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Rockwell Automation MagneMotion QuickStick HT User Manual

Rockwell Automation MagneMotion QuickStick HT
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Design Guidelines
Transport System Design
QuickStick HT User Manual 97
Rockwell Automation Publication MMI-UM007F-EN-P - September 2020
Track_location
Purpose
Identifies the motor position in the specified path. Switches are represented as two motors.
The motors in a Diverge Node are always the first motors on each path and the motors in a
Merge Node are always the last motors on each path.
Syntax
<Track_location>Location</Track_location>
Attributes
None
Parent Tag
<Motor>
Contents
Location – The location is identified as PnMn. Where Pn is the path number and Mn is the
location of the motor in the path.
Validation
Node controller requirements for startup and initialization:
Must not contain any child tags.
Must not contain a value that is equal to another <Track_location> tag.
Example
Motor:
<!-- PATH 3 -->
<Track_location>P3M2</Track_location>
Switch (Diverge), straight section of switch determines the path that switch is identified on:
<!-- PATH 2 -->
<Track_location>P2M1</Track_location>
<Track_location>P3M1</Track_location>
Switch (Merge), straight section of switch determines the path that switch is identified on:
<!-- PATH 2 -->
<Track_location>P2M3</Track_location>
<Track_location>P3M5</Track_location>

Table of Contents

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Rockwell Automation MagneMotion QuickStick HT Specifications

General IconGeneral
BrandRockwell Automation
ModelMagneMotion QuickStick HT
CategoryAccessories
LanguageEnglish

Summary

Introduction

Overview

Provides an overview of the QuickStick HT components and their use in a transport system.

QuickStick HT Transport System Overview

Details the QuickStick HT transport system, its components, and key capabilities.

QSHT Transport System Components

Identifies the main components of the QSHT transport system and their functions.

Transport System Software Overview

Describes the software applications used for configuring, testing, and administering the system.

Getting Started with the QuickStick HT Transport System

Provides a guide for installing and servicing the QuickStick HT components.

Safety Guidelines

Overview

Describes safety guidelines for QuickStick HT components and their use in a transport system.

Regulatory Compliance

Covers CE and UL compliance, and other regulatory information for system components.

Agency Compliance

Details CE mark requirements and regulations for systems installed within the European Union.

Equipment Regulatory Guidelines

Provides guidelines related to the use and service of QSHT components in a transport system.

Safety Considerations

Covers personnel and equipment safety, and hazardous points within the QuickStick HT transport system.

Mechanical Hazards

Details hazards related to moving parts, pinch points, and physical forces within the system.

Electrical Hazards

Identifies shock hazards, equipment damage risks, and proper grounding requirements.

Magnetic Hazards

Addresses risks associated with strong Neodymium Iron Boron magnets used in the system.

Handling Magnet Arrays

Provides specific guidelines for safely handling NdFeB magnet arrays.

Shipping Magnet Arrays

Specifies regulations for shipping magnet arrays according to DOT and IATA.

Recycling and Disposal Information

Provides guidelines for the proper disposal and recycling of system components.

Design Guidelines

Overview

Provides guidelines for designing a QuickStick HT transport system.

Transport System Layout

Defines the layout of motors, drives, paths, nodes, and connections for the transport system.

Motors, Motor Drives, Switches, and Vehicles

Illustrates the layout of key transport system components and their relationships.

Paths

Defines the routes for vehicle motion, including motors and node connections.

Nodes

Defines path beginnings, ends, and connections between paths, including node types.

Node Controllers

Details the types of node controllers and their communication connections.

Additional Connections

Defines remaining components like power supplies, network switches, and I/O.

Power Supplies

Describes power supply requirements for different motor families and configurations.

Network Switches

Explains Ethernet switches for communication routing between system components.

Transport System Design

Covers basic considerations for designing the track system, including guideway and motor mounting.

Motors

Provides guidelines for mounting and orienting QuickStick HT motors.

Motor Drives

Describes the function of QSMC Motor Controllers and QSHT 5700 Inverters.

Electrical Wiring

Details wiring QSHT motors using QSMC controllers and QSHT 5700 inverters.

Ethernet Motor Communication Recommendations

Provides recommendations for Ethernet addressing, topology, and network design.

Ethernet Motor Connection Examples

Illustrates various Ethernet wiring topologies for connecting motors.

Magnet Arrays

Describes the high flux magnet array, its characteristics, and physical properties.

Vehicles

Details vehicle design guidelines, material considerations, and configurations.

Vehicle Gap

Specifies the distance between the magnet array and the QSHT motor.

Mounting Magnet Arrays to Vehicles

Provides guidance on attaching magnet arrays to vehicles using locating features and hardware.

Guideways

Covers guideway design, support materials, and basic design guidelines.

Motor Mounts

Provides guidelines for designing motor mounts to interface with motor mounting features.

Motor Mounting Methods

Details methods for attaching motors to tracks or mounting plates, including bracket use.

Guideway Examples

Illustrates examples of guideway and vehicle configurations.

Transport System Configuration

Covers configurations for straight, curve, switch, and moving path layouts.

Specifications and Site Requirements

Overview

Describes specifications for QuickStick HT components and installation requirements.

Mechanical Specifications

Provides dimensions, exposed materials, and IP ratings for system components.

1 Meter Motor

Details mechanical specifications, exposed materials, and IP rating for the 1 meter motor.

1/2 Meter Motor

Provides mechanical specifications, exposed materials, and IP rating for the 1/2 meter motor.

1/2 Meter Double-wide Motor

Details mechanical specifications, exposed materials, and IP rating for the 1/2 meter double-wide motor.

QSMC Motor Controller

Provides mechanical specifications, exposed materials, and IP rating for the QSMC motor controller.

QSMC-2 Motor Controller

Details mechanical specifications, exposed materials, and IP rating for the QSMC-2 motor controller.

QSMC Rack Mounting Bracket

Describes the rack mounting bracket for QSMC motor controllers in a 19-inch rack.

QuickStick HT 5700 Inverter

Provides mechanical specifications, exposed materials, and IP rating for the QSHT 5700 inverter.

Magnet Array, High Flux

Details mechanical specifications, weights, and exposed materials for high flux magnet arrays.

Electrical Specifications

Covers motor connections, pinouts, power requirements, and wiring specifications.

Motors (Stators)

Details electrical specifications, connector types, and pinouts for motors.

Site Requirements

Specifies environmental conditions, lighting, floor space, facilities, and service access.

Environment

Defines operating and storage temperature and humidity requirements for components.

Lighting, Site

Notes that no special lighting is required for system operation.

Floor Space and Loading

Specifies minimum space requirements for installation, operation, and service.

Facilities

Outlines user responsibilities for providing electrical power and connections for system operation.

Service Access

Describes typical service space requirements for motors, drives, and node controllers.

Installation

Overview

Provides installation procedures for various QuickStick HT component configurations.

Unpacking and Inspection

Details steps for unpacking, inspecting, and verifying system components against shipping documents.

Transport System Installation

Covers proper location, leveling, securing, and installing the transport system.

Installing Hardware

Provides instructions for installing motors on user-supplied supports and making adjustments.

Required Tools and Materials

Lists tools and materials needed for installation procedures, including wrenches and levels.

Installation Overview

Provides a sequence for installing QuickStick HT motors and QSHT components.

System Installation

Covers guideway assembly, leveling the transport system, and securing the track.

Installing Electronics

Details mounting of motor drives, node controllers, network switches, and power supplies.

Installing QSMC Motor Controller Power Cables

Describes connecting HVDC and LVDC power cables to QSMC motor controllers.

Installing QSHT 5700 Inverter Power Cables

Details connecting DC-bus power cables to QSHT 5700 inverters.

Magnet Array Installation

Provides guidelines for attaching magnet arrays to vehicles, including single and multiple arrays.

Installing Vehicles

Describes how to add or remove vehicles from the transport system after installation.

Facilities Connections

Covers electrical power and communication connections to external facilities.

Network Connections

Details Ethernet network connections to node controllers and switches.

Electrical Connections

Describes electrical power connections for system operation, including AC and DC power.

E-stop Circuit

Explains connecting digital I/O for an E-stop circuit, including user-supplied components.

Interlock Circuit

Details connecting digital I/O for interlock circuits, requiring user-supplied power.

Light Stack Circuit

Describes connecting digital I/O for light stack circuits for system status indication.

General Purpose Digital I/O

Covers monitoring and controlling digital inputs and outputs for host controller interaction.

Software

Covers software overview, configuration, and installation for the transport system.

Software Overview

Describes software components, images, and their installation requirements.

Software Configuration

Guides creating and uploading the Node Controller Configuration File for system definition.

Node Controller Software Installation

Details uploading node controller image and configuration files via web interface.

Motor Software Installation

Covers programming motors using MICS files and ERF Image files for QSHT 5700 inverters.

Check-out and Power-up

Covers system check-out, mechanical, facility, and pre-operation checks before power-up.

System Check-out

Details pre-power-up checks for operating and safety features, and component installation.

System Power-up

Describes the procedure for initial installation power-up and system grounding.

Operation

Overview

Provides an overview of QSHT transport system operation for normal and emergency conditions.

Theory of Operation

Explains LSM technology, system advantages, motion control, and motor topology.

Motor Topology

Describes how QuickStick HT motors are constructed as discrete blocks of coils.

Motor Operation

Details how QuickStick HT motors provide asynchronous control of vehicles.

Motor Cogging

Explains cogging forces in BPM and linear motors and methods to minimize them.

Motor Blocks

Defines a motor block as a discrete motor primary section with independently controlled coils.

Block Acquisition

Describes how the drive takes ownership of vehicles as they enter the motor.

Block Ownership

Explains vehicle ownership of motor blocks and minimum separation distances.

Block Release

Details how drives release block ownership once the vehicle exits the block.

Anti-Collision

Covers how block allocation prevents vehicle collisions by allowing one vehicle per block.

Safe Stopping Distance

Ensures vehicles maintain a safe stopping distance (brick-wall headway) using motion profiles.

Thrust Limitations

Discusses limitations on acceleration rate, deceleration capability, and motor thrust.

In Queue

Describes vehicle queuing, obstructions, and jam conditions.

Vehicle Length Through Curves and Switches

Addresses defining vehicle length for collision avoidance in curved sections.

Locating Vehicles During Startup

Explains how node controllers locate and assign IDs to vehicles during system startup.

Moving Vehicles by Hand

Provides guidelines and precautions for manually moving vehicles using QSHT motors.

Electrical System

Discusses voltage fluctuations, power regeneration, and power management within motors.

Power Regenerated by a Vehicle

Explains how mechanical energy converts to electrical energy during braking and deceleration.

Power Management Within the Motor

Covers methods of internally consuming regenerated power within QSHT motors.

Power-Related Warnings and Faults when using QSMC Motor Controllers

Details voltage-related warnings and faults for QSMC controllers and their causes.

Soft Start

Explains the soft start circuit, resistor, and power cycle timing requirements.

Block Level Power Management

Describes dissipating unused power through motor blocks when propulsion bus voltage is high.

Power-Related Warnings and Faults when using QSHT 5700 Inverters

Details voltage-related warnings and faults for QSHT 5700 inverters.

Power-Related Fault Resolution

Provides possible solutions to mitigate power-related errors and faults.

Hardware Overcurrent Warning

Addresses warnings for phase or input current exceeding ±25 A limits.

Hardware Overcurrent Fault

Details faults that occur when overcurrent warnings fail to clear, requiring inverter reset.

Controls and Indicators

Describes controls and indicators for monitoring system status, setting parameters, and troubleshooting.

Track Display

Explains the NCHost Graphics Window for real-time transport system monitoring.

E-stops

Details connecting and operating E-stop circuits for halting motion in emergencies.

Interlocks

Describes connecting and operating interlock circuits for halting motion temporarily.

Light Stacks

Covers connecting and configuring light stacks for system status indication.

FastStop

Explains the FastStop command for immediate vehicle deceleration and motion suspension.

Digital I/O

Covers monitoring and controlling digital inputs and outputs for host controller interaction.

Software Status Indicators

Describes status messages and fault data returned by QSHT drivers.

Transport System Simulation

Covers simulating system configuration, vehicle motion, and operational differences.

Configuring a Simulation

Details steps to configure a node controller for simulation mode and upload files.

Running a Simulation

Explains how to run a simulation and highlights differences from physical operation.

Stopping a Simulation

Provides steps to suspend motion and reset a simulation.

Return the System to Normal Operation

Guides configuring the node controller back to Normal Mode from simulation.

Transport System Operation

Covers system power-up, normal running, and shutdown procedures.

Power-up

Describes applying power and initial system startup procedures.

Normal Running

Details host controller management of the QuickStick HT transport system during normal operation.

Shut-down

Provides a procedure for orderly power removal and component shutdown.

QSHT 5700 Inverter Safe Torque-off Function

Overview

Provides an overview of the safe torque-off (STO) functionality built into the QSHT 5700 Inverter.

Introduction

Details STO requirements, certification, safety considerations, and stop category definitions.

Important Safety Considerations

Lists user responsibilities for system validation, risk assessment, and proof testing.

Stop Category Definition

Defines Stop Category 0 for immediate removal of force-producing power to the actuator.

Performance Level (PL) and Safety Integrity Level (SIL)

Explains PL and SIL ratings for safety-related control systems and component requirements.

Average Frequency of a Dangerous Failure

Relates SIL value for safety-related functions to the probability of dangerous failure per hour (PFH).

Safe Torque-off Feature

Describes the STO design, its protection capabilities, and correct application.

Safe Torque-off Status

Describes safety-related status data available to the host controller via UDT tags.

Hardwired Safe Torque-off

Introduces the hardwired STO feature, its requirements, and operational description.

Description of Operation

Explains how STO turns off output-power transistors for a Category 0 Stop and response time.

Safe Torque-off Connector Data

Provides pinouts and descriptions for the 16-pin Safe Torque-off (STO) connector.

Wire the Safe Torque-off Circuit

Provides guidelines for wiring STO connections to the QSHT 5700 inverter.

Safe Torque-off Wiring Requirements

Details wiring requirements, wire size, strip length, and torque for the STO connector.

Safe Torque-off Feature Bypass

Explains how to bypass the STO circuitry using jumper wires if the feature is not required.

Cascade the Safe Torque-off Signal

Describes wiring for cascading STO signals between multiple QSHT 5700 inverters.

Hardwired Safe Torque-off Electrical Specifications

Provides electrical specifications for the hardwired STO feature, including input parameters.

Maintenance

Overview

Provides maintenance schedules and procedures for QuickStick HT components and QSHT transport system.

Preventive Maintenance

Details preventive maintenance schedules for cleaning, inspections, and log file transfers.

Cleaning

Describes general cleaning procedures for transport system surfaces and components.

Wear Surface Maintenance

Covers rotating vehicles to ensure even wear on wheels, especially for unidirectional motion.

Cable Connection Inspection

Details verifying cable connector seating, security, and cable routing for continuity.

Hardware Inspection

Covers checking motor, stand, mount, and guideway hardware security and vehicle grounding.

Transfer Log Files

Explains how to review and transfer log files from node controllers and HLC for troubleshooting.

Cleaning Magnet Arrays

Provides procedures for cleaning magnet arrays to remove ferrous particles and debris.

Troubleshooting

Describes common difficulties and provides direction for problem determination and resolution.

Initial Troubleshooting

Covers initial problem determination and directs users to specific troubleshooting sections.

Power-Related Troubleshooting

Details troubleshooting steps for power-related problems with system components.

Node Controller Troubleshooting

Covers determination of problems within node controllers, such as clock issues.

Communication Troubleshooting

Determines communication-related problems between system components and the host controller.

Motion Control Troubleshooting

Covers determination of motion-related problems, including vehicle movement and noise.

Light Stack Troubleshooting

Determines problems related to the function of the light stack indicators.

QSHT 5700 Inverter Fault Troubleshooting

Provides detailed descriptions and solutions for QSHT safety faults identified via MMI tags.

Contact ICT Customer Support

Provides information and required details for contacting ICT Support Specialists.

Repair

Covers procedures for component repair, replacement, and ordering parts.

Replacing Motors

Details procedures for removing and installing QuickStick HT motors.

Replacing Motor Drives

Provides steps for removing and installing motor drives (QSMC and QSHT 5700).

Programming Motors

Explains how to program motors using ERF Image and MICS files.

Separating Magnet Arrays

Provides guidelines for safely separating stuck magnet arrays.

Cleaning or Replacing the Motor Controller Fan Filter

Details cleaning or replacing the fan filter in QSMC motor controllers.

Ordering Parts

Provides contact information for ordering new or replacement parts from ICT Sales.

Shipping

Provides procedures for handling and packaging QuickStick HT components for shipment.

Packing Procedure

Details the correct method for handling and packaging components for shipment.

Appendix

Overview

Provides information related to interconnect diagrams, design calculations, file maintenance, and limits.

Interconnect Diagrams

Provides wiring examples and system block diagrams for QSHT 5700 inverter and Kinetix power supply.

Interconnect Diagram Notes

Provides notes applicable to wiring examples for the QSHT drive system.

Power Wiring Examples

Illustrates DC-bus power supply configurations for QSHT 5700 inverters.

Data for Transport System Design Calculations

Provides tables and curves for determining thrust, vehicle gap, and magnet array size.

Thrust Force Data

Shows available thrust for QSHT motors at different vehicle gaps and magnet array cycles.

Attractive Force Data

Provides data on attractive force between QSHT motors and magnet arrays based on vehicle gap.

File Maintenance

Recommends regular backups of files and procedures for creating and restoring backup files.

Additional Documentation

References Release Notes and Upgrade Procedures for software.

Transport System Limits

Lists system limits for motors, nodes, paths, stations, and vehicles.

Glossary

Lists terms and definitions used in the manual and for the transport system components.

Index

Provides a cross-reference to manual content organized by subject.

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