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Error Handling

Overview

The project has an error handling system to process faults. It consist of the following

Type	Name	Output
MachineThe complete assembly of all connected parts or devices, of which at least one is movable Level	M1_ErrorHanding Program executing fbMainErrorHandler subprogram	This Machine level program outputs a machine status word. Certain bits are set when an error occurs
Axis Level	Ax_ErrorHandling (one for each axis) executing fbAxisErrorHandler subprogram	These axis level programs output a status word for each axis. Certain bits are set when an error occurs

Each axis has a status word which causes certain bits to be set when an error occurs.

Error Handling Programs

Machine Level (M1_ErrorHandling)

This program executes the fbMainErrorHandler subprogram which outputs the M1_StatusWord that provides an overall status of the machine.

fbMainErrorHandler inputs:

Parameter	Input Name	Details
bM1_ErrorReset	biResetError	ResetNew start of the microprocessor button in Control Panel screens
A1_StatusWord	iA1_StatusWord	Axis1 Status
A2_StatusWord	iA2_StatusWord	Axis2 Status
A3_StatusWord	iA3_StatusWord	Axis3 Status
A4_StatusWord	iA4_StatusWord	Axis4 Status
MSK_M1_StatusErrorStop 16#00000201	mskiErrorStop	A Defines parameter that sets which faults will place the state machine in the Error Stop State: Bits 0, 9 (see table below)
MSK_M1_StatusErrorFatal 16#000000FE	mskiErrorFatal	A Defines parameter that sets which faults will place the state machine in the Error Fatal State: Bits 2 to 8 (see table below)
MSK_M1_StatusReset 16#0000C2FF	mskiErrorReset	A Defines parameter that sets which faults will cause a drive reset: Bits 0 to 7, 9 (see table below)

The Main Status Mask bit definition is as follows:

Details on each bit are as follows:

Bit #	Description	Source of Information
0	StatusErrorStopDrive	Reads Ax_StatusErrorStop bit in the Axis status word for each axis. If any are set then this bit is set.
1	StatusErrorFatalDrive	Reads Ax_StatusErrorFatal bit in the Axis status word for each axis. If any are set then this bit is set.
2	ErrorFuse24V	Input Name: DI_M1_Fuse24VOK.
3	ErrorTensionTimeOut	Not Used
4	ErrorRadiusSensorLeft	Reads left winder radius sensorA sensor is a type of transducer that converts one type of energy into another for various purposes including measurement or information transfer, Input Name: DI_M1_RadiusSensorA1RTO
5	ErrorRadiusSensoRight	Reads right winder radius sensor, Input Name: DI_M1_RadiusSensorA4RTO
6	ErrorWebEdgeControlAutoOn	Input Name: DI_M1_WebEdgeCntrlAutoAndMaterial
7	ErrorWebEdgeControlAutoOff	Input Name:DI_M1_WebEdgeCntrlCenterPos
8	EstopCircuitClosed	Reads Output of PNOZ relay, Input Name: DI_M1_PilzPnozDelayed
9	ErrorCStop	Reads bAx_ControlStopSwitch for each axis. If any set then this bit is set.
14	Error Stop	If one of the bits determined by MSK_Mi_StatusErrorStop (bit 0 and 10) is set, then this bit is set. Machine state then goes into Error Stop State
15	Error Fatal	If bits determined by MSK_Mi_StatusErrorFatal (bits 1 to 7) are set then set this bit. Machine state then goes into Error Fatal State.

Axis Level (Ax_ErrorHandling)

This program executes the fbAxisErrorHandler subprogram which outputs the Ax_StatusWord that provides individual axis status:

fbErrorHandler inputs:

Parameter	Input Name	Details
PipeNetwork.AXI_A1_Axis	iAxisID	Name of Axis (in pipe network)
bM1_ErrorReset	biResetError	Reset button in the Kollmorgen AKI and Control Panel screens.
A1_StatusWord	iAxisStatusWord	Present Axis Status
MSK_A1_StatusErrorStop 16#0000000E	mskiErrorStop	A Defines parameter that sets which faults will place the axis state machine in the Error Stop State: Bits 0 to 3 (see table below)
MSK_A1_StatusErrorFatal 16#00000041	mskiErrorFatal	A Defines parameter that sets which faults will place the axis state machine in the Error Fatal State: Bits 0 and 6 (see table below)
MSK_A1_StatusReset 16#0000C04F	msk1ErrorReset	A Defines parameter that sets which faults will cause a drive reset: Bits 0 to 3, 6,14, and 15 (see table below)
ControlledStopSwitch	biControlledStopSwitch	Not Used
NegLimitSwitch	biNegLimitSwitch	Not Used
PosLimitSwitch	biPosLImitSwitch	Not Used

The Axis Status Bits are as follows:

Details of each bit:

Bit #	Description	Source of Information
0*	drive error	DriveControl device for regulating the speed, torque and position of a motor error Information (SDO1003)
1*	motor position lag error	Drive error Information (SDO1003)
2*	motor temperature too high	Drive error Information (SDO1003)
3*	external stop	fbAKDErrorHandler Input (biControlledStopSwitch) or SDO1002 Bit 16 (AS EnableEnable signal for the drive, Hardware-Enable with 24V signal to X8, Software-Enable command by setup Software, fieldbus or permanently set. Both are required for enabling the drive. Input) or NOT SDO1002 Bit 29 (HW enable input)
4*	negative limit switch reached	fbAKDErrorHandler(biNegLimitSwitch ) Input
5*	positive limit switch reach	fbAKDErrorHandler(biPosLimitSwitch ) Input
6*	UDFB"User Defined Function Block" UDFB can be used as a sub-function block in another program of the application. It is described using FBD, LD, ST or IL language. Input / output parameters of a UDFB (as well as private variables) are declared in the variable editor as local variables of the UDFB error (application dependent)	Drive parameter save or restore error, Set by SaveParamIntoFile FB in A1_StateController (Standby state)
7*	controlled Stop	fbAKDErrorHandler Input (biControlledStopSwitch)
8	drive HW enable	Drive status Information (SDO1002 bit 29)
9*	drive AS enable	Drive status information (SDO1002 bit 13)
10	axis is powered on	MLAxisStatus Bits 1 and 2 set
11	axis is homed	Set in A1_StateController after axis is homed
12*	axis is running	Use MLAxisCmdPos FB to test if position command is changing
13*	pipe is connected to the axis	MLAxisStatus FB Bits 8 output
14	error stop	Summary of multiple sources
15	error fatal	Summary of multiple sources

*Axis errors are reset by the error reset button (bM1_ErrorReset) on the Kollmorgen AKI or internal Control Panel. The Axis Status Word bits that are reset is defined by the define parameter MSK_Ax_StatusReset. Default value is 16#0000C2FF which resets this bit.

Kollmorgen AKI Alarms

The Kollmorgen AKI contains alarms to notify the operator when certain issues occur:

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