Motion control in a PLC

Omron has launched the MC402 servo motion controller, which mounts onto the backplane of its C200H PLC range.

Omron has launched the MC402 servo motion controller, which mounts onto the backplane of its C200H PLC range.

This ensured rapid and robust communications between motion controller and PLC, simplifies systems integration for busy OEMs, and reduces panel space requirements.

The MC402, a standard sized card able to control up four axes of motion, is programmed using a dedicated PC package based on Basic and then runs as a standalone unit.

To aid set up it is multitasking, allowing complex motion profiles to be developed in small, simple, independent parts, which are then automatically integrated through shared data and hardware.

With this set up Omron is offering users the best of both worlds: the power of a dedicated motion controller, coupled with the PLC's abilities to handle large amounts of I/O, to network and interface and to run other complementary functions such as temperature control.

"We have created in effect a top-flight motion controller with virtually infinite I/O, that is easy to build into a system and has state of the art HMI," enthuses Robert Brooks, Omron's motion control marketing manager.

"All the strengths of the two technologies have been captured, and all their weakness designed out.

"Bus communications over the backplane are hundreds of times faster than over a standard serial link, which brings data reading and reaction times into the real time environment." Current status can be displayed through the PLC, either as motion control parameters (speed, position, following error, etc), or as process information such as registration compliance or production rate.

The data can also be fed through to other processors and/or controllers, and the motion controller can monitor external data sources for real time tuning to changing conditions.

As well as developing advanced technology, the MC402 designers were briefed to address real-world criteria, such as the need for saving space in control panels and ensuring ease of use.

Their solution is a fraction the size of a conventional standalone four-axis controller; in effect it takes up no panel room at all as it resides inside the PLC.

The wiring required for the MC402 is far less than that for separate PLC and motion controller, reducing the time to completion and the likelihood of installation errors.

The MC402 has 16 input and eight outputs, all 24V opto-isolated digital formats, while the internal motion controller can provide linear, circular and helical interpolations, cam profiles, speed and accel/decel control, electronic gearing and auto-registration.

"The MC402 is so fully featured that it can provide a solution to virtually all motion control requirements," says Brooks.

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