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3. Cylinder Assembly ( Servo Motor, etc )
Check the cylinder assembly before operating and driving of the motion platform always. Check the
coupling status of each mechanical part and the lubrication condition.
Grease Feeding Point of the Cylinder Assembly
DO NOT USE WD40 or similar with WD40 instead of grease. It can damage the cylinder assembly
inside. USE ONLY Grease (At least every 3 month).
Coupling Housing
Air Outlet
End point of theCylinder
Lower Hinge Block
(Inside the Cover)
Upper Hinge Block(Inside the Cover)
End point of theCylinder
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Cylinder Assembly Check List
No. ItemResult Cycle
RemarkNormal Bad Daily Weekly Cycle
1The upper limit switch is working correctly.
(The operation of the lever on stopping)O
2The lower limit switch is working correctly.
(The operation of the lever on stopping)O
3The coating of the wire of limit switch is
normal.O
4 The bolt for securing the limit is fastened. O
5 The cable of servo motor is connected exactly. O
6 All of the hinge caps are fixed exactly. O
7 Air outlet is not blocked by contaminants. O
8 Lock-nut for fix the cylinder and the bearinghousing is fastened.
O
9Coupling bolt for securing the motor shaft and
the ball screw is fastened.O 3 month
10Coupling bolt for securing the bearing housing
and the coupling housing is fastened.O
11Bolt for securing the motor post and the
coupling housing is fastened.O
12Bolt for securing the upper and lower joint
block is fastened.O
13Anchor bolt for lower frame of the motion
platform is fastened. O 6 month
14After motion operation, it does not generator
higher heat than usual.O 3 month
15In motion operation, it does not make the
louder noise than usual.O 3 month
16 Joint block rotation is smooth. O 3 month
17 Joint block axis rotation is smooth. O 3 month
Note
Inspection should be done just before the operation or driving of the motion platform or weekly.
Coupling bolts of every part of the motion platform should be inspected every day.
They are can be loosen because of the vibration of the motion platform.
Inspect the anchoring status of the lower frame of the motion platform before the operation or driving,
and fasten if it is loosened.
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4. Other Inspection and Measures
Other Inspection and Measures
Inspection Item Cycle Description Remark
Cable Connection Every time
Check the cable connection with the
motor power, encoder, and limit
sensor.
Foreign bodies on the
equipment and the room
Instantly when
foundVacuum clean.
Lubricant 3 Month USE Grease ONLYDO NOT USE
WD40
Overall 6 Month -